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FIELD OF THE INVENTION
[0001] The invention relates to a printer, in particular for dispensing, through an outlet, printed documents such as, for example, tickets, receipts or slips.
BACKGROUND OF THE INVENTION
[0002] Specifically but not exclusively, the invention can be applied to a distributor of tickets, receipts or slips located in a public place, for example self-service kiosks (information, service or other types of kiosk), bank counters or instant teller machines, terminals for paying for parking or public transport, access control systems, gaming machines, automatic distributors in general, etc.
[0003] In particular, the present invention refers to a printer made in accordance with the preamble of the first claim. Such a printer is already known, for example from the patent publication FR 2728988 A1.
SUMMARY OF THE INVENTION
[0004] One object of the invention is to make a printer that is able to transfer information to the exterior simply and reliably.
[0005] One advantage is making a printer that is easily identifiable and distinguishable in a certain and reliable manner from a counterfeited clone.
[0006] One advantage is enabling the transfer of information using the signal emitting device that are normally already present in a printer and without adding further signal emitting device.
[0007] One advantage is enabling information to be transferred by a light signal emitting device that is normally used to emit light signals that are visible to a user removing a printed document from the printer.
[0008] One advantage is providing a printer that is able to emit modulated signals to the exterior that are invisible to the naked eye and/or contain useful information, for example information relating to the origin and/or to the use of the printer.
[0009] One advantage is that the information transferred outside the printer can be received and read by an external reader (decoder).
[0010] One advantage is making a printer available that is able to transmit information at a distance in a wireless manner.
[0011] One advantage is providing a printer that is able to transmit information on the history of the printer, in particular relating to statistical data (for example, the number of given operations performed by the printer over a given time) or information on production data (for example serial number, production batch, purchase date, installation date, etc).
[0012] One advantage is enabling information to be transmitted outside the printer in a form that is encrypted and readable by a decoder.
[0013] One advantage is protecting in a simple and reliable manner the brand of the manufacturer of the printer and enabling product traceability.
[0014] Such objects and advantages, and still others, are achieved by the printer according to one or more of the claims set out below.
[0015] In one example, the printer comprises at least one light source, for example one or more LEDs, having a visible signalling operating mode in which it emits light visible to a user removing a printed document; the printer can further comprise a control device that is able to transfer information to the exterior using the light source without adding further light emitting device, by means of a modulator that induces the light source for emitting a pulsed modulated light signal, in particular in a form that is not visible to the human eye; the modulated signal may contain information relating to the identity of the printer; the modulated signal may be received and decoded by an external decoder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention can be better understood and implemented with reference to the attached drawings that illustrate an embodiment thereof by way of non-limiting example.
[0017] FIG. 1 is a diagram of an embodiment according to the invention of a ticket printer provided with at least one light source.
[0018] FIG. 2 is a diagram of the control system of the printer in FIG. 1 .
[0019] FIG. 3 is an example of a graph of pulsed wave shapes containing information to be transmitted by the light source of the printer in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] With reference to the above figure, overall with 1 a printer has been indicated, in particular a printer of tickets, receipts or slips. The printer may be, for example, a printer for dispensing a printed document in real time in public places.
[0021] The printer 1 may comprise a magazine 2 of a printing support P. The printing support P may comprise, for example, a (continuous) strip of paper, for example thermal paper, or of another printable material. The magazine 2 may comprise, as in this case, at least one reel. It is possible to provide other types of magazine or printing supports. It is possible to use, for example, a pack of single sheets of stacked paper, or a pack of “fan folder” sheets, etc.
[0022] The printer 1 may comprise a supply path of the printing support along which the printing support P proceeds (from the magazine 2 ) to an outlet 3 . The outlet 3 may be arranged at the end of the aforesaid path. In particular, the outlet 3 may be arranged in such a manner that a user can remove the printed document.
[0023] The printer 1 may further comprise a supply arrangement for supplying the printing support P along the aforesaid path. Such supply arrangement may comprise, for example, one or more dragging rollers 4 .
[0024] The printer 1 comprises a printing device for printing a document (ticket, receipt, or slip) on the printing support P, in particular along the aforesaid path. Such printing device may comprise, as in this example, a thermal printing head 5 . The printing head 5 may comprise a dragging roller 4 facing and cooperating with the head 5 such that the printing support P advancing along the path is guided to pass between the thermal head 5 and the dragging roller 4 .
[0025] The printer 1 may comprise an electronic control device (for example a CPU in the form of a circuit or board) for controlling actuators A of the printer (the supply arrangement and/or the printing device and/or other possible actuators). The (programmable) electronic control device may be arranged for receiving signals from a possible sensor arrangement S of the printer, for example a paper-finished sensor that signals that the magazine 2 is empty and/or a paper-present sensor that indicates the presence or lack of paper at a determined point of the supply path, etc.
[0026] The printer 1 comprises a light source arranged for emitting light, in particular light that is visible to the user withdrawing the printed document. The light source may comprise, as in the specific example, one or more LEDs 6 .
[0027] The light source (LED 6 ) may be connected to the control device to emit light according to one or more predetermined operating states of the printer 1 .
[0028] In particular the control device (CPU) may comprise an arrangement for controlling the light source in at least one operating mode in which the light source emits light that is visible to the user.
[0029] This operating mode may be activated, for example, in response to at least one operation performed and/or being performed and/or about to be performed by the supply arrangement and/or by the printing device and/or by other actuators. It is possible, for example, to program the control unit in such a manner that the light source emits light that is visible to the user for a certain time during printing and subsequent dispensing through the outlet 3 of the printed document by the printer 1 .
[0030] The printer comprises a modulating device (for example a modulator M that may comprise an electronic circuit or board) for modulating a light emitted by the light source (LED 6 ) with a modulated signal that is able to convey predetermined useful information.
[0031] The signal that modulates the light emitted by the light source (LED 6 ) may convey, in particular, identifying information relating to the printer 1 or at least one component of the printer 1 .
[0032] The conveying signal may be, for example, an amplitude modulated signal, or a frequency modulated signal. In particular, the modulating device (modulator M) may be programmed for modulating the light with the conveying signal so that the effect of this modulation is not visible to the human eye.
[0033] FIG. 3 shows a graph schematically, as a function of the time T, of a possible pulsed wave shape of the modulated light signal by means of the modulating device (modulator M). A given set of pulses may be, for example, emitted periodically, at preset intervals of time, or may be emitted in response to a preset external command sent by a user through a user (graphic) interface connected to the control device of the printer and/or through a preset (wireless) signal that is receivable by a receiver associated with the printer.
[0034] It is possible, as in this example, that a pulsed wave shape contains the information that is useful for transmitting to the exterior. It is possible to use any wave shape that is able to transmit a piece of information.
[0035] FIG. 3 shows a simplified diagram of the electronic control system of the printer, that may comprise a CPU circuit, configured for receiving signals from the sensor arrangement S of the printer and for transmitting signals to one or more actuators A of the printer 1 (printing device and/or paper supply arrangement and/or elements for separating the printed document), and/or a modulator circuit M, and/or a driving circuit D of the light source (LED 6 ).
[0036] The useful information to be transmitted by the modulation of the light signal may comprise, for example, a code identifying the origin of the printer (for example a manufacturing code or a counterfeiting code or the like), and/or information on the operations performed by the printer (for example the number and/or the type of tickets dispensed in a day, or the hours of accumulated work or the like), and/or information on faults or malfunctions that have occurred and/or on (scheduled or extraordinary) maintenance tasks to be performed, and/or information on the history of the printer (for example purchase date and/or installation date), etc.
[0037] The printer 1 may further comprise, as in the specific example, a case that may contain the magazine 2 of the printing support and/or the supply path of the printing support P or at least a part of this path and/or the supply arrangement of the printing support and/or the printing device of the document and/or other actuators A and/or the electronic control device (CPU) and/or the light source (LED 6 ) and/or the modulating device (modulator M) and/or the sensor arrangement S.
[0038] The case may comprise, for example, a (front) wall 7 that has an outlet mouth 8 that defines the outlet 3 . The printed document will in this case be presented to the user through the outlet mouth 8 .
[0039] The light source (LED 6 ) may be (at least in part) arranged near the outlet mouth 8 . The outlet mouth 8 may be made, as in this case, of transparent plastics and the light source (LED 6 ) may be at least partially arranged embedded in the material of the outlet mouth 8 . It is nevertheless possible to provide other arrangements of the light signal emitting device.
[0040] The printer may comprise, as in this case, a separating element (for example a stationary or movable cutter 9 commanded by the control device) to separate the printed document from the rest of the printing support P.
[0041] The information conveying signal modulates the light emitted by the light source (LED 6 ). This information conveying signal may be, for example, a signal of the type that is receivable from an external optoelectronic receiver. This information conveying signal may be decodeable by an external decoder.
[0042] The emitted light signal may thus be a pulsing signal according to the specific information to be transmitted. The emitted light signal may comprise a pulsed signal with a preset frequency and/or amplitude. The emitted light signal may comprise a pulsed signal that transmits information in a form that is encrypted and readable by a decoder.
[0043] The modulated light signal emitted by the printer 1 can be used in many different manners, in particular for identifying the printer and thus for distinguishing an original printer from a counterfeited clone, checking simply and rapidly the authenticity of the product by reading and possibly decoding the signal.
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A ticket printer that includes a plurality of LEDs for emitting light that is visible to a user removing a ticket, wherein the printer is able to transfer information to the exterior, using the light of the LEDs without adding further light emitting means, by means of a modulator that enables the LEDs to emit a pulsed light signal that contains information on the identity of the printer and which can be received and read by an external decoder.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of pending application Ser. No. 08/443,075 filed May 17, 1995.
BACKGROUND OF THE INVENTION
The present invention relates to systems an articles for assembling structural framing components. More particularly, the invention pertains to methods and apparatus for erecting habitable structures.
Western construction methods are not particularly tolerant of seismic vibration. These methods are characterized by assemblies of rigid but friable materials such as brick, stone and mortar. Although modern commercial construction usually relies upon a steel superstructure that is paneled with masonry and plaster, the steel load bearers are heavily stressed and joined by welded or riveted shear joints. When whipped by the high amplitude, low frequency ground movement of a seismic disruption, welds are broken and rivets are sheared and the steel superstructure collapses.
Others have observed that construction methods and materials used by native cultures of the Pacific Rim are very earthquake tolerant. Significant characteristics of this technology include the use of wood and bamboo assembled by leather thongs, grass and leaves. Timbers are joined without nails or pegs. Rather than rupture, such joints merely slip in their lashings or sockets.
Although primitive construction methods and materials may be earthquake survivable, they also are not particularly fire or rot resistant. Neither are such construction methods particularly weathertight, draft resistant or suitable for multistory structures.
However, the central essence of these earthquake resistant construction methods is not so much in the indigenous materials used but in the absence of rigidly joined points of high load and stress concentration. It is in the capacity of the structural joints to yield, slip and twist without stressing the fasteners or load bearers beyond the point of failure that distinguishes the primitive Pacific construction methods for being earthquake proof.
It is, therefore, an object of the present invention to provide some construction assembly techniques that adapt the primitive low stress joint technology to modern, high strength materials.
Another object of the present invention is to provide methods and apparatus for erecting habitable structures with ferrous, non-ferrous metallic or plastic tube but without welding or threaded fasteners.
SUMMARY OF THE INVENTION
These and other objects of the invention are accomplished by a habitable structure construction system of thin-wall tubing wherein load bearing walls are formed as a woven matrix of tubing having socket intersections. Joist and sill joints are formed by interference fitting socket joints. Habitable structures may include residential dwelling, both foundation secured and mobile, truck bodies and agriculture out-buildings such as barns.
Collectively, the structure is assembled with the strength and compliance of a woven wire cage or basket wherein dynamic loads are adsorbed as frictional heat and spring stress. Standardized blocks, preferably of a ferrous material, are bored along mutually perpendicular axes to receive the end of a joint pin. The internal diameter dimensions of the joint block bores are formed smaller than the outside diameter of respective pins. A joint is made by heating or cooling one member of the joint and quickly inserting one joint element coaxially within the other.
Alternatively, the pin surfaces and block bores may be turned to low, 5% or less, taper angles and driven together with shock force.
Continuous length tube elements are formed similarly by joining short lengths of tubing with an internal tubular lap splice. Such internal lap splice tubes correspond to the pins that are joined in the bores of corner blocks.
Biased frictional joints in a load bearing wall matrix socket together with uniformly spaced, oppositely facing saddles formed along a tube length. Sloping sides to the joint saddles and the resilient properties of steel tubing bias the saddle bights back together when displaced by a high amplitude shock wave.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention are described in further detail with reference to the drawings wherein:
FIG. 1 is a front elevation of a rectangular structure constructed according to the present invention;
FIG. 2 is an end elevation of the FIG. 1 structure.
FIG. 3 represents the foundation of a construction sequence.
FIG. 4 represents the vertical tube erection in a construction sequence.
FIG. 5 represents the positionment of horizontal tubes in the construction sequence.
FIG. 6 represents the completed end wall matrix of the invention.
FIG. 7 represents the roof construction of the invention.
FIG. 8 represents a foundation section for the invention.
FIG. 9 illustrates the sequence of a tube lap splice.
FIG. 10 illustrates the sectioned elevation of a 90° intersection joint for the invention.
FIG. 11 illustrates the plan of the intersection joint of FIG. 10.
FIG. 12 illustrates the end elevation of the intersection joint of FIG. 10.
FIG. 13 illustrates the sectioned elevation of a punctured tube intersection of the invention.
FIG. 14 illustrates the plan view of the FIG. 13 intersection.
FIG. 15 illustrates the front elevational view of a woven wall matrix of the invention.
FIG. 16 illustrates the end elevational view of the woven wall matrix.
FIG. 17 is a sectioned view of an intersecting saddle joint.
FIG. 18 is a sectional view of the saddle joint along cut plane 18--18 of FIG. 17.
FIG. 19 is a sectional view of the saddle joint along cut plane 19--19 of FIG. 17.
FIG. 20 is an elevational view of a circular plan structure according to the invention.
FIG. 21 is a plan view of the circular structure of FIG. 20.
FIG. 22 is a sectional elevation of a yoke joint as viewed along cutting plane 2--2 of FIG. 23.
FIG. 23 is a sectional plan of a yoke point as viewed along cutting plane 3--3 of FIG. 22.
FIG. 24 is a side elevational view of a joint yoke.
FIG. 25 is an end elevational view of a yoke element.
FIG. 26 is a plan view of a yoke element.
FIG. 27 is a side elevational view of an eye element.
FIG. 28 is an end elevational view of an eye element.
FIG. 29 is a plan view of an eye element.
FIG. 30 is a sectional elevation of a joint clevis as viewed along cutting plane 4--4 of FIG. 31.
FIG. 31 is a plan view of a clevis element.
FIG. 32 is an end view of a clevis element.
FIG. 33 is a sectional elevation of tongue element.
FIG. 34 is a plan view of a tongue element.
FIG. 35 is an end view of a tongue element.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Relative to the drawings wherein like reference characters designate like or similar elements throughout the several figures of the drawings, FIGS. 1 and 2 illustrate a traditional western style rectangular structure 10 having a covered porch 12 along the entire front length dimension. The porch roof overhang is supported by columns 14. Windows 16 and doors 18 are openings in the vertical load bearing wall panels. Additional load bearing panels for support of roof, floor and ceiling loads are positioned internally of the outer walls. These load bearing walls and panels are constructed as substantially uniform, orthogonal distributions of vertical and horizontal structural tube elements, 20 and 22, respectively. The preferred cross-sectional geometry of such transversely intersecting tube elements 20 and 22 is circular. However, the invention features may be readily adapted for other cross-sectional shapes such as square or rectangular. As tubes, the cross-sectional geometry of elements such as 20 and 22 comprises a relatively thin perimeter wall about an internal void space. Definitively, a "tube", as the term is applied to this invention, is not a structural member having a solid material cross-section. In the case of a circular tube 20 or 22 for the present invention, the perimeter wall cross-section is substantially annular, e.g. the material substance of the tube wall occupies the space between substantially concentric inside and outside circular diameters.
Another characteristic of the tube elements 20 and 22 is that both elements of a transversely intersecting group are preferably of the same transverse sectional dimension. Simply stated, all of the tube elements 20 and 22 in a structure are of the same size and shape. For example, circular tubes 20 and 22 preferably have the same outside dimension and the same inside diameter dimension.
It will be appreciated that a load bearing panel must also include a defining or delineating perimeter whereat the panel is joined to one or more other panels. In the case of a wall, for example, the panel perimeter may include a floor perimeter line, a ceiling perimeter line and usually a vertical corner perimeter line. Accordingly, a group of parallel tube elements 20 or 22 will be secured, at least at one end thereof, at substantially uniform separation increments along a perimeter line common to the respective group. Hence, the plane and shape of a load bearing panel is substantially defined by at least a pair of mutually intersecting perimeter lines.
From the perimeter line of structural attachment, longitudinal or axial extensions of the structural tube elements 20 and 22 make a matrix of substantially coplanar intersections of the tubular axes without a rigid connection therebetween. The respective tubes may slide from these intersection points at least along one axis, without a structural failure of the joint: albeit, such sliding is attended by considerable friction. FIGS. 13 and 14 illustrate one embodiment of such a joint wherein a receptacle tube of the intersection, in the horizontal run 22, for example, is penetrated by the continuous cooperative tube 20. Since both tubes are of substantially the same outside diameter, the girth of the receptacle tube 22 must be expanded to accommodate the penetrant 20. Preferably, the receptacle aperture is formed by mechanical puncture as distinguished from boring. Boring forms the aperture by material removal. Puncture, on the other hand, forms the receptacle aperture by piercing and stretching the tube wall material away from the aperture axis. Puncture apertures are formed by sharply pointed punch tools having an outside diameter shank of the desired aperture diameter. Advancement of the punch tool through the wall of tube 22 stretches and rolls tube wall material from the punch path into a friction flange 23. At the same time, the inside diameter of the receptacle tube 22 is stretched in a direction transverse to the penetrant tube 20 axis. Accordingly, the receptacle tube 22 outside diameter is deformed to bulge around the penetrant tube 20 by the approximately tube wall thickness on diametrically opposite sides.
As another form of matrix intersection joint consistent with the objectives of this invention, FIGS. 15 and 16 illustrate a woven wall, roof or floor load panel of circular cross-section stringers 20 and longerous 22. There stringers and longerons are, for example, round, thin-wall, architectural steel tubing of 2 in. nominal diameter. Both, stringers and longerons are formed to a saddle profile 26 (FIG. 17) at each matrix intersection. Along each tube element, the saddle seat surfaces 27 are sequentially turned in oppositely facing directions. This alternating saddle seat orientation sequence of one element is orthogonally coordinated with the cooperative tube elements also having alternately facing saddle seats 27. In mutual assembly after the manner of a simple basketweave, the saddle socket 29 of one element is detent confined within the saddle socket 29 of the cooperative element.
These intersecting saddles may be field formed with relatively light weight hydraulic forming equipment. Preferably, however, such alternating saddle shapes are formed on continuous production equipment that automatically maintains the spacing and orientation of all saddles in a tube length.
With particular reference to FIGS. 17, 18 and 19, each saddle 26 is shown to include a flattened seat surface 27 that is essentially square having an axial length dimension corresponding to a traverse width dimension. Broadly, the circular perimeter of a tube wall is reconfigured to a rectangular prism having a depth that is substantially equal to the outside radius of the undistorted tube circle. Shoulders 29 axially delineate the seat surface 27 to restrain the cooperative saddle seated therewith. From the outer elements of the tubes, a tube ramp face 28 adjacent each shoulder 27 funnels a cooperative saddle into an appropriate intersection and confines it there without the rigid, unyielding attachment of rivets, bolts or welds, for example. Even when a pair of saddles is separated, the statically standing, stable bias of the assembly is a return to the preferred, mutually clasping alignment.
As primary structural elements of the present invention, a length of preformed tubing may be selectively trimmed in the traditional manner of sawing or roll cutting. Unconventionally, however, thin wall steel tubing may be axially extended by means of an internal lap splice joint in the manner of FIG. 9. With the objective of axially extending the length of tubing joint 20a, the end of a metallic joint 20a is heated by means of a portable torch or furnace to enlarge the tubing inside diameter. While the end of tube 20a is hot, approximately half of a lap splice pin 30, at ambient temperature, is inserted coaxially into the open-ended bore of the tube-end. When cooled, the internal bore surface of the tube end shrinks upon the external surface of the pin 30 for a constrictive, interference fit therebetween.
Free dimensions at ambient temperatures will necessitate an inside diameter of the tube end 20a that is less than the outside diameter of the splice pin 30. In assembly, such a dimensional relationship is characterized as an interference fit. Both elements of the joint thermally stabilize to respective states of prestress with the tube 20a in tensile hoop stress and the pin 30 in compressive hoop stress. Preferably, such stress is substantially balanced. Control over the degree of stress in the respective elements is predominately controlled by the percentage of diameter differential. A standardized interference fit stress calls for an inside interference diameter difference of 0.6 of 1.0% and an outside interference diameter of 0.1 of 1.0%. Assuming a 2 in. ambient interference fit diameter, the ambient inside diameter of the tube 20a end may be for example:
2 in.-(2 in.×0.006)=2-0.012=1.988 in.
A corresponding ambient outside diameter for the pin 30 may be:
2 in.+(2 in.×0.001)=2+0.002=2.002 in.
In total, therefore, the interference fit differential is
2.002 in.-1.988 in.=0.014 in.
Interference fit dimensions may be established for 0.002 to 0.015 in. interference differentials.
Duplicating the foregoing assembly of tube 20a with pin 30, tubing element 20b is heated and quickly pushed upon the projecting half of lap pin 30. Preferably, the two tube ends 20a and 20b are pushed into coaxially abutting union as at joint 32 of FIG. 9B. A conservative empirical lapping dimension could be a pin 30 axial penetration depth into the ends of tubes 20a and 20b of about three to four pin diameters.
Although the preferred embodiment of my invention utilize a heated interference fit as described for steel, ferrous alloys, aluminum, brass and other metallic tube forming materials, other coaxial joint techniques may be satisfactorily employed. For example, a slip fit joint of fiberglass and plastic tubing as well as metallic tubing may be axially secured by polymer bonding agents such as epoxies and polyester resins. Also, an axial slip fit joint of metallic tubing may be positionally secured after assembly by staking or beading. Staking is a procedure whereby a dull pointed tool is struck against the outer element wall of a coaxial assembly to dimple the outer wall into the inner wall. Depending on the degree of security required between the two coaxial elements, numerous dimples may be struck around the tube perimeter.
Beading may be considered a circumferentially continuous form of staking whereby a circumferential bead is rolled into the outer assembly element wall of such depth as to form a radially aligned bead into the wall of the inner assembly element.
Coaxial joints may also be secured by tapered pin and socket assembly whereby an internal surface of a tube socket is formed with a smooth, low angle, tapered face. Five degree or less taper angles have been used. A corresponding taper angled surface on the pin element of an assembly is mated into the socket.
There are numerous construction circumstances that require abrupt 90° planar intersections. The present invention construction system provides appliances of FIGS. 10, 11 and 12 based upon an elbow block 34 having bores 36a and 36b with mutually perpendicular axes 38a and 38b, respectively. Lap splice pins 30a and 30b are interference fit to the respective bores. To the lap splice pins 30a and 30b, panel tubes 20 or 22 are secured by interference fit.
This same principle of an elbow block may be further developed to additional configurations not illustrated such as a tee having a lap splicing length of lap pin 30a projecting from booth axial ends of bore 36a.
Those of ordinary skill in the art will recognize that the construction principles embodied in the elbow block and lap pin corner assembly appliance may be expanded to include axial projections in 3, 4, 5 and 6 directions. A particular application of the appliance is illustrated by FIG. 8 as a foundation interface for the shelter superstructure. Lap pins 30a and 30b are interference fitted to a common elbow block 34. The projected ends of the lap pins receive and secure the lower ends of vertical tubes 20 along a first, vertical plane and the ends of slab panel tubes 22 in the horizontal plane. The horizontal plane including a multiplicity of parallel aligned horizontal tubes 22 is cast in concrete for a reinforced slab 40.
With reference to the construction sequence of FIGS. 3 through 7, FIG. 3 illustrates a foundation slab 40 from which vertical lap pins 30a project along the lines of the load bearing vertical walls and partitions. FIG. 4 illustrates the vertical tubes 20 to form an outside load bearing wall erected over the lap pins 30a in free-standing, vertical alignment. At positions along the wall corresponding to the location of windows and doors in the wall panels, the vertical tubes 30a are shortened as those represented by 42 or eliminated.
Referring to FIG. 5, the horizontal tubes 22 are matrix mated to the vertical tubes 20. In the case of a penetrated intersection matrix as shown by FIG. 14, a single horizontal tube length 22 may include several penetration points to be mated by an overlay procedure with corresponding vertical tubes 20. For convenience, the vertical tubes 20 may be extended axially by relatively short sections jointed by lap pins 30. As a section of vertical tube is extended, lengths of punctured horizontal tube 22 are impaled upon the free-standing vertical joints.
A woven intersection matrix as represented by the clasp saddle intersections of FIGS. 15 through 19, may be constructed with the vertical tubes erected to their upper terminus. Appropriate care should be taken, however, to horizontally align the adjacent saddles 26.
The assembly components illustrated by FIGS. 22 through 29 are constituents of a first panel joint embodiment whereby the planar intersections of different panels are secured together along the common perimeter line. For example, corner tube 60 may be temporarily secured along a line of intersection 68 common to panels that include horizontal tubes 22a and 22b, respectively. The distal ends of the tubes 22a telescopically receive, with a sliding fit, shanks 64 respective to a yoke joint 62. Rigidly integral with each yoke joint 62 are a pair of collars 66. The collars 66 are internally bored to a diameter corresponding to a slip fit around the outside diameter of the corner tube 60. Set screws not shown are turned through the collars 66 into the corner tube 60 to secure an axial location thereon.
Eye joints 70 also have a shank 72 sized for a telescopically sliding fit into the end of a panel tube 22b. The eye 74 of the joint is also bored to a sliding fit over the outside diameter of the corner tube 60. The width of the eye 74 is also coordinated to the gap between the yoke collars 66 for caged confinement therebetween when in mutual embracement around the corner tube 60. If desired, the eye joint could also be secured to an axial position along the corner tube 60 by set screws not shown.
Although the yoke and eye joints are secured to axial positions along the corner tube 60, the individual horizontal tubes 22a and 2a are given compliance from the corner tube 60 along the horizontal axis.
A second panel joint embodiment of the invention is represented by FIGS. 30 through 35 and comprises clevis joints 80 and 90. The clevis yoke joint 80 includes a sleeve 82 with a slip fit internal bore for telescopic receipt of a tubing 22a end. A pair of clevis yokes 84 extend rigidly from the sleeve 82. The clevis tongue joint 90 comprises a sleeve 92 having a sliding fit bore to receive the end of tubing 22b. From the sleeve 92, a clevis tongue 94 is projected with a width corresponding to the gap between the yokes 84. Both the yokes 84 and the tongue 94 have cooperative pin bores to receive a common fastener therethrough such as a pin or bolt shank.
As the matrix grows vertically, window and door frames are positioned and secured by traditional means and procedures. Matrix tubing upper ends are terminated by appropriate elbow blocks 34 into either roof rafters 44 or stringers 46. The potential for extremely rapid construction progress using the above described erection system will be apparent to those of ordinary skill in the art. Common construction materials such as low carbon steel are substantially stable dimensionally over temperate climatic conditions. Consequently, well known prefabrication techniques permit considerable off-site material cutting and forming without concern for humidity changes.
At the construction site, large numbers of tubing ends may be simultaneously heated in portable furnaces and selectively withdrawn for socketing upon a corresponding pin 30a. It is necessary to plumb only a select few of the vertical "studs" 20 due to the resilient nature of the material. The ordered spacing of the matrix intersections on the horizontal longerons 22 tends to correct any vertical misalignments relative to the plumbed tube element 20.
The shelter of FIGS. 20 and 21 is constructed to a circular plan form having no inside or outside corners. In lieu of elbow blocks 34, short radius bends 50 are formed in short lengths of tubing and arced in a hydraulically powered tubing bending machine. Lap pins 30 are inserted in both ends of the tubing arc to axially add length extensions from the bend 50. Horizontal ring tubes 52 may be joined with the riser tubes 20 and rafter tubes 54 by either the punctured apertures of FIG. 13 or the clasp saddle means of FIG. 17.
The foregoing description of my invention has been of a structural skeleton assembly. Those of ordinary skill in the art, however, will understand that most if not all traditional enclosure materials such as brick stone, wood and plaster may be integrated with the present invention by means of appropriate ties and/or clamps to the structural tubing. In doing so, however, due consideration should be given to the structural properties and characteristics of the facade material. For example, brick ties between a tube wall of the present invention and a veneer wall of brick are of poor risk for holding the brick facade together during a major earthquake. Conversely, exterior plaster secured by metal lathing at densely distributed tie points represents a wall that will maintain its essential structural integrity notwithstanding cracking and small particle dislodgment.
Having fully disclosed my invention, those of ordinary skill in the art will perceive obvious variations and alternatives to combine with the invention.
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Load bearing panels and walls for habitable shelters are formed from relatively thin wall metallic tubing on widely spaced centers joined by a multiplicity of joint systems including shrink fit lap splicing, detent forming at standardized positional increments and frictional heat dissipation. The metallic tubing is arranged in rows along a line as well as intersecting rows along a second perpendicular line so as to form a load bearing panel with rows of tubes lying in a single plane. Tubing elements of one row intersecting and secured to the tubing elements of the second row without mechanical fasteners. Discreet interference fit tolerances facilitate the construction of a non-welded, stress distributing structure highly suitable for earthquake resistance and wildfire survival.
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CROSS-REFERENCE TO RELATED APPLICATIONS:
[0001] PROVISIONAL APPLICATION FOR: “SPINE-O-VATION”
[0002] Ser. No. 60/391,765
[0003] FILED: Jun. 26, 2002
[0004] FOR INVENTOR: JAMES D. MAHAN
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0005] NOT APPLICABLE
REFERENCE TO A MICROFICHE APPENDIX
[0006] NOT APPLICABLE
BACKGROUND OF THE INVENTION
[0007] Many people have discovered that their medical problems often can be solved by obtaining help from trained personnel, such as masseurs, athletic trainers and chiropractors to massage the spinal areas along the length of the spinal column. These trained professionals have knowledge of many manual techniques that can be applied to one's back, using the hands and fingers. Accordingly, various massage machines have been developed for manipulating and flexing the back muscles on both sides of the spinal column of a person lying in a supine position such as seen, for example, in U.S. Pat. No. 2,175,614. This patent discloses a machine having a plurality of rollers that are each supported by coil springs arranged along each side of a carriage that is movably mounted on tracks arranged to move along the spinal area. The carriage is moved back and forth along its tracks so that the rollers engage and massage the back of the person lying face-up on a hammock suspended above the rollers but with the rollers being in contact with the spinal area.
[0008] U.S. Pat. No. 2,577,646, also discloses a massaging machine having a horizontal table that accommodates a person lying face-up on the table with his spine centered over an elongated longitudinal opening in the central portion of the table. A plurality of rollers are rotatably mounted to the edges of parallel endless belts arranged below the surface of the table within the opening. The belts drive the rollers to move along the length of the elongated opening and thereby contact the spine with a rolling action to the spinal area of the person lying on the table.
[0009] U.S. Pat. No. 3,640,272 discloses therapeutic traction applied to the body by carriages supported on rails for cyclic longitudinal movement.
[0010] Further, U.S. Pat. No. 4,011,862 shows another massaging machine which includes two sets of rollers having ends positioned to provide an upwardly-facing concavity for receiving the back of a person as the rollers are moved along each side of the spinal column of that person.
[0011] U.S. Pat. No. 4 , 085 , 738 is a disease testing apparatus for the spine and is cited to show an arrangement of pressure members 64 , as seen in FIG. 8 thereof, for example.
[0012] Another prior-art massaging apparatus arranged to impart upward and downward movements to a massaging device is seen in U.S. Pat. No. 1,638,025. This massaging apparatus includes elongated bars that are operatively journaled at their ends to rotate and move the bars about parallel longitudinal axes, with there being curved portions of the bars transversely aligned and the ends of a plurality of closely-spaced slats are loosely connected to the bars to support a person midway between the bars. As the bars rotate, the slats remain horizontal and move vertically for imparting a rocking and undulating motion to the back of a person lying on the slats.
[0013] U.S. Pat. No. 3,628,528 shows a machine with a single horizontal roller mounted on a carriage that is moved to selectively position the roller below a person's back area that requires a massaging action. The roller is rotatably mounted between spaced vertically-movable members and reciprocated by cranks mounted in an out-of-phase relationship on opposite ends of a rotating shaft, whereupon rotation of the shaft rocks the roller in a vertical plane as the opposed ends alternately move up and down by the members.
[0014] U.S. Pat. No. 5,163,808 applies cyclic thrusting force against the back of a person by the use of thruster members around one or more vertebra of the spinal column, as shown in FIG. 3 at 201 , 202 and 203 . Fluid cylinder 300 reciprocates the rod 200 longitudinally to engage the back with the round members at 260 , 261 and 262 .
[0015] By the present invention, there is made available an improved massaging machine, made in accordance with the present invention, which is capable of imparting a selected massaging action to a multiplicity of areas adjacent the spinal column on the back of a person in a new and different manner. The resultant massaging action provides unexpected beneficial results that would be difficult to manually duplicate by most trained professionals. This desirable massaging treatment is achieved by the provision of an array of massaging thrusters, each having a massaging fixture attached thereto and having a massaging members depending therefrom for engaging both sides of the spinal column at the same time with an unusual motion that commences in proximity of the lower spinal column where a relative large circular motion is imparted to the massaging member; and terminates at the head end of the spinal column where a relative small circular motion is imparted to the massaging members contacting the back. At the same time, the array of thrusters are all moved up and down longitudinally of the spinal column at a low rate of travel respective to the rate of rotation imparted into each of the thrusters. Accordingly, the combination of the reciprocating movement and the circular movement provides a resultant motion that describes a spiral pattern commencing with a large diameter spiral in the lower spinal region and progressively diminishes along the spinal column towards the head.
[0016] The thrusters are resiliently biased into engagement with the spinal area with an adjustable force that include means for selecting the magnitude of the force of the engaging massaging members.
[0017] An unexpected advantage of this method and apparatus of mechanically massaging a persons back in the area of the spinal column is realized from an apparatus made in accordance with this invention. The geometry of the thrusters together with the supporting structure and the complex pattern of movement described by the thrusters induce a harmonic motion into the resiliently biased thrusters which is translocated to the interface between the skin of the back and the massaging member whereby unexpected low friction engagement is realized while the longitudinal and circular moving massaging members bear against the skin, which is very desirable for it enhances the therapeutic value of the massaging action of the massaging apparatus.
[0018] Method and apparatus for achieving the above desirable results is made possible by the provision of an apparatus made in accordance with the present invention as will be more fully realized when this disclosure is more fully digested.
BRIEF SUMMARY OF THE INVENTION
[0019] In the preferred embodiment of this invention, a table mounted apparatus massages the back of a person in a new and different manner that provides unexpected results. The term “massage” as used herein, is intended to include kneading, tapping and otherwise manipulating the area proximate to the spine. Massaging the area located on each side of the back adjacent the spine induces relaxation and comfort while conditioning a person for further chiropractic treatment. Additionally, the massage treatment provided by this invention is a superior substitute that is available to a skilled chiropractor, and when the advantages of the invention are coupled with the work of the chiropractor, the resultant treatment provides a synergistic system because the chiropractor is relieved of the time consuming massage duties and therefore can conserve and direct all his efforts towards improvement of the patient, while the patient derives a more extensive treatment at a lower cost.
[0020] This desirable result is achieved by the provision of a massaging table having an upwardly opening chamber or groove, longitudinally disposed respective the table top. Within the opening there are mounted a multiplicity of vertical movable thrusters, typically 8 to 16, that work automatically to adjust to the contour of patient's back. The pressure of the vertical thrusters can be regulated to control the force exerted on the patient's back. The thrusters are rapidly moved within a horizontal plane to describe small circles which are relatively small at the head end of the spine and grow progressively larger toward the foot end. At the same time the thrusters are moved more slowly longitudinally of the spinal column, thus this combination of thruster motion provides a unique spiral-like massaging action sequentially changing along the entire spine. The horizontal movement of the thrusters as well as the vibration intensity to the patient's back can be varied.
[0021] Accordingly, a primary object of the present invention is the provision of a method and apparatus for massaging the back with an array of massaging elements that manipulate the muscles of the back with variable intensity commencing with the greatest intensity occurring in proximity of the lower spinal column where a relative large circular motion is imparted to the massaging member; and terminates at the head end of the spinal column where a relative small circular motion is imparted to the massaging members contacting the back, and at the same time, the array of thrusters are all moved up and down longitudinally of the spinal column at a slow rate of travel respective to the rate of circular motion or speed imparted into each of the thrusters.
[0022] Another object of the present invention is the provision of improvements in massaging apparatus by the provision of a massaging table having an upwardly opening chamber or groove longitudinally disposed respective the table top; within the opening there are mounted multiple pairs of movable vertical thrusters that work automatically to adjust to the contour of patient's back whereby the pressure of the vertical thrusters can be regulated to reduce or increase the force exerted on the patient's back.
[0023] A further object of this invention is the provision of multiple thrusters mounted for rapidly moving within a horizontal plane to describe small circles against the spine and wherein the circles grow larger from the head to the foot end of the spinal column; while at the same time the thrusters are moved longitudinally along the spinal column with the horizontal movement of the paired vertical thrusters being varied in the amount of forward and reverse travel or motions.
[0024] A still further object of this invention is the provision of an array of back engaging thrusters that are individually mounted on a vibrator bar and can be variably adjusted to increase or decrease the vibration intensity to the patient's back so that all motions respective the intensity of the massaging action can be selected as desired.
[0025] Another and still further object of this invention is the provision of massaging apparatus and method by which the geometry of a plurality of thrusters together with the supporting structure thereof are moved while vibrating in a horizontal plane to provide a complex massaging pattern of movement which additionally induces a harmonic motion into the resiliently biased thrusters which enables low friction engagement to be realized at the interface between the massaging members and the back as the members bear against the skin.
[0026] These and other objects and advantages of the present invention will become readily apparent to those skilled in the art upon reading the following detailed description and claims and by referring to the accompanying drawings.
[0027] The above objects are attained in accordance with the present invention by the provision of an improved method of massage treatment and apparatus fabricated in a manner substantially as described herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0028] Three sheets of drawings containing 9 Figures are included in this application, of which are seen:
[0029] [0029]FIG. 1 is a perspective view of a massage table made in accordance with this invention, with some parts thereof being removed to disclose the interior;
[0030] [0030]FIG. 2 is a part diagrammatical, part schematical, part cross-sectional side view illustrating a preferred embodiment of the invention;
[0031] [0031]FIG. 2A is a plan view of the foregoing figures;
[0032] [0032]FIG. 3 is a part diagrammatical, part schematical, part cross-sectional enlarged detailed view illustrating the preferred embodiment of the invention;
[0033] [0033]FIG. 4 is an enlarged part cross-sectional view taken along line 4 - 4 of FIG. 2;
[0034] [0034]FIG. 5 is a fragmentary top view of part of the apparatus seen in FIGS. 3 and 4;
[0035] [0035]FIG. 6 is a fragmentary cross-sectional view taken along line 6 - 6 of FIGS. 7 and 8;
[0036] [0036]FIG. 7 is a top plan view of part of the apparatus of FIGS. 2, 3 and 4 , and
[0037] [0037]FIGS. 8 and 9 are schematical representations illustrating the geometry of part of the apparatus of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Referring to the Figures of the drawings and particularly to FIG. 1, a massage table 10 is seen illustrated that has a top or uppermost surface 11 of leather or vinyl cover with suitable padding. The uppermost surface 11 of table 10 includes a head portion 12 , a hump portion at 14 to accommodate the small of the back, and a leg portion 16 . An area is referred to as shoulder portion 120 , because with a person 15 lying on table 10 , his shoulder 120 would be about in that area. Also, with a person lying on the table, there may be seen that the small of his back would be on hump 14 while his feet and legs would extend to the portion identified as leg portion 16 . This configuration of surface 11 of table 10 is desired because a person, when reclining on table 10 , will naturally position himself in this most desirable manner to properly orient his spinal column respective to the massaging apparatus 17 associated with table 10 , and described herein, in accordance with this invention.
[0039] Looking now to FIG. 2, in conjunction with FIGS. 1 and 3, it will be noted that midway between the sides 18 , 118 of table 10 is a groove, or upwardly opening recess 20 , formed within the top surface 11 of table 10 in communication with the interior. This groove 20 is seen to extend longitudinally along the table from shoulder portion 120 , across hump portion 14 , and terminates beyond a buttocks portion 220 so that the entire spinal area is accessible through the groove 20 . The upwardly opening groove communicates with the interior such that the massaging apparatus 17 has the upper part thereof partially extending through the groove 20 into contact with a person resting face-up on the table surface 11 , as illustrated by numeral 14 of FIGS. 1 and 2.
[0040] A main frame 24 supports most all of the elements of this invention 18 , including the table surfaces 11 as well as a vibrating unit 26 , made in accordance with this invention and as disclosed in greater detail in other figures of the drawings.
[0041] As seen in FIGS. 2 and 3, together with other figures of the drawings, a base plate 28 is mounted for horizontal fore and aft movement respective to a pair of opposed base plate bearing slides 30 , 31 . The bearing slides 30 , 31 are supported by main frame 24 to permit base plate 28 to slidably move horizontally along its longitudinal axis for a distance of at least 4 inches (see FIGS. 4 and 5). Hence, base plate 28 is slidably captured for limited fore and aft movement whereby it continually reciprocates back and forth along the opposed bearing slides 30 , 31 , which is along a path parallel to groove 20 . Base plate motor 32 is attached to frame 24 and can take on a number of different forms so long as it is geared or otherwise arranged to rotate a crank that has a crank pin off-set 2 inches to effect longitudinal movement of 4 inches. The radius of 2 inches can be changed to reciprocate base plate 28 other lengths, as desired. The movement of base plate 28 is preferably confined to a range of approximately 6 or 12 reciprocation each minute, which is to say, a cycle that is adjustable within a range of 5 or 10 seconds.
[0042] In FIG. 4, the bearing slides 31 , 32 are formed within the illustrated main support member 29 and are suitably attached to the main frame 24 (FIGS. 1 and 2) to enable the entire vibrating massage apparatus 26 to be properly supported in a structurally acceptable manner.
[0043] Hence, base plate 28 is slidably received within slide bearings 31 , 32 of main support member 29 and is located beneath top 11 of table 10 . The slide bearings 31 , 32 are in the form of the illustrated confronting inwardly opening slots formed within member 29 , and thereby capture the opposed marginal edges 33 , 133 of baseplate 28 therewithin, with main support member 29 being positioned within the interior of table 10 and in underlying relationship respective to a person's back. Main support member 29 is the lowermost member of vibrating unit or apparatus 26 and is rigidly attached to main frame 24 . The motor 32 , having a gear box 132 , rotatably drives a crank at the end of its output shaft. Motor 32 is rigidly mounted respective frame 24 or main support member 29 and is connected to reciprocate base plate 28 so that base plate 28 moves longitudinally respective groove 20 . The length of the crank attached to the output shaft is selected to provide the desired stroke length in the same manner seen illustrated at numerals 52 , 54 , 56 of FIGS. 7, 8 and 9 , as will be more fully described later on herein.
[0044] As further illustrated in FIG. 4, together with other figures of the drawings, elevating member 36 has formed therein perpendicular bores that slidably receive a medial length of several vertical guide members 34 , 134 therethrough for properly positioning of elevating member 36 respective the vibrating mount assembly 40 that also is supported from the base plate 28 that underlies elevating member 36 as suggested by numeral 236 . A guide bushing fitted within a bore formed perpendicular through each corner of elevating member 36 is provided for proper alignment and weight distribution of the imposed loads and is comprised of return springs 140 , 240 captured between abutment 138 , 238 and upper surface 136 of elevating member 36 , along with vibrator mount assembly 40 connected by suitable support 236 as well as the load presented by compressed spring 50 .
[0045] Base plate 28 supports an elevating member 36 having a spring board 38 rigidly attached thereto and lies in underlying relationship respective a vibrating mount assembly 40 , which will be more fully discussed later on herein. Hence, the vibrator mount assembly 40 is positioned in supported relationship above elevating member 36 and base plate 28 to move the vibrator mount assembly 40 in unison with base plate 28 .
[0046] Still looking at FIG. 4, in conjunction with other figures of the drawings, the vibrator mount assembly 40 includes an elongated vibrating member 42 which supports and guides a multiplicity of spaced thrusters 44 , and, for purposes of illustration, there are thirteen thrusters 44 , each having a splined shaft 46 (shown square in cross-section) received within complementary apertures 48 (shown as square apertures) formed perpendicularly respective the vibrating member 42 . Each of the apertures 48 reciprocatingly receive the splined rectangular shaft 46 of thrusters 44 . The rectangular shaft 46 of thrusters 44 extends through the complimentary apertures 48 so that rectangular shaft 46 remains properly oriented in indexed relationship respective a person's spinal column. That is, fixture 45 is positioned laterally respective a person's spine to dispose protrusions 145 , 245 in a working area on opposite sides of the spine.
[0047] The thrusters 44 are actuated vertically when pushed upward by biasing means in the form of springs 50 . The lower end of the springs 50 are received in supported relationship by spring board 38 . The member 52 forms a supporting surface for springs 50 along the interior of spring board 38 and is curved as it follows the contour of the upper surface of table 10 , whereby springs 50 are supported to regulate the height of thrusters 44 , and the back engaging fixture 45 closely follow the contour of the table surface, or the person's back, while at the same time spring board 38 is moved vertically a predetermined amount to concurrently lift all of the massaging elements 145 , 245 into proper engagement with the spinal column area.
[0048] Therefore, the protrusions 145 that form the massaging elements are about the level with the table top 11 and follow this level throughout the curvature of the table. Hence, the springs are jointly simultaneously adjustable for selecting the ideal pressure that each of the protrusions 145 exert against the back of the person lying face-up on the table, with the protrusions 145 being separated or spaced apart from one another by a distance equal to the spacing of the illustrated apertures 48 as described above.
[0049] As seen in FIGS. 7, 8 and 9 , the vibrator mount 42 is vibrated by a crank 52 that is rotated by motor 154 (see FIG. 3) having a shaft at 54 connected for rotating the crank 52 at a high rate of rotational speed. The foot end of the vibrating rod 42 is connected to a crank journal at 56 in a manner to be rotated approximately 1780 rpm thereby rotating the foot end of the vibrating rod 42 at the speed of the crank, which is a circle equal to the radius of the crank 52 .
[0050] While crank 52 is vibrating the foot end of the vibrating bar 42 within the 0.2 inch radius circle, the head end of the vibrating bar 42 is reciprocatingly received at 43 within a bearing 70 seen in FIG. 6 which pivots along axis 76 to allow the 0.4 in stroke or oscillation while concurrently allowing the bearing to pivot within that range. Opposed mounting ears 74 , 174 are received within members 78 , 79 connected, for example, to the bearing slide in any reasonable manner.
[0051] In the illustration of FIGS. 7, 8 and 9 , the geometrical pattern described by the protrusions 145 (FIG. 4) of the thrusters shaft 46 (see FIGS. 3 and 4) as they are moved by the vibrating bar 42 can be described as a spiral-like or a moving elliptical or circular figure as the thrusters are vibrated 1780 times a minute and while simultaneously traveling back and forth a total length of four inches in a fore and aft or reciprocating manner. Accordingly, this complex motion will be described as an oscillatory circular path or spiral 60 of FIGS. 7, 8 and 9 to avoid misdescription. At the foot end 16 of table 10 , shaft 54 of motor 254 is connected to rotate the before mentioned crank 52 which is connected to move the foot end of the vibrating bar in a circle, in a manner as noted in FIG. 7 in order to reciprocatingly vibrate mount or bar 54 . The crank arm is 0.2 inch in effective length, which describes a 0.4 diameter circle as it is revolved. The other end of vibrating bar 42 is reciprocatingly received within a bearing 70 (seen in FIG. 6) which is mounted to the head end of vibrating member 40 and is free to pivotally move about journals 74 , 174 having an axis 76 while concurrently being reciprocated within bearing 70 as it moves in a horizontal plane. This universal action will cause the thrusters to reciprocate back and forth 1780 times a minute, which is a total of 3560 strokes/minute, there being two strokes for each cycle of the crank. The springs 50 bias or push the knobs against the flesh of the person receiving the treatment with spring pressure exerting no greater than 6 pounds for each fixture. The pressure exerted on the patient's back can be increased or decreased by adjustment of the compression of the springs. The spring pressure can each be adjusted individually, by selecting the curvature of the member 52 of FIG. 4, or by placing individual spacers between the lower ends of the spring. The spring pressure is adjusted during operation by the controlled movement of the illustrated springboard 38 by means of the pneumatic cylinder 54 . It is preferred that the knobs 45 of the fixture do not press against the flesh of the back with more than 6 pounds applied at each shaft 46 . As knobs 45 are moving against the body they will also be making a complete cycle of the 0.4 inch movement 30 times every second in addition to the longitudinal movement of 2 to 4 inches each 5-10 seconds. It will be remembered that the thruster movement near the legs will be describing a relatively large circle with a 0.20 inch radius, while the adjacent knobs cycle within a sequentially diminishing radius due to the forever changing geometry of the mechanism, as illustrated in FIGS. 7, 8 and 9 .
[0052] The spring board 38 is elevated by air cylinder 54 having piston 56 thereof attached to a regulated source of pressure such as an air compressor (not shown). Spring board 38 is mounted to 36 and is moved vertically by Piston 56 with the vertical displacement being within an adjustable range of 3 or 4 inches in order to bring fixture 45 into proper contact with a person's flexible flesh. The spring pressure imposed on each fixture at fixture 45 is determined by the pneumatic pressure of the air cylinder 54 , which elevates 36 to move 38 against 50 to thereby resiliently compress 50 and thereby bias shaft 46 with a constant upward force of about 6 pounds or less. As stated above, spring board 38 along with the base plate 28 are moved longitudinally by a crank about 4 inches at a rate of 6-12 reciprocation in one minute. During this time interval, springs 50 maintain all the springs of thrusters 44 simultaneously compressed or relaxed according to the pressure force each asserts against shaft 46 .
[0053] The rapid vibration of vibrator bar 42 is transmitted into each thruster 44 , causing each spring 50 to induce a harmonic motion therein, depending on how closely the vibrating mount assembly 40 is tuned to the oscillatory motion of the rotating crank. Hence, a maximum of a 6 pound compression between the vibrating shaft end and the stationary spring board 38 together with the horizontal vibration of vibrator bar 42 results in a minute vertical vibration which allows the knobs at 45 to move more freely against the skin with less friction than would otherwise be realized, thus allowing for low frictional contact between the constantly moving knobs 45 and the spinal area of the patient.
[0054] As described above, the vertical positioning of the spring board is achieved by air cylinder 54 , which is controlled by throttling the flow from an air compressor (not shown). The vertical position of spring board 38 is controlled by vertical piston shaft 56 which extends from base plate 28 , through a an aperture formed in spring board 56 . Rod springs 26 placed around vertical support rods 29 force the spring board down when the pressure at air cylinder 53 is relaxed.
[0055] In operation, the patient lies on his back with his spinal column area superimposed over the array of knobs. The desired spring pressure is selected, the machine is energized, and the massaging treatment commences and continues for whatever length of time is deemed desired. An appropriate person can terminate the treatment by reducing the pressure when desired by changing the air regulator valve to the 54 .
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A physical therapy apparatus having a padded top surface upon which a patient comfortably reclines in the face up position with the spinal area being placed in contact respective a plurality of massaging members. The massaging members are recessed within the padded top and have a massaging members extending into contact with the patients back while jointly moved along the spine with the members being individually rapidly oscillated in a circular pattern at a selected magnitude of pressure and rate of travel. At the same time, the massaging members are moved a limited length along the entire spine causing each to describe a longitudinally moving circular pattern of a spiral, with each massaging member describing a different size pattern with the member that contacts the uppermost part of the spinal column moving within a relatively small pattern while the massaging members that contact the lower part of the spinal column move within a relatively large pattern with the pattern of movement progressively increasing sequentially from one to the other end of the spinal column. The terminal ends of the massaging members each are elevated into contact with the spine and assume a curve approximating the curvature of the spinal area so that a patient reclining in a supine position will gravitate into proper contact with all of the massaging members.
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TECHNICAL FIELD
[0001] This disclosure relates to vehicle heating ventilation and air conditioning (HVAC) system blower fans and blower housings.
BACKGROUND
[0002] Vehicle HVAC systems have a separate air inlet for fresh air and for recirculated air. Air is directed from the fresh air inlet and/or the recirculated air inlet to the blower within the blower housing. The blower housing structurally supports the blower fan. Blower housings with separate fresh air inlets and recirculated air inlets may encounter problems relating to noise levels and vibration.
[0003] Another problem encountered by vehicle HVAC systems is that they tend to be bulky. As the volume of air moved through the system is increased, the space required to house the blower housing also increases. Space available for a blower housing in a vehicle is limited and may impact vehicle design freedom.
[0004] In HVAC systems having more than one fan, each fan typically has one inlet that is shifted between a fresh air source and a recirculation air source. Multiple fans are not used to draw fresh air and recirculated air through the same inlet.
[0005] The above problems and other problems are addressed by this disclosure as summarized below.
SUMMARY
[0006] This disclosure is directed to a HVAC housing for a dual wheel/dual scroll fan blower that is assembled to a blower housing to create a coaxial air flow path within the blower housing. The blower housing may have integral internal ribs that direct air flow from the cowl air flow inlet and indirectly to the blower. The internal rib design in the coaxial fan chamber also provides structural support for directly assembling the fans, motor and other components to the blower housing assembly. The internal rib design reduces noise and vibrations while improving the flow of air into the blower inlet.
[0007] In one embodiment, the fresh air from the cowl air flow inlet may be the only fresh air inlet that provides fresh air to both fans. Fresh air may be provided to two more inlet openings from the cowl area to the fans. Recirculation air inlets may also be provided that may operate in combination with or independently of the fresh air inlets.
[0008] The dual wheel/dual scroll fan blower may be horizontally oriented, vertically oriented or oriented in any angular orientation required to meet the packaging requirements in the limited space available for the HVAC blower housing assembly in a vehicle. The size of the HVAC blower housing assembly may be reduced due to increased efficiency of the coaxial fans and, as a direct result, the size and weight of the instrument panel may be reduced. A smaller HVAC blower housing assembly allows more design freedom for instrument panel designs.
[0009] The HVAC blower housing assembly may facilitate providing a partial recirculation strategy that permits part of the air flow to be recirculated with fresh air. Partial recirculation of air within the vehicle in combination with limited fresh air may reduce the load on the HVAC system and may permit system specifications to be less rigorous.
[0010] According to one aspect of this disclosure, a HVAC blower housing assembly is disclosed that includes a housing and a motor assembled to the housing. A first fan and a second fan are operatively connected to the motor and are coaxially aligned to draw air from a first inlet and a second inlet, respectively. An outlet receives air from the first fan and the second fan and forces the air to the passenger compartment.
[0011] According to another aspect of this disclosure, a HVAC blower housing assembly is disclosed that includes a housing that defines a first opening and a second opening. A motor is disposed within the housing and is connected to a first blower scroll fan and a second blower scroll fan. The first blower scroll fan is operatively connected to the motor that draws air through the first opening. The second blower scroll fan is operatively connected to the motor that draws air through the second opening. A first closure member controls the flow of air through the first opening by controlling the volume of air drawn from a fresh air source and the volume of air drawn from a passenger compartment. A second closure member controls the flow of air through the second opening from the passenger compartment.
[0012] According to further aspects of this disclosure, the HVAC blower housing assemblies summarized above may also include a jacket that defines an annulus disposed around the housing that facilitates air flow around the housing from one end of the housing to the opposite end of the housing. A wide variety of fresh air and recirculated air inlets are disclosed. Different door combinations may be provided to control the sources of air provided to the blower scroll fans. The blower scroll fans are coaxially aligned and may be oriented vertically, horizontally or in another orientation to suit packaging requirements and space limitations within an instrument panel.
[0013] The above aspects of this disclosure and other aspects will be more fully described in the following detailed description of the illustrated embodiments and with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a cross-sectional view of a HVAC blower housing assembly having recirculation air inlets on both ends of the assembly and a fresh air inlet on one ends of the assembly that also provides fresh air through a partial annulus to the opposite end of the assembly.
[0015] FIG. 2 is a diagrammatic cross-sectional view taken along the line 2 - 2 in FIG. 1 .
[0016] FIG. 3 is a cross-sectional view of a HVAC blower housing assembly having recirculation air inlets on both ends of the assembly and a fresh air inlet on one end of the assembly that also provides fresh air through a cylindrical annulus to the opposite end of the assembly.
[0017] FIG. 4 is a cross-sectional view of a vertically oriented HVAC blower housing assembly having recirculation air inlets on both ends of the assembly and fresh air inlets on both ends of the assembly.
[0018] FIG. 5 is a cross-sectional view of a horizontally oriented HVAC blower housing assembly having recirculation air inlets on both ends of the assembly and fresh air inlets on both ends of the assembly.
DETAILED DESCRIPTION
[0019] The illustrated embodiments are disclosed with reference to the drawings. However, it is to be understood that the disclosed embodiments are intended to be merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts.
[0020] Referring to FIG. 1 , a blower assembly 10 is illustrated that includes a housing 12 . A motor 16 is disposed within the housing and is operatively connected to a first scroll fan 18 and a second scroll fan 20 by a shaft 22 . The first and second scroll fans 18 and 20 are coaxially aligned on the shaft 22 and draw air from opposite ends of the housing because they are oppositely oriented on the shaft 22 . The first scroll fan 18 is connected to a first end 26 of the shaft 22 and the second scroll fan 20 is connected to a second end 28 of the shaft 22 . The motor 16 rotates the shaft 22 to operate the first and second scroll fans 18 and 20 .
[0021] A fresh air port 30 admits fresh air F into the housing 12 . The fresh air F is also selectively provided to the fresh air duct 32 . The fresh air duct 32 is a semi-annular duct that routes air around the first and second scroll fans 18 and 20 . A fresh air door 34 may be shifted between a position blocking the fresh air port 30 and an open position in which fresh air F may be provided to the fresh air duct 32 . A first recirculated air duct 36 provides recirculated air R. A first recirculated air door 38 may be opened and closed to permit or prevent the flow of recirculated air R through the first recirculated air duct 36 . The first recirculated air door 38 may be a pivoting door or a roll film door depending on cost and space requirements. A second recirculated air duct 40 is provided at the opposite or lower end of the housing 12 and an alternate recirculated air duct 42 may also be provided on the housing 12 to permit recirculated air R to flow into housing 12 . A combination door 44 may be moved to a blocking position blocking the second recirculated air duct 40 and the alternate recirculated air duct 42 . The combination door 44 may also be moved to block the flow of fresh air F through the fresh air duct 32 .
[0022] Referring to FIG. 2 , a diagrammatic representation of the apparatus shown in FIG. 1 is provided. The first scroll fan 18 is shown disposed within the housing 12 . The fresh air duct 32 is shown to be a semi-annular duct attached to the outside of the housing 12 . The first scroll fan 18 is shown in operation expelling air into an outlet duct 50 . The air in the outlet duct 50 is outlet air that is provided to a passenger compartment 52 .
[0023] Referring to FIG. 3 , a blower assembly 54 is shown that includes a housing 56 . The blower assembly 54 is attached to a bulkhead 58 by a fastener 60 . A cowl 62 is also shown at one end of the housing 56 that separates the interior of the vehicle (not shown) from the exterior.
[0024] A motor 64 is assembled to the housing 56 and bulkhead 58 by motor mount ribs 66 that operatively support the motor 64 within the housing 56 . A first scroll fan 68 and a second scroll fan 70 are provided on opposite ends of a shaft 72 . The shaft 72 is rotated by the motor 64 to provide air flow by rotation of the scroll fans 68 and 70 .
[0025] A fresh air port 76 is defined by the cowl 62 and the housing 56 . Fresh air F is supplied to the blower housing assembly 54 through the fresh air port 76 when a fresh air door 78 is opened. Fresh air door 78 may be closed to operate the blower housing assembly 54 in a recirculation mode. A fresh air duct 80 is provided that encloses the housing 56 . The fresh air duct 80 may be a cylindrical annulus through which fresh air is permitted to flow from the fresh air port 76 through a plurality of acoustic air flow ribs 82 to the opposite ends of the blower assembly 54 . The acoustic air flow ribs 82 support the housing 56 within the fresh air duct 80 and are constructed to eliminate unwanted noise in the blower assembly 54 . A first recirculated air duct 84 is provided in the fresh air duct 80 adjacent the fresh air port 76 . Recirculated air R is admitted through the first recirculated air duct 84 from the passenger compartment 52 (shown in FIG. 2 ). The first recirculated air duct 84 may be opened and closed by a first roll film door 86 depending upon whether air is requested to be recirculated through the blower assembly 54 . A second recirculated air duct 88 is provided on the opposite end of the blower assembly 54 from the fresh air port 76 . A second roll film door 90 may be provided that opens and closes the second recirculated air duct 88 to either permit or restrict air from being recirculated by the blower housing assembly 54 .
[0026] Referring to FIG. 4 , another alternative embodiment of a blower assembly 96 is illustrated. A housing 98 of the blower assembly 96 is attached to a cowl 100 of the vehicle (not shown).
[0027] A first scroll fan 106 and a second scroll fan 108 are attached to opposite ends of a shaft 110 . A motor 102 operates the scroll fans 106 and 108 , as previously described. A first fresh air port 112 is provided through the cowl 100 and may be opened and closed by a first fresh air door 114 . A second fresh air port 116 is provided near the other end of the housing 98 and is adapted to be opened and closed by a second fresh air door 118 . The second fresh air port 116 may receive air from the outer side of the bulkhead (not shown) that is similar to the bulkhead 58 shown in FIG. 3 . A second fresh air door 118 may be opened and closed to allow fresh air F to flow into the housing 98 . A first recirculated air duct 120 is provided in the housing 98 near the first fresh air port 112 . A first roll film door 122 is provided to open and close the first recirculated air duct 120 . A second recirculated air duct 124 is provided in the opposite end of the housing 98 from the first fresh air port 112 . The second recirculated air duct 124 may be opened and closed by a second roll film door 126 , as previously described.
[0028] Referring to FIG. 5 , a horizontal blower assembly 130 is illustrated that includes a housing 132 that is adapted to be secured below the cowl 134 of the vehicle (not shown). A motor 136 is operatively connected to a first scroll fan 140 and a second scroll fan 142 by a shaft 144 .
[0029] A first fresh air port 146 is provided in the housing 132 on the left side of FIG. 5 . The first fresh air port 146 may be opened and closed by rotating a dual function door 148 to open and close the first fresh air port 146 . A second fresh air port 150 may be provided between the cowl 134 and housing 132 . The second fresh air port 150 is adapted to be opened and closed by a second fresh air door 152 . A first recirculated air duct 154 may be provided in the housing 132 to permit air to be recirculated in the passenger compartment 52 (as shown in FIG. 2 ). The dual door 148 may be used to open and close the first recirculated air duct 154 by rotating the dual door 148 between the position shown in FIG. 5 in solid lines and a position shown in phantom lines in FIG. 5 .
[0030] A second recirculated air duct 158 is provided in the opposite end of the housing 132 from the first recirculated air duct 154 . The second recirculated air duct 158 may be opened and closed by a roll film door 160 , as previously described.
[0031] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosed apparatus and method. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure as claimed. The features of various implementing embodiments may be combined to form further embodiments of the disclosed concepts.
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A blower assembly including a housing for a first scroll fan and a second scroll fan that are connected by a shaft to a motor that rotates the fans. The first and second scroll fans are coaxially mounted on the shaft. Fresh air ports and recirculated air ports are provided for the circulation of fresh air and recirculated air, respectively. The fresh air ports and recirculated air ports may be selectively opened and closed by doors to control the flow of air from the outside and from the passenger compartment as controlled by the HVAC system.
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STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment of any royalty thereon.
BACKGROUND OF THE INVENTION
This invention relates generally to an arrangement for preventing the pollution of a body of water having variable levels and more particularly to a buoy type oil gate which holds back pollutant products. Previously, oil spills into a stream of water having variable flow and, therefore, variable water levels, involved the use of high priced oil separators through which the flow of water was made to pass. In addition to expensive equipment costs required for an oil separator system, a requirement exists for much costly manpower and maintenance for effective operation. The high costs have inhibited adoption of ecological control systems because of the economic impact of high cost maintenance and equipment on the industries causing the pollution. My invention avoids the high costs attendant to prior art water pollutant control systems.
SUMMARY OF THE INVENTION
The invention relates to a buoy type oil gate which straddles a stream having variable water levels. The gate is arranged to float such that it has an area extended above the water level and has ends which ride in and seal to channels proximate to the banks of a stream.
Accordingly, it is a primary object of this invention to provide a buoy type oil gate which floats on the surface of a body of water and rides up and down within a pair of channels such that it has the capability of holding back oil from passing downstream of said gate.
It is another object of this invention to provide a buoy type gate having the gate portion of polyurethane coated timber.
It is still another object of this invention to provide a buoy type oil gate which rides in guide means located at the sides of a body of water having variable levels.
It is a further object of this invention to provide a series of buoy type oil gates for controlling the spread of petroleum and other floatable pollutants downstream of the location of the gates.
It is a still further object of this invention to provide a buoy type oil gate which is easy and economical to produce of standard, conventional, currently available materials that lend themselves to conventional manufacturing techniques.
Another object of this invention is to provide a passive control system for holding back pollutants in a stream without damming the stream.
These and other advantages, features and objects of the invention will become more apparent from the following description taken in connection with the illustrative embodiments in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section across a creek or river bed illustrating the positioning of the parts forming the buoy type gate of this invention;
FIG. 2 is a pictorial representation of a channel and the gate member of this invention;
FIGS. 3 and 4 are alternative embodiments for the ends of the gate member; and
FIG. 5 is a schematic illustration of a series of gates which may be utilized for wider body of water.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the Figures there is shown a device for holding back contaminants which float upon a body of water and more particularly one which has variable levels due, for example, to the effects of rainy seasons, etc. In order to perform the invention as best illustrated in FIG. 1 a hole is excavated at 10 into the bank 12 of a brook or river and filled with fieldstone 14. At the builders option, cement or cemented fieldstone may be utilized. A channel 16 is placed at each side of the stream and abuts the fieldstone such that the channel now seals the water from going around the system of the invention. A coated timber 18 is placed across the body of water and is installed such that it floats thereon with a portion below the water level and a portion above. The timber gate is constrained by the engagement of the ends thereof with the channels 16. The channel members 16 may be of a conventional U-shaped construction or I-beam construction, as illustrated in FIG. 2, and would be driven into the ground or bed of the stream for a number of feet and would extend above the flood level of said stream.
The ends of the timber 18 are trimmed, as illustrated at 20 in FIG. 2, to fit loosely within a channel 16 of the I-beam. The corners are rounded or beveled as at 22 in order to minimize the amount of friction and to allow free movement of the timber to follow the level of the stream. The loose fit and beveling is to reduce the friction and allow for free movement with the stream thereby avoiding a seizing of the gate to the channel by pollutents or snow and ice. A polyurethane coating is applied to the timber to seal it and provide for extended life.
The height of the gate timber 18 should be sufficient to hold back pollutants and debris that might possibly be carried over the timber if they should impinge against it with any appreciable amount of momentum.
FIG. 3 illustrates an alternative embodiment of the end 20 of the timber 18. Here a wire 30 is applied to the end portion engaged by the channel 16. The wire is of the heating element type, for example, of nichrome, and is connected to a source 32 and a switch 34 in series therewith to allow for a closure of the circuit and a heating of the wire. This avoids a seizing of the timber in the channel by melting ice during the winter that would not allow the gate timber 18 to follow the level of the stream. The wire could also run lengthwise from end to end along the timber 18 in order to assure freedom of the entire gate from ice. The wire may be embedded in grooves 36 in the timber in order to avoid having them short circuit against the metal of the channel member 16.
The avoidance of seizing at channel 16 may also be controlled by means of a teflon coating 40 applied to the ends of the gate 18, as illustrated in FIG. 4, thereby minimizing friction and providing a surface to which ice does not readily adhere.
The invention thus far described can also be utilized for large spans for large bodies of water and would have the system illustrated in FIG. 5 applied thereto. In this instance a series of gates 18 are formed and connected to a number of I-beam type channels 16 to straddle the stream.
STATEMENT OF OPERATION
With the buoy type gate or gates, previously described, installed across a stream, the gate timber 18 would float on the water and the pressure of the stream flow would cause the timber to seal across the downstream portion of the interior of the channels 16. Pollutants such as oil or gasoline and other contaminants which float on water would be held back by the timber. The same type of operation would occur with multiple gates straddling a single stream. At intervals personnel would take a pump to skim the contaminants off the top of the water and keep the system in operation. Additional timbers 18 could be stacked to form a higher gate thereby cutting down on the frequency of pollutant removal. Also, in place of the vertical orientation illustrated the channels 16 could be tilted in a downstream direction in order to assure smooth operation of the system by minimizing frictional forces.
Although the invention has been described with reference to particular embodiments, it will be understood to those skilled in the art that the invention is capable of a variety of alternative embodiments within the spirit and scope of the appended claims. For example, the gate portion need not be of wood but may be of any material or construction that floats.
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For use in a body of water having variable levels, means sealing channels to the banks of said body of water, and floatable means extending across said body of water and into said channels capable of holding back petroleum products and other floatable debris released upstream into said body of water.
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Cross Reference to Related Applications
This application is a continuation of copending application Ser. No. 656,046 now abandoned, filed on Sept. 28, 1984, which is a continuation of application Ser. No. 364,179, filed on Apr. 1, 1982, now abandoned, which is a continuation-in-part of application Ser. No. 250,491, filed Apr. 2, 1981, now abandoned, the entire disclosure of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to radiation cross-linked conductive polymer PTC compositions and devices comprising them.
2. Introduction to the Invention
Conductive polymer compositions and devices comprising them, have been described in published documents and in previous applications assigned to the same assignee. Reference may be made for example to U.S. Pat. Nos. 2,978,665 (Vernet et al.), 3,243,753 (Kohler), 3,351,882 (Kohler et al), 3,571,777 (Tully), 3,793,716 (Smith-Johannsen), 3,823,217 (Kampe), 3,861,029 (Smith-Johannsen), 4,017,715 (Whitney et al), 4,177,376 (Horsma et al), 4,237,441 (Van Konynenburg et al), 4,246,468 (Horsma) and 4,272,471 (Walker); U.K. Pat. No. 1,534,715; the article entitled "Investigations of Current Interruption by Metal-filled Epoxy Resin" by Littlewood and Briggs in J. Phys D: Appl. Phys, Vol. II, pages 1457-1462; the article entitled "The PTC Resistor" by R. F. Blaha in Proceedings of the Electronic Components Conference, 1971; the report entitled "Solid State Bistable Power Switch Study" by H. Shulman and John Bartho (Aug. 1968) under Contract NAS-12-647, published by the National Aeronautics and Space Administration; J. Applied Polymer Science 19, 813-815 (1975), Klason and Kubat; Polymer Engineering and Science 18, 649-653 (1978) Narkis et al; and commonly assigned U.S. Ser. Nos. 601,424 (Moyer), now abandoned, published as German OLS 2,634,999; 750,149 (Kamath et al), now abandoned, published as German OLS Nos. 2,755,077; 732,792 (Van Konynenburg et al), now abandoned, published as German OLS Nos. 2,746,602; 751,095 (Toy et al), now abandoned, published as German OLS Nos. 2,755,076; 798,154 (Horsma et al), now abandoned, published as German OLS Nos. 2,821,799; 965,344 (Middleman et al), published as German OLS No. 2,948,281 U.S. Pat. Nos. 4,238,812; 965,345 (Middleman et al) now abandoned, published as German OLS Nos. 2,949,173; and 6,773 (Simon), published as German OLS No. 3,002,721 now U.S. Pat. Nos. 4,255,698; 67,207 (Doljack et al), now abandoned, published as European Patent Application Nos. 26,571; 88,304 (Lutz), now abandoned, published as European Patent Application Nos. 28,142; 98,711 ( Middleman et al) now U.S. Pat. Nos. 4,315,237; 141,984 (Gotcher et al) now abandoned; 141,987 (Middleman et al) now U.S. Pat. Nos. 4,413,301; 141,988 (Fouts et al); 141,989 (Evans) published as European Patent Application Nos. 38,713; 141,991 (Fouts et al) now U.S. Pat. Nos. 4,545,926; 142,053 (Middleman et al); 142,054 (Middleman et al); 150,909 (Sopory); 150,910 (Sopory); 150,911 (Sopory); 254,352 (Taylor) now U.S. Pat. Nos. 4,426,633; 300,709 (Van Konynenburg et al) now abandoned, published as European Patent Application No. 74,281; and the application filed on Feb. 17, 1982 by McTavish et al now U.S. Pat. No. 4,481,498. The disclosure of each of the patents, publications and applications referred to above is incorporated herein by reference.
Conductive polymer compositions are frequently cross-linked, e.g. by radiation, which is generally preferred, or by chemical cross-linking, in order to improve their physical and/or electrical characteristics. Compositions exhibiting PTC behavior, which are used in self-limiting heaters and circuit protection devices, are usually cross-linked to ensure that the resistivity of the composition remains at a high level as the temperature of the composition is increased above the switching temperature (T s ) of the composition. The extent of cross-linking which has been used in practice has in general been relatively low; thus the dose used in radiation cross-linking has typically been 10 to 20 Megarads. Cross-linking by radiation using higher doses has, however, been suggested in the literature. Thus U.S. Pat. No. 3,351,882 (Kohler et al) discloses the preparation of a resistor comprising a melt-extruded PTC conductive polymer element and two planar electrodes embedded therein, followed by subjecting the entire resistor to about 50 to 100 megarads of radiation of one to two million electron volt electrons in order to cross-link the conductive polymer, particularly around the electrodes. Ser. No. 601,424 (Moyer), now abandoned, published as German OLS 2,634,999, recommends radiation doses of 20 to 45 megarads to cross-link a PTC conductive polymer, thus producing a composition which has high peak resistance and maintains a high level of resistivity over an extended range of temperatures above T s . U.K. Specification No. 1,071,032 describes irradiated compositions comprising a copolymer of ethylene and a vinyl ester or an acrylate monomer and 50-400% by weight of a filler, e.g. carbon black, the radiation dose being about 2 to about 100 Mrads, preferably about 2 to about 20 Mrads, and the use of such compositions as tapes for grading the insulation on cables.
SUMMARY OF THE INVENTION
This invention is concerned with improving the performance of electrical devices comprising conductive polymers, in particular PTC conductive polymers, which operate at a voltage of at least 200 volts. Thus the devices include for example self-limiting heaters and circuit protection devices which operate in circuits whose normal power source has a voltage of at least 200 volts, and circuit protection devices which operate in circuits whose normal power source has a voltage below 200 volts, eg. 110 volts AC or 30-75 volts DC, and which protect the circuit against intrusion of a power source having a voltage of at least 200 volts.
We have discovered that if the potential drop across a device comprising a radiation cross-linked PTC conductive polymer composition exceeds about 200 volts (voltages given herein are DC voltages or RMS values for AC power sources), the ability of the device to withstand cycling from a low resistance state to a high resistance state and back again (the high resistance state being induced by internal resistive heating) is critically dependent on the radiation dose used to cross-link the polymer.
In one aspect, the invention provides a process for the preparation of an electrical device comprising (a) a cross-linked PTC conductive polymer element and (b) two electrodes which can be connected to a source of electrical power to cause current to flow through the PTC element, said process comprising the step of irradiating the PTC element to a dosage of at least 120 Mrads.
In another aspect, the invention provides a process for the preparation of an electrical device which comprises the steps of
(1) melt-extruding a radiation cross-linkable PTC conductive polymer composition around a pair of columnar electrodes; and
(2) irradiating the extrudate obtained in step (1) to a dosage of at least 50 Mrads.
In another aspect, the invention provides a process for the preparation of an electrical device which comprises the steps of
(1) melt-extruding a radiation cross-linkable PTC conductive polymer composition to form a laminar extrudate which does not contain an electrode;
(2) irradiating the extrudate from step (1) to a dosage of at least 50 Mrads; and
(3) securing metal foil electrodes to the irradiated extrudate from step (2).
In another aspect, the invention provides a process for the preparation of an electrical device which comprises
(1) melt-extruding a radiation cross-linkable PTC conductive polymer composition to form an extrudate which does not contain an electrode;
(2) dividing the extrudate from step (1) into a plurality of discrete PTC elements, each PTC element being in the form of a strip with substantially planar parallel ends;
(3) securing to each end of the PTC element an electrode in the form of a cap having (i) a substantially planar end which contacts and has substantially the same cross-section as one end of the PTC element and (ii) a side wall which contacts the side of the PTC element; and
(4) irradiating the PTC element to a dosage of at least 50 Mrads.
In another aspect, the invention provides a process for the preparation of an electrical device which comprises
(1) forming a laminar PTC element of a radiation cross-linkable conductive polymer composition;
(2) securing electrodes to the laminar PTC element, the electrodes being displaced from each other so that at least a substantial component of current flow between the electrodes is along one of the large dimensions of the element; and
(3) irradiating the PTC element to a dosage of at least 50 Mrads.
Our experiments indicate that the higher the radiation dose, the greater the number of "trips" (i.e. conversions to the tripped state) a device will withstand without failure. The radiation dose is, therefore, preferably at least 60 Mrads, particularly at least 80 Mrads, with yet higher dosages, e.g. at least 120 Mrads or at least 160 Mrads, being preferred when satisfactory PTC characteristics are maintained and the desire for improved performance outweighs the cost of radiation.
We have further discovered a method of determining the likelihood that a device will withstand a substantial number of trips at a voltage of 200 volts. This method involves the use of a scanning electron microscope (SEM) to measure the maximum rate at which the voltage changes in the PTC element when the device is in the tripped state. This maximum rate occurs in the so-called "hot zone" of the PTC element. The lower the maximum rate, the greater the number of trips that the device will withstand.
In another aspect, the invention provides an electrical device which comprises (a) a radiation cross-linked PTC conductive polymer element and (b) two electrodes which can be connected to a power source to cause current to flow through the PTC element, said device when subjected to SEM scanning, showing a maximum difference in voltage between two points separated by 10 microns of less than 3 volts.
In another aspect, the invention provides an electrical device which comprises (a) a radiation cross-linked PTC conductive polymer element and (b) two columnar electrodes which are embedded in the PTC element and can be connected to a power source to cause current to flow through the PTC element, said device, when subjected to SEM scanning, showing a maximum difference in voltage between two points separated by 10 microns of less than 4.2 volts.
In another aspect, the invention provides an electrical device which comprises
(a) a radiation cross-linked PTC conductive polymer element in the form of a strip with substantially planar parallel ends, the length of the strip being greater than the largest cross-sectional dimensions of the strip;
(b) two electrodes, each of which is in the form of a cap having (i) a substantially planar end which contacts and has substantially the same cross-section as one end of the PTC element and (ii) a side wall which contacts the side of the PTC element;
said device, when subjected to SEM scanning, showing a maximum difference in voltage between two points separated by 10 microns of less than 4.2 volts.
BRIEF DESCRIPTION OF THE DRAWING
The invention is illustrated in the accompanying drawing, in which
FIG. 1 is diagrammatic representation of a typical photomicrograph obtained in the SEM scanning of a device of the invention, and
FIGS. 2, 3, 4 and 5 illustrate devices of the invention.
FIG. 6 is a block diagram of a process of the invention in which an electrical device is made by melt-extruding a PTC conductive polymer to form an extrudate which does not contain an electrode, dividing the extrudate into discrete PTC elements, each in the form of a strip with substantially parallel planar ends, cross-linking the conductive polymer by irradiating substantially the whole of each discrete PTC element to the desired dosage, and securing a cap electrode to each end of the discrete PTC elements; and
FIG. 7 is a block diagram of a process which is the same as that shown in FIG. 6 except that the cap electrodes are secured to the PTC elements before the irradiation step.
DETAILED DESCRIPTION OF THE INVENTION
The term "SEM scanning" is used herein to denote the following procedure. The device is inspected to see whether the PTC element has an exposed clean surface which is suitable for scanning in an SEM and which lies between the electrodes. If there is no such surface, then one is created, keeping the alteration of the device to a minimum. The device (or a portion of it if the device is too large, e.g. if it is an elongate heater) is then mounted in a scanning electron microscope so that the electron beam can be transversed from one electrode to the other and directed obliquely at the clean exposed surface. A slowly increasing current is passed through the device, using a DC power source of 200 volts, until the device has been "tripped" and the whole of the potential dropped across it. The electron beam is then traversed across the surface and, using voltage contrast techniques known to those skilled in the art, there is obtained a photomicrograph in which the trace is a measure of the brightness (and hence the potential) of the surface between the electrodes; such a photomicrograph is often known as a line scan. A diagrammatic representation of a typical photomicrograph is shown in FIG. 1. It will be seen that the trace has numerous small peaks and valleys and it is believed that these are due mainly or exclusively to surface imperfections. A single "best line" is drawn through the trace (the broken line in FIG. 1) in order to average out small variations, and from this "best line", the maximum difference in voltage between two points separated by 10 microns is determined.
When reference is made herein to an electrode "having a substantially planar configuration", we mean an electrode whose shape and position in the device are such that substantially all the current enters (or leaves) the electrode through a surface which is substantially planar.
The present invention is particularly useful for circuit protection devices, but is also applicable to heaters, particularly laminar heaters. In one class of devices, each of the electrodes has a columnar shape. Such device is shown in isometric view in FIG. 2, in which wire electrodes 2 are embedded in PTC conductive polymer element 1 having a hole through its center portion.
In a second class of devices, usually circuit protection devices,
(A) the PTC element is in the form of a strip with substantially planar parallel ends, the length of the strip being greater than the largest cross-sectional dimension of the strip; and
(B) each of the electrodes is in the form of a cap having (i) a substantially planar end which contacts and has substantially the same cross-section as one end of the PTC element and (ii) a side wall which contacts the side of the PTC element.
Such a device is shown in cross-section in FIG. 3, in which cap electrodes 2 contact either end of cylindrical PTC conductive polymer element 1 having a hole 11 through its center portion.
In a third class of devices, usually heaters,
(A) the PTC element is laminar; and
(B) the electrodes are displaced from each other so that at least a substantial component of the current flow between them is along one of the large dimensions of the element.
Such a device is illustrated in cross-section in FIG. 4 and comprises metal strip electrodes 2 which contact laminar PTC element 1 and insulating base 5.
In a fourth class of devices, each of the electrodes has a substantially planar configuration. Such a device is illustrated in cross-section in FIG. 5 and comprises a laminar PTC element sandwiched between metal electrodes 2. Meshed planar electrodes can be used, but metal foil electrodes are preferred. If metal foil electrodes are applied to the PTC element before it is irradiated, there is a danger that gases evolved during irradiation will be trapped. It is preferred, therefore, that metal foil electrodes be applied after the radiation cross-linking step. Thus a preferred process comprises
(1) irradiating a laminar PTC conductive polymer element in the absence of electrodes;
(2) contacting the cross-linked PTC element from step (1) with metal foil electrodes under conditions of heat and pressure, and
(3) cooling the PTC element and the metal foil electrodes while continuing to press them together.
PTC conductive polymers suitable for use in this invention are disclosed in the patents and applications referenced above. Their resistivity at 23° C. is preferably less than 1250 ohm.cm, eg. less than 750 ohm.cm, particularly less than 500 ohm.cm, with values less than 50 ohm.cm being preferred for circuit protection devices. The polymeric component should be one which is cross-linked and not significantly degraded by radiation. The polymeric component is preferably free of thermosetting polymers and often consists essentially of one or more crystalline polymers. Suitable polymers include polyolefins, eg. polyethylene, and copolymers of at least one olefin and at least one olefinically unsaturated monomer containing a polar group. The conductive filler is preferably carbon black. The composition may also contain a non-conductive filler, eg. alumina trihydrate. The composition can, but preferably does not, contain a radiation cross-linking aid. The presence of a cross-linking aid can substantially reduce the radiation dose required to produce a particular degree of cross-linking, but its residue generally has an adverse effect on electrical characteristics.
Shaping of the conductive polymer will generally be effected by a melt-shaping technique, eg. by melt-extrusion or molding.
The invention is illustrated by the following Example
EXAMPLE
The ingredients and amounts thereof given in the Table below were used in the Example.
TABLE______________________________________ Masterbatch Final Mix g wt % vol % g wt % vol %______________________________________Carbon black 1440 46.8 32.0 1141.5 33.7 26.7(Statex G)Polyethylene 1584 51.5 66.0 1256.2 37.1 55.2(Marlex 6003)Filler 948.3 28.0 16.5(Hydral 705)Antioxidant 52.5 1.7 2.0 41.5 1.2 1.6______________________________________ Notes: Statex G, available from Columbian Chemicals, has a density of 1.8 g/cc, surface area (S) of 35 m.sup.2 /g, and an average particle size (D) of 60 millimicrons. Marlex 6003 is a high density polyethylene with a melt index of 0.3 which is available from Phillips Petroleum. Hydral 705 is alumina trihydrate available from Aluminum Co. of America. The antioxidant used was an oligomer of 4,4thiobis (3methyl-6-5-butyl phenol) with an average degree of polymerization of 34, as described in U.S. Pat. No. 3,986,981.
After drying the polymer at 70° C. and the carbon black at 150° C. for 16 hours in a vacuum oven, the ingredients for the masterbatch were dry blended and then mixed for 12 minutes in a Banbury mixer turning at high gear. The mixture was dumped, cooled, and granulated. The final mix was prepared by dry blending 948.3 g. of Hydral 705 with 2439.2 g. of the masterbatch, and then mixing the dry blend for 7 minutes in a Banbury mixer turning at high gear. The mixture was dumped, cooled, granulated, and then dried at 70° C. and 1 torr for 16 hours. Using a cross-head die, the granulated final mix was melt extruded as a strip 1 cm. wide and 0.25 cm. thick, around three wires. Two of the wires were preheated 20 AWG (0.095 cm. diameter) 19/32 stranded nickel-plated copper wires whose centers were 0.76 cm. apart, and the third wire, a 24 AWG (0.064 cm. diameter) solid nickel-plated copper wire, was centered between the other two. Portions 1 cm. long were cut from the extruded product and from each portion the polymeric composition was removed from about half the length, and the whole of the center 24 AWG wire was removed, leaving a hole running through the polymeric element. The products were heat treated in nitrogen at 150° C. for 30 minutes and then in air at 110° C. for 60 minutes, and were then irradiated. Samples were irradiated to dosages of 20 Mrads, 80 Mrads or 160 Mrads. These samples, when subjected to SEM scanning, were found to have a maximum difference in voltage between two points separated by 10 microns of about 5.2, about 4.0 and about 2.0 respectively. Some of these samples were then sealed inside a metal can, with a polypropylene envelope between the conductive element and the can. The resulting circuit protection devices were tested to determine how many test cycles they would withstand when tested in a circuit consisting essentially of a 240 volt AC power supply, a switch, a fixed resistor and the device. The devices had a resistance of 20-30 ohms at 23° C. and the fixed resistor had a resistance of 33 ohms, so that when the power supply was first switched on, the initial current in the circuit was 4-5 amps. Each test cycle consisted of closing the switch, thus tripping device, and after a period of about 10 seconds, opening the switch and allowing the device to cool for 1 minute before the next test cycle. The resistance of the device at 23° C. was measured initially and after every fifth cycle. The Table below shows the number of cycles needed to increase the resistance to 11/2 times its original value.
______________________________________Device irradiated to Resistance increased toa dose of 11/2 times after______________________________________ 20 Mrads 40-45 cyc1es 80 Mrads 80-85 cyc1es160 Mrads 90-95 cycles______________________________________
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Conductive polymer PTC compositions have improved properties, especially at voltages of 200 volts or more, if they are very highly cross-linked by means of irradiation, for example to a dosage of at least 50 Mrads, preferably at least 80 Mrads, e.g. 120 to 600 Mrads. The cross-linked compositions are particularly useful in circuit protection device and layered heaters.
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TECHNICAL FIELD
The present invention relates to a cyclic process for the production of taurine from ammonium isethionate in a high overall yield (i.e., greater than 90% to nearly quantitative) by carrying out the ammonolysis reaction of alkali isethionate to alkali taurinate in the presence of a mixture of alkali ditaurinate and alkali tritaurinate, followed by reacting with ammonium isethionate.
BACKGROUND OF THE INVENTION
Taurine can be referred to as 2-aminoethanesulfonic acid and is one of the amino sulfonic acids found in the tissues of many animals. Taurine is an extremely useful compound with beneficial pharmacological effects, such as detoxification, fatigue-relief, and nourishing and tonifying effects. As a result, taurine finds wide applications as an essential ingredient for human and animal nutrition.
Taurine is currently produced in an amount of over 50,000 tons per year from either ethylene oxide or monoethanolamine. At the present time, most taurine is produced from ethylene oxide, following a three-step process: (1) the addition reaction of ethylene oxide with sodium bisulfite to yield sodium isethionate; (2) the ammonolysis of sodium isethionate to yield sodium taurinate; (3) the neutralization with an acid, i.e., hydrochloric acid and, preferably, sulfuric acid, to generate taurine and inorganic salts.
Although the ethylene oxide process is well established and widely practiced in commercial production, the overall yield is not very high, less than 80%. Moreover, the process generates a large waste stream that is increasingly difficult to dispose of.
The first stage of the ethylene oxide process, the addition reaction of ethylene oxide with sodium bisulfite, is known to yield sodium isethionate in high yield, practically quantitative, as disclosed in U.S. Pat. No. 2,820,818 under described conditions.
Therefore, the problems encountered in the production of taurine from the ethylene oxide process arise from the ammonolysis of sodium isethionate and from the separation of taurine from sodium sulfate
U.S. Pat. No. 1,932,907 discloses that sodium taurinate is obtained in a yield of 80%, when sodium isethionate undergoes ammonolysis reaction in a molar ratio of 1:6.8 for 2 hours at 240 to 250° C. U.S. Pat. No. 1,999,614 describes the use of catalysts, i.e., sodium sulfate, sodium sulfite, and sodium carbonate, in the ammonolysis reaction. A mixture of sodium taurinate and sodium ditaurinate is obtained in a yield as high as 97%. However, the percentage for sodium taurinate and sodium ditaurinate in the mixture is not specified.
DD219023 describes detailed results on the product distribution of the ammonolysis reaction of sodium isethionate. When sodium isethionate undergoes the ammonolysis reaction with 25% aqueous ammonia in a molar ratio of 1:9 at about 280° C. for 45 minutes in the presence of sodium sulfate and sodium hydroxide as catalyst, the reaction products comprise 71% of sodium taurinate and 29% of sodium di- and tri-taurinate.
WO01/77071 is directed to a process for the preparation of ditaurine by heating an aqueous solution of sodium taurinate at a temperature of 210° C. in the presence of a reaction medium. A mixture of sodium taurinate and sodium ditaurinate is obtained.
It is therefore concluded from the foregoing references that the ammonolysis of sodium isethionate invariably yields a mixture of sodium taurinate, sodium ditaurinate, and sodium tritaurinate. The percentage yield of sodium taurinate has not been more than 80%.
In order to obtain taurine from sodium taurinate, U.S. Pat. No. 2,693,488 discloses a method of using ion exchange resins involving a strongly acid ion exchange resin in hydrogen form, and then an anion exchange resin in basic form. This process is complicated and requires the use of a large quantity of acid and base to regenerate the ion exchange resins in each production cycle.
On the other hand, CN101508657, CN101508658, CN101508659, and CN101486669 describe a method of using sulfuric acid to neutralize sodium taurinate to obtain a solution of taurine and sodium sulfate. Crude taurine is easily obtained by filtration from a crystalline suspension of taurine after cooling. However, the waste mother liquor still contains taurine, sodium sulfate, and other unspecified organic impurities, which are identified as a mixture of sodium ditaurinate and sodium tritaurinate.
U.S. Pat. No. 9,428,450 and U.S. Pat. No. 9,428,451 overcome some of the problems in the known ethylene oxide process by converting the byproducts of the ammonolysis reaction of alkali isethionate, alkali ditaurinate and alkali tritaurinate, into alkali taurinate. The overall yield of the cyclic process for producing taurine from sodium isethionate is increased to from 85% to nearly quantitative.
U.S. Pat. No. 8,609,890 discloses a process of using isethionic acid or sulfur dioxide to neutralize alkali taurinate to producing taurine and to regenerate alkali isethionate. U.S. Pat. No. 9,108,907 further discloses a process of using isethionic acid prepared from ethanol to neutralize alkali taurinate to regenerate alkali isethionate. The aim is to reduce or eliminate the use of sulfuric acid as an acid agent in the production of taurine.
U.S. Pat. No. 9,061,976 discloses an integrated production scheme by using sulfur dioxide as an acid and by converting the byproducts of the ammonolysis reaction, alkali ditaurinate and alkali tritaurinate, to alkali taurinate. The overall production yield is increased to greater than 90% and alkali sulfate is eliminated from the production process. One drawback of this process is the use of gaseous sulfur dioxide, which imparts a slight smell on the product. Another significant drawback is that the taurine product from this process may contain trace amount of alkali sulfite which could be an allergen for certain people.
Copending U.S. Ser. No. 15/238,621 discloses a cyclic process for producing taurine from isethionic acid in a high overall yield of greater than 90% to nearly quantitative, while generating no inorganic salt as byproducts. However, the starting material, isethionic acid, is difficult to obtain commercially and is produced by a costly process of bipolar membrane electrodialysis of alkali isethionate.
CN 101717353A describes a process of preparing taurine by (1) reacting ethylene oxide with ammonium sulfite to yield ammonium isethionate and ammonia; (2) ammonolysis of the obtained product to ammonium taurinate; (3) acidifying with sulfuric acid to afford taurine. However, repeated attempts fail to produce any taurine under disclosed conditions.
It is an object of the present invention to overcome the disadvantage of the known processes for the production of taurine and to provide, in addition, advantages, which will become apparent from the following description.
It is another object of the present invention to disclose a process for the production of taurine from ammonium isethionate in a high overall yield (i.e., greater than 90% to nearly quantitative) without generating any inorganic salt as byproduct.
The starting material, ammonium isethionate, can be readily and economically produced by reacting ethylene oxide with ammonium bisulfite according to prior arts, e.g., U.S. Pat. No. 5,646,320 and U.S. Pat. No. 5,739,365.
According to the process of the present invention, a solution of alkali isethionate or regenerated alkali isethionate, alkali ditaurinate, and alkali tritaurinate is mixed with an excess ammonia and is subjected continuously to the ammonolysis reaction to form a mixture of alkali taurinate, alkali ditaurinate, and alkali tritaurinate, in the presence of one or more catalysts. After ammonium isethionate is added to the ammonolysis solution, excess ammonia is removed to obtain a crystalline suspension of taurine in a solution of alkali isethionate, alkali ditaurinate, and alkali tritaurinate. Upon the solid-liquid separation of taurine, the mother liquor is directly recycled to the ammonolysis step.
The advantage of using ammonium isethionate as a starting material becomes apparent in that no isolation of alkali salt as a byproduct is necessary after the separation of crystalline taurine from the mother liquor containing alkali isethionate, alkali ditaurinate, and alkali tritaurinate.
DESCRIPTION OF THE INVENTION
The present invention relates to a cyclic process for the production of taurine from ammonium isethionate in a high overall yield of greater than 90% to nearly quantitative without generating any inorganic salt as byproduct.
The starting material, ammonium isethionate is produced by reacting ethylene oxide with ammonium bisulfite according to the following equation:
Ammonium isethionate, produced in a solution, can be used directly for the production of taurine. Preferably, ammonium isethionate is purified by concentrating the solution to obtain crystalline materials. When solid ammonium isethionate is used in the production of taurine, the quality of taurine produced is improved and almost no purge of mother liquor is required from the cyclic process.
The process according to the present invention starts with mixing a solution of alkali isethionate or regenerated alkali isethionate, alkali ditaurinate, and alkali tritaurinate, with an excess of ammonia. The presence of alkali ditaurinate and alkali tritaurinate in the reaction solution inhibits the formation of byproducts, increases the production yield, and greatly reduces or eliminates the waste discharge from the production process. The alkali metals are lithium, sodium, or potassium.
The ammonolysis reaction is carried out at a temperature from 160° C. to 260° C. under the pressure from autogenous to 260 bars for 1 to 6 hours.
After the ammonolysis reaction, ammonium isethionate is added to the ammonolysis solution to react with alkali taurinates. Excess ammonia is dispelled from the reaction solution and reclaimed for reuse. Upon concentrating and cooling, a crystalline suspension of taurine is obtained in a solution of alkali ditaurinate, alkali tritaurinate, and a trace amount of unreacted alkali isethionate.
The amount of ammonium isethionate in relation to alkali taurinate in the ammonolysis solution can be from 0.1 to 10 on the molar basis. Preferably, the molar ratio is from 0.5 to 1.5, more preferably from 0.9 to 1.1, and most preferably from 0.95 to 1.05. When the ratio is lower than the equivalent, the final pH after ammonia removal tends to be higher than 7 and more taurine will remain in the solution. When the ratio is greater than equivalent, the final pH is in the desirable range of 5 to 6, but additional alkali hydroxide will be consumed during the ammonolysis stage.
The reaction of alkali taurinate formed in the ammonolysis stage with ammonium isethionate proceeds according to the following equation:
Removal of the excess ammonia and ammonia released from the above reaction can be effected by heating or by stripping with steam. After complete removal of ammonia, the strongly basic solution becomes neutral to yield a crystalline suspension of taurine in a solution of alkali isethionate, alkali ditaurinate, alkali tritaurinate, and a small amount of unreacted alkali isethionate. The initial suspension is optionally concentrated, then cooled to crystallize taurine. Taurine is obtained by means of solid-liquid separation.
After separation of taurine, the mother liquor, containing regenerated alkali isethionate, alkali ditaurinate, and alkali tritaurinate, is saturated with ammonia and is subjected to the ammonolysis reaction.
It becomes apparent that alkali in the reaction system is continuously recycled in the process and only ammonium isethionate is transformed to taurine. The net reaction of the cyclic process is:
Useful and effective catalysts for the ammonolysis reaction are found among the alkali salts of hydroxide, carbonate, bicarbonate, hydrogen sulfate, sulfate, bisulfite, sulfite, nitrate, phosphate, chlorate, and perchlorate. Such salts are sodium hydroxide, lithium hydroxide, potassium hydroxide, lithium carbonate, lithium bicarbonate, sodium bicarbonate, sodium bicarbonate, potassium bicarbonate, lithium carbonate, sodium carbonate, potassium carbonate, lithium sulfate, sodium sulfate, potassium sulfate, lithium phosphate, sodium phosphate, potassium phosphate, lithium sulfite, sodium sulfite, and potassium sulfite.
The catalyst for the ammonolysis reaction of alkali isethionate in the presence of alkali ditaurinate and alkali tritaurinate can be one component or a combination of two or more components. Preferable catalysts are alkali hydroxide and the most preferable catalyst is sodium hydroxide.
The amount of the catalyst used is not limited, but is usually from 0.01 to 10 in molar ratio of the catalyst to alkali isethionate. The ratio is preferably in the range of 0.01 to 1, more preferably 0.1 to 0.5, most preferably 0.2 to 0.3. A suitable amount of catalyst can be selected by those skilled in the art for the ammonolysis reaction to complete in desired time.
As a catalyst, alkali hydroxide is introduced into the reaction system and additional ammonium isethionate is required to neutralize the strong base. The result is an increased accumulation of alkali in the cyclic process. It is thus preferable to generate the alkali hydroxide within the production unit. A convenient way is to split alkali ditaurinate in the mother liquor into an acid component, ditaurine, and a alkali hydroxide component, by using bipolar membrane electrodialysis. The ditaurine solution is used as an acid after the ammonolysis while alkali hydroxide is used as a catalyst for the ammonolysis reaction.
The cyclic process according to the present invention affords taurine in a yield of greater than 90%, to nearly quantitative, and generates no waste other than a small amount of purge from the cyclic system.
The process according to the present invention can be carried out discontinuously, semi-continuously, and continuously.
DESCRIPTION OF THE DRAWING
FIG. 1 illustrates one embodiment of a flowchart for producing taurine from ammonium isethionate.
EXAMPLES
The following examples illustrate the practice of this invention but are not intended to limit its scope.
Example 1
To a 2-L autoclave are added 1200 mL of 24% ammonia solution, 296 g of sodium isethionate, and 2 g of sodium hydroxide. The solution is heated to 260° C. for 2 hours under autogenous pressure. After cooling, 286.2 g of ammonium isethionate is added and ammonia is removed by boiling to bring the pH of the solution to pH 6.5. After heating to remove excess ammonia, concentrating and cooling to room temperature, a suspension of crystalline taurine is obtained. Taurine is recovered by filtration and dried to 189.3 g. Taurine is recovered in a yield of 75.7%.
Example 2
To the mother liquor of Example 1 is added 340 g of gaseous ammonia and total volume is adjusted to 1500 mL with deionized water, followed by addition of 12.4 g of sodium hydroxide. The solution is placed in a 2-L autoclave and is subjected to ammonolysis reaction and treatment with ammonium isethionate as described in Example 1.
Taurine, 241.2 g after drying, is obtained in a yield of 96.2% on the basis of ammonium isethionate used.
Examples 3 to 8
The mother liquor after isolation of taurine, after being saturated with ammonia, is repeatedly subjected to the ammonolysis reaction in the presence of 15 g of sodium hydroxide 5 times for an overall yield of taurine of 96.4% on the basis of ammonium isethionate used.
It will be understood that the foregoing examples, drawing, and explanation are for illustrative purposes only and that various modifications of the present invention will be self-evident to those skilled in the art. Such modifications are to be included within the spirit and purview of this application and the scope of the appended claims.
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There is disclosed a process for producing taurine from ammonium isethionate by the ammonolysis of alkali isethionate in the presence of alkali ditaurinate or alkali tritaurinate, or their mixture, to inhibit the formation of byproducts and to continuously convert the byproducts of the ammonolysis reaction to alkali taurinate. Alkali taurinate is reacted with ammonium isethionate to obtain taurine and to regenerate alkali isethionate. The production yield is increased to from 90% to nearly quantitative. The ammonolysis reaction is catalyzed by alkali salts of hydroxide, sulfate, sulfite, phosphate, or carbonate.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] This invention relates to apparatus and methods for efficiently computing and recomputing hash values for strings.
[0003] 2. Background of the Invention
[0004] Sequences of characters, commonly referred to as “strings,” are used extensively in modern-day programming languages. For example, the Java runtime uses the String class extensively. In the Java runtime, every string has a hash value computed over the contents of the string which is used to identify the string. Because strings may be long, computing the hash value for strings can be computationally expensive. Furthermore, because string objects are used heavily by the Java Virtual Machine (JVM) as well as applications running on the JVM, the hash function is invoked frequently. Operation of the hash function, therefore, consumes significant computational resources.
[0005] Each time a string is modified, such as by concatenating a substring to an existing string, removing a substring from the beginning or end of an existing string, or modifying a substring within an existing string that preserves the length of the string, the hash value of the modified string needs to be recomputed. Like the original hash value computation, recomputing the hash value can be computationally expensive since the hash value is typically recomputed from scratch. Because string modifications may occur frequently, such recomputations may also occur frequently, consuming significant computational resources.
[0006] In view of the foregoing, what are needed are apparatus and methods to efficiently compute and recompute hash values for strings and other sequences of characters. Ideally, such apparatus and methods may be used to efficiently recompute hash values for modified strings without having to start from scratch.
SUMMARY
[0007] The invention has been developed in response to the present state of the art and, in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available apparatus and methods. Accordingly, the invention has been developed to provide apparatus and methods for efficiently computing hash values for strings. The features and advantages of the invention will become more fully apparent from the following description and appended claims, or may be learned by practice of the invention as set forth hereinafter.
[0008] Consistent with the foregoing, a method for efficiently computing a hash value for a string is disclosed herein. In one embodiment, such a method includes receiving an original string comprising multiple characters. The method computes an original hash value for the original string. The method produces an updated string by performing at least one of the following updates on the original string: adding leading/trailing characters to the original string; removing leading/trailing characters from the original string, and modifying characters of the original string while preserving the length of the original string. The method then computes an updated hash value for the updated string by performing at least one operation on the original hash value, wherein the at least one operation takes into account the updates that were made to the original string.
[0009] A corresponding apparatus and computer program product are also disclosed and claimed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through use of the accompanying drawings, in which:
[0011] FIG. 1 is a high-level block diagram showing one example of a computing system in which an apparatus and method in accordance with the invention may be implemented;
[0012] FIG. 2 is a high-level block diagram showing one example of an object-oriented managed runtime, in this example the Java Virtual Machine, comprising a hash module in accordance with the invention;
[0013] FIG. 3A shows a first scenario where a substring is concatenated to an existing string to produce an updated string;
[0014] FIG. 3B shows a technique for efficiently computing the hash value for the updated string illustrated in FIG. 3A .
[0015] FIG. 4A shows a second scenario where a substring is removed from an existing string to produce an updated string;
[0016] FIG. 4B shows a technique for efficiently computing the hash value for the updated string illustrated in FIG. 4A .
[0017] FIG. 5A shows a third scenario where a substring is modified within an existing string while preserving the length of the existing string;
[0018] FIG. 5B shows a technique for efficiently computing the hash value for the updated string illustrated in FIG. 5A .
DETAILED DESCRIPTION
[0019] It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of certain examples of presently contemplated embodiments in accordance with the invention. The presently described embodiments will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
[0020] As will be appreciated by one skilled in the art, the present invention may be embodied as an apparatus, system, method, or computer program product. Furthermore, the present invention may take the form of a hardware embodiment, a software embodiment (including firmware, resident software, microcode, etc.) configured to operate hardware, or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “module” or “system.” Furthermore, the present invention may take the form of a computer-usable storage medium embodied in any tangible medium of expression having computer-usable program code stored therein.
[0021] Any combination of one or more computer-usable or computer-readable storage medium(s) may be utilized to store the computer program product. The computer-usable or computer-readable storage medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device. More specific examples (a non-exhaustive list) of the computer-readable storage medium may 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), a portable compact disc read-only memory (CDROM), an optical storage device, or a magnetic storage device. In the context of this document, a computer-usable or computer-readable storage medium may be any medium that can contain, store, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
[0022] Computer program code for carrying out operations 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, conventional procedural programming languages such as the “C” programming language, scripting languages such as JavaScript, or similar programming languages. Computer program code for implementing the invention may also be written in a low-level programming language such as assembly language.
[0023] Embodiments of the invention may be described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus, systems, and computer program products. 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, may be implemented by computer program instructions or code. 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.
[0024] The computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks. The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus 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.
[0025] Referring to FIG. 1 , one example of a computing system 100 is illustrated. The computing system 100 is presented to show one example of an environment where an apparatus and method in accordance with the invention may be implemented. The computing system 100 is presented only by way of example and is not intended to be limiting. Indeed, the apparatus and methods disclosed herein may be applicable to a wide variety of different computing systems in addition to the computing system 100 shown. The apparatus and methods disclosed herein may also potentially be distributed across multiple computing systems 100 .
[0026] As shown, the computing system 100 includes at least one processor 102 and may include more than one processor 102 . The processor 102 may be operably connected to a memory 104 . The memory 104 may include one or more non-volatile storage devices such as hard drives 104 a , solid state drives 104 a , CD-ROM drives 104 a , DVD-ROM drives 104 a , tape drives 104 a , or the like. The memory 104 may also include non-volatile memory such as a read-only memory 104 b (e.g., ROM, EPROM, EEPROM, and/or Flash ROM) or volatile memory such as a random access memory 104 c (RAM or operational memory). A bus 106 , or plurality of buses 106 , may interconnect the processor 102 , memory devices 104 , and other devices to enable data and/or instructions to pass therebetween.
[0027] To enable communication with external systems or devices, the computing system 100 may include one or more ports 108 . Such ports 108 may be embodied as wired ports 108 (e.g., USB ports, serial ports, Firewire ports, SCSI ports, parallel ports, etc.) or wireless ports 108 (e.g., Bluetooth, IrDA, etc.). The ports 108 may enable communication with one or more input devices 110 (e.g., keyboards, mice, touchscreens, cameras, microphones, scanners, storage devices, etc.) and output devices 112 (e.g., displays, monitors, speakers, printers, storage devices, etc.). The ports 108 may also enable communication with other computing systems 100 .
[0028] In certain embodiments, the computing system 100 includes a network adapter 114 to connect the computing system 100 to a network 116 , such as a LAN, WAN, or the Internet. Such a network 116 may enable the computing system 100 to connect to one or more servers 118 , workstations 120 , personal computers 120 , mobile computing devices, or other devices. The network 116 may also enable the computing system 100 to connect to another network by way of a router 122 or other device 122 . Such a router 122 may allow the computing system 100 to communicate with servers, workstations, personal computers, or other devices located on different networks.
[0029] As shown in FIG. 2 , in the Java Runtime Environment, a Java Virtual Machine 202 may be configured to operate on a specific platform, which may include an underlying hardware and operating system architecture 204 , 206 . As shown, the Java Virtual Machine 202 receives program code 200 , compiled to an intermediate form referred to as “bytecode” 200 . The Java Virtual Machine 202 translates this bytecode 200 into native operating system calls and machine instructions for execution on the underlying platform 204 , 206 . Instead of compiling the bytecode 200 for the specific hardware and software platform 204 , 206 , the bytecode 200 may be compiled once to operate on all Java Virtual Machines 202 . A Java Virtual Machine 202 , by contrast, may be tailored to the underlying hardware and software platform 204 , 206 . In this way, the Java bytecode 200 may be considered platform independent.
[0030] As previously mentioned, the Java runtime uses the String class extensively. In the Java runtime, every string has a hash value computed over the contents of the string in order to identify the string. Each time a string is modified, such as by concatenating a substring to an existing string, removing a substring from the beginning or end of an existing string, or modifying a substring within an existing string that preserves the length of the string, the hash value for the modified string needs to be recomputed. For the purposes of this disclosure, the functionality used to compute or recompute a hash value associated with a string will be referred to as a hash module 208 . While the hash module 208 is shown in a Java Virtual Machine 202 , it should be recognized that the hash module 208 may also be adapted to programming languages and runtime environments other than Java. Thus, nothing in this disclosure should be interpreted to limit the hash module 208 to the Java Runtime Environment.
[0031] As shown, in certain embodiments, the hash module 208 may include one or more of a computation module 212 , a determination module 214 , and a recomputation module 216 . When a string is initially created, the computation module 212 may compute the hash value for the string from scratch. When such a string is updated, however, a determination module 214 may determine the type of change that has occurred to the string. For example, the determination module 214 may determine whether a substring has been concatenated 218 to the existing string, a substring has been removed 220 from the beginning and/or end of the existing string, a substring has been modified 222 within the existing string while preserving the length of the existing string, or the like. Based on the type of change that has occurred to the existing string, a recomputation module 216 may efficiently recompute the hash value for the updated string. In doing so, the recomputation module 216 may compute the hash value for the updated string by performing one or more operations on the original hash value of the original string. This recomputation may be less computationally intensive than recomputing the hash value for the updated string from scratch.
[0032] In the following discussion associated with FIGS. 3A through 5B , various techniques will be described for computing the hash value for strings which are derived from other strings that already have their hash value computed. The following techniques avoid the need to recompute a hash value for an updated string from scratch, thereby increasing efficiency. Various equations will be presented below to illustrate these techniques. In these equations, the “%” symbol will be used to represent a modulus operator and the “.” symbol will be used to indicate string concatenation.
[0033] Referring to FIG. 3A , consider the case where a substring T is concatenated to an existing string S, such as where the string “g h i j” is concatentated to the end of the existing string “a b c d e f”. The n-byte string S may be represented as follows:
[0000] S={s[ 0], s[ 1], s[ 2] . . . s[n' 1 2], s[n− 1]}
[0000] where s[0], s[1], . . . , s[n−1] represent each of the characters of the string S.
[0034] The hash value H(S) may be computed using the following polynomial:
[0000] H ( S )= k (n−1) s[ 0]+ k (n−2) s[ 1]+ k (n−3) s[ 2]+ . . . + k 2 s[n− 3]+ k 1 s[n− 2]+ k 0 s[n− 1]
[0000] where k (n—1) , k (n−2) , k (n−3) , . . . , k 2 , k 1 , k 0 are coefficients. In certain embodiments, all addition is performed modulo g. In the case of Java, modulus g is equal to 2 32 and the constant k is equal to 31.
[0035] The polynomial illustrated above may be expressed in the form of Homer's rule as follows:
[0000] H ( S )= k ( k ( . . . ( k ( k ( ks[ 0]+ s[ 1])+ s[ 2])+ s[ 3]) . . . + s[n− 3])+ s[n− 2])+ s[n− 1]
[0036] Given two strings S and T of lengths n and m respectively, the hash value H(S.T) for the concatenated strings may be expressed as follows:
[0000] H ( S.T )= k (n+m−1) s[ 0]+ k (n+m−2) s[ 1]+ k (n+m−3) s[ 2]+ . . . + k (m+2) s[n− 3]+ k (m+1) s[n− 2]+ k (m) s[n− 1]+ k (m−1) t[ 0]+ k (m−2) t[ 1]+ k (m−3) t[ 2]+ . . . + k (2) t[m− 3]+ kt[m− 2]+ t[m− 1]
[0037] Assuming that H(S) and H(T) have already been computed, the hash value of the concatenated string S.T may be computed as follows, as illustrated in FIG. 3 B:
[0000] H ( S.T )= k m H ( S )+ H ( T )
[0000] The above equation avoids the need to recompute the hash value of the concatenated string S.T from scratch.
[0038] This equation may be extended to compute the hash value of more than two concatenated strings, such as the following equation which computes the hash value for three concatenated strings:
[0000] H ( S.T.U )= k (m+n) H ( S.T )+ H ( U )
[0039] In certain embodiments, the techniques described above may be used to compute the hash value of a long string in parallel. For example, consider a string S which is the concatenation of multiple substrings S 0 , S 1 , . . . , Sf−1, Sf. Without a loss of generality, assume that each substring is of length p. The sub-hash values H[S 0 ], H[S 1 ], . . . , H[Sf−1], H[Sf] may be computed and combined as follows:
[0000] H ( S )= H ( S 0)( k (pf) )+ H ( S 1)( k ((p(f−1)) )+ . . . + H ( Sf− 1)( k P )+ H ( Sf )
[0000] where each of the components H(S 0 )(k (pf)), H(S1)(k ((p(f−1)) ), . . . , H(Sf−1)(k P ), H(Sf) may be processed by a different processor core.
[0040] Alternatively, the sub-hash values may be computed in an interleaved fashion. For example, assuming the sub-hash values are computed in a four-way parallel fashion, the four sub-hash values may be computed as follows:
[0000] H ( S 0)= k (n−1) s[ 0]+ k (n−5) s[ 4]+ k (n−9) s[ 8]+ . . .
[0000] H ( S 1)= k (n−2) s[ 1]+ k (n−6) s[ 5]+ k (n−10) s[ 9]+ . . .
[0000] H ( S 2)= k (n−3) s[ 2]+ k (n−7) s[ 6]+ k (n−11) s[ 10]+ . . .
[0000] H ( S 3)= k (n−4) s[ 3]+ k (n−8) s[ 7]+ k (n−12) s[ 11]+ . . .
[0000] where S 0 contains the first character of each substring in the string S, S 1 contains the second character of each substring in the string S, S 2 contains the third character of each substring in the string S, and S 3 contains the fourth character of each substring in the string S. Once the sub-hash values for S 0 , S 1 , S 2 , and S 3 are calculated, the hash value for the string S may be computed by summing the results as follows:
[0000] H ( S )= H ( S 0)+ H ( S 1)+ H ( S 2)+ H ( S 3)
[0041] Referring to FIG. 4A , consider the case where a substring T is removed form a string S, leaving the substring U, such as where the leading substring string “a b c d e f” is removed from the string “a b c de f g h i f”, thereby leaving the string “g h i j”. The n-byte string S may be represented as follows:
[0000] S=T.U
[0000] where substring T is of length m.
[0042] Accordingly, the hash value for the substring U may be computed as follows, as shown in FIG. 4 B:
[0000] H ( U )= H ( S )− k m H ( T )
[0000] where the hash value H(S) is known (assuming it has already been computed) and the hash value H(T) is unknown.
[0043] To compute the hash value H(T) of the leading substring T, it can be shown how to compute H(T) when the length of U is one character. Since the value of the polynomial without the modulus operation is generally greater than g, the following equation generally applies:
[0000] H ( S )=( H ( T ) k+H ( U )) % g
[0000] or
[0000] H ( T ) k+H ( U )= H ( S )+ m
[0000] where m is an integer multiple of g.
[0044] Rearranging the terms yields:
[0000] H ( T ) k=H ( S )− H ( U )+ m
[0045] Dividing both sides of the equation by k yields:
[0000] H ( T )=( H ( S )− H ( U )+ m ) k
[0000] which leaves no remainder.
[0046] To find m, the remainder r may be calculated as follows:
[0000] r= ( H ( S )− H ( U ))% k
[0047] This in turn yields:
[0000] m= ( k−r ) u
[0000] where u is a multiple of g selected in advance such that:
[0000] u % k= 1
[0048] This equation may be applied recursively to compute the hash value when several characters are removed from the end of a string. Furthermore, by replacing k in the above equations with a power of k, multiple characters may be removed simultaneously.
[0049] Referring to FIG. 5A , consider the case where a substring (indicated in the dotted box) within a string S is modified to yield an updated string S′ that preserves the length of the original string S. In the illustrated example, the substring “d e f g” within the string S is changed to “k l m n” to yield the updated string S′.
[0050] The original string S may be represented as follows:
[0000] S={s[ 0], s[ 1], s[ 2], . . . , s[p], s[p− 1], . . . , s[q+ 1], s[q], . . . , s[n− 2], s[n− 1]}
[0000] where the characters between s[p] and s[q] are those that are to be modified.
[0051] The updated string S′ may be represented as follows:
[0000] S′={s[ 0], s[ 1], s[ 2] . . . s′[p], s′[p− 1], . . . s′[q+ 1], s′[q] . . . s[n− 2], s[n− 1]}
[0000] where s′[p] and s′[q] are the first and last characters respectively of the modified substring.
[0052] The hash value of the altered string S′ may be computed by examining the modified characters, such that:
[0000]
S′=S+R
[0000] where
[0000] R={ 0 . . . 0, s′[p]−s[p], s′[p− 1]− s[p− 1], . . . , s′[q+ 1]− s[q+ 1], s′[q]−s[q], 0 . . . 0}
[0053] The hash value of the updated string S′ may then be computed as follows, as shown in FIG. 5 B:
[0000] H ( S′ )= H ( S )+ H ( R )
[0000] where
[0000]
H
(
R
)
=
k
p
(
s
′
[
p
]
-
s
[
p
]
)
+
k
(
p
-
1
)
(
s
′
[
p
-
1
]
-
s
[
p
-
1
]
)
+
k
(
q
+
1
)
(
s
′
[
q
+
1
)
-
s
[
q
+
1
]
)
+
k
q
(
s
′
[
q
]
-
s
[
q
]
)
[0054] The block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer-usable storage media according to various embodiments of the present invention. In this regard, each block in the 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 discussed in association with a block may occur in a different order than discussed. For example, two functions occurring in succession may, in fact, be implemented in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams, and combinations of blocks in the block diagrams, may be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
|
A method for efficiently computing a hash value for a string is disclosed. In one embodiment, such a method includes receiving an original string comprising multiple characters. The method computes an original hash value for the original string. The method produces an updated string by performing at least one of the following updates on the original string: adding leading/trailing characters to the original string; removing leading/trailing characters from the original string, and modifying characters of the original string while preserving the length of the original string. The method then computes an updated hash value for the updated string by performing at least one operation on the original hash value, wherein the at least one operation takes into account the updates that were made to the original string. A corresponding apparatus and computer program product are also disclosed.
| 6
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FIELD OF THE INVENTION
[0001] This invention relates to an extended release composition of paliperidone for maintaining desired therapeutic drug effect over a prolonged period of time within gastrointestinal track in an extended release manner and thereby reducing the side effects resulting due to excess drug blood plasma concentration.
BACKGROUND AND PRIOR ART
[0002] The present invention describe with an extended release of paliperidone, a hydroxyl derivative of risperidone. Paliperidone is insoluble in water, partly soluble in methyl chloride and soluble in 0.1 N HCl. It has a long half-life of about one day and degrades into detectable amount of impurities like C-9 ketoes, N-Oxides, and dimmers. Further high blood plasma concentration of paliperidone restricts its immediate release dosage administration as high concentration of drug in blood plasma produces several side effects like anxiety, somnolence, dizziness, constipation, and extrapyrimidal symptoms.
[0003] U.S. Pat. No 5,158,952 claims paliperidone or its pharmaceutically acceptable acid addition salts. Further it also claims for method of treating warm-blooded animals suffering from psycotic disease.
[0004] U.S. Pat. No. 5,536,507 discloses enteric coated pellets comprising a core of active ingredient, microcrystalline cellulose, pH sensitive polymer and optionally osmotic agent wherein core is coated with non-water soluble polymers followed by enteric coat. The disclosed compositions mainly applicable to active substances, which are unstable in the lower pH range of gastrointestinal tract, can cause stomach irritation or weak bases or salts.
[0005] WO 2004010981 & WO 2006085856 discloses osmotic system to achieve extended release of paliperidone. This system utilize osmotic pressure to generate driving force for imbibing fluid into a compartment formed by a semi permeable membrane that permits free diffusion of fluid but not drug or osmotic agent. This pH independent system comprising semi permeable membrane surrounding three-layer core, wherein first drug layer, adjacent to an orifice drilled through the membrane, comprising low amount of drug and osmotic agents; middle layer containing higher amount of drug, excipients and no salt and third push layer, contains osmotic agents and no drug. Further these patents also disclose the method of release of drug through the said composition.
[0006] WO 2006017537 discloses double matrix layered extended release dosage form wherein first delay layer comprising matrix polymer and microencapsulated drugs, free from non-microencapsulated drug while other layer comprising polymer matrix and non-microencapsulated drug and both the layers are adjacent to each other. This patent has focused to micro encapsulation of drug that is benefited to slow release of drug compared to non-microencapsulated drug.
[0007] The inventors of the present invention have tried to achieve extended release of paliperidone through conventional economic process by incorporating matrixing agent intragranularly and extra granularly and functional coat of pH independent polymer.
OBJECT OF THE INVENTION
[0008] The main object of the invention is to attain extended release of paliperidone by making dosage form in conventional way that is benefited with respect to economy and reduction of time consumption to industry.
[0009] Another object of the invention is to develop extended release composition that control the blood plasma concentration of a drug and thereby prevent the side effects occurred due to high blood plasma concentration of drug.
[0010] Still one more object of the invention is to provide extended release oral composition having more retentive and complete release of an active ingredient after its administration.
[0011] Still another object of the invention is to provide a process for preparing extended release composition by incorporating matrixing agent intragranularly and extra granularly in conventional way.
[0012] Still one more object of the invention is to attain at least 50% of the release of active ingredient in 12 hours.
SUMMARY OF THE INVENTION
[0013] The present invention is directed towards extended release solid oral composition comprising a core, inclusive of intragranular-extragranular application of matrixing agent, comprising active ingredient, one or more polymer matrix and one or more pharmaceutically acceptable excipients wherein granules are subject to compression followed by functional coat of pH independent polymer.
[0014] Further the present invention is also directed toward the process for preparation of extended release composition of paliperidone as describe below.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In one of the embodiment of the present invention is compressed solid dosage form, provided for extended release of drug.
[0016] The composition of the present invention includes two compartments: First compartment, the core, is manufactured by use of matrixing agent intragranularly and extra granularly wherein the other intragranular ingredients comprises paliperidone or its pharmaceutically acceptable salts, one or more matrixing agent and other pharmaceutically acceptable excipients and extragranuler comprises one or more matrixing agent and/or other pharmaceutically acceptable excipients.
[0017] The second compartment of the composition, functional coat, comprises low permeable polymer and other acceptable excipients. Composition may also be further coated with color coat for aesthetic appeal.
[0018] The active ingredient in the present composition is ranged from 1-20% w/w of the composition.
[0019] Matrixing agent used in both intragranular as well as extragranuler, in the range of 1-80%, includes natural or synthetic are selected from the group comprising polysaccharides such as xanthan, pullulan, chitosan and the like; Gums like guar gum, gum arabic, gum karaya, and the like; and cellulose ethers, such as hydroxymethylcellulose (HMC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC), methylcellulose (MC), ethylcellulose (EC), Carboxyethylcellulose (CEC), ethylhydroxyethylcellulose (EHEC), Carboxymethylhydroxyethylcellulose (CMHEC), hydroxypropylethylcellulose (HPEC), Hydroxypropyl methyl cellulose (HPMC) and sodium carboxymethylcellulose (Na CMC); Polymeric methacrylates; Carbomers as well as copolymers and/or mixtures of any of the above polymers, provided that matrixing agent characterized variant water permeability within intragranuler and extragranular.
[0020] The pharmaceutically acceptable excipients within the intragranular as well as extragranuler of the core may include diluent, binder, glidant, lubricant, antioxidant, solvents or mixtures thereof.
[0021] Diluent in core, ranges from 5 to 95% w/w of the composition, is selected from the group comprising but not limited to lactose, sucrose, mannitol, sorbitol, maltodextrin, erythritol, powdered cellulose, microcrystalline cellulose, silicified microcrystalline cellulose, starch, dibasic calcium phosphate anhydrous, tribasic calcium phosphate, kaolin, precipitated calcium carbonate.
[0022] Binders in the core, ranges from 1-25% w/w of the composition, is selected from the group comprising but not limited to povidone, hydroxypropylmethylcellulose, acacia, starch, alginic acid, hydroxyethylcellulose, carboxymethylcellulose sodium, sugar, gelatin, liquid glucose, methyl cellulose, pregelatinized starch and the like
[0023] Antioxidant in the core, ranges from 0.05-2% w/w of the composition, is selected from the group comprising butylated hydoxyl anisol(BHA), Butylated hydroxyl Toluene (BHT), Vitamin E and the like
[0024] Solvents, used for the preparation of binding solution, are selected from the group comprising but not limited to water, isopropyl alcohol, ethanol, methanol, acetone, acetonitril, methylenechloride, ether, nucleotides, chloroform, 1,4-dioxane, tetrahydrofuran, dimethyl sulfoxide, ethylacetate, methylacetate or mixtures thereof;
[0025] Lubricant in the core, ranges from 0.5-10% w/w of the composition, is selected from the group comprising but not limited to stearic acid, polyethylene glycol, magnesium stearate, calcium stearate, talc, zinc stearate, hydrogenated castor oil, silica, colloidal silica, cornstarch, calcium silicate, magnesium silicate, silicon hydrogel and the like.
[0026] Further functional coat of pH independent polymer, ranges of 2-20% w/w of the core, comprises low water permeable polymers, plasticizers, opacifiers, colorants and other suitable excipients.
[0027] Low water permeable polymer, having an active character in extended release of active ingredient, are selected from the group comprising but not limited to co-polymers of acrylic and methacrylic acid esters like Eudragit RL, ethyl cellulose, prolamine, polyethylene oxide, polyvinyl acetate, zein.
[0028] Plasticizers range from 5 to 50% w/w of film forming polymer. Plasticizers can be selected from polyethylene glycol, acetyl triethyl citrate, acetyl tributyl citrate, triethyl citrate, acetylated monoglycerides, glycerol, triacetin, propylene glycol, dibutyl phthalate, diethyl phthalate, isopropyl phthalate, dimethyl phthalate, dactyl phthalate, dibutyl sebacate, dimethyl sebacate, castor oil, glycerol monostearate, fractionated coconut oil, others or a combination thereof.
[0029] Opacifiers, ranges from 8-25% of the coat, include water insoluble pigments comprising titanium dioxide, calcium carbonate, calcium sulfate, magnesium oxide, magnesium carbonate, aluminum silicate, aluminum hydroxide, talc and iron oxide.
[0030] Colorants, ranges from 0.05-8% w/w of coat, include water soluble dyes, water insoluble pigments and natural colorants.
[0031] Another embodiment of the present invention includes process for preparation of extended release pharmaceutical composition of paliperidone by incorporating matrixing agent intragranularly and extra granularly.
[0032] The above process mainly includes three steps from which First step, intragranulation by wet granulation, comprising granulation of geometric mixture of API, diluents and matrixing agent with binder solution followed by drying and sieving to get dry granules. Second step, extra granulation, comprising incorporating matrixing agent and lubricant to dry granules obtained through the first step followed by compression. Finally in Third step, functional coating of pH independent polymer to compressed dosage form obtained in second step.
[0033] The present invention as classify serves in attaining extended release of paliperidone or its pharmaceutically acceptable salts wherein at least 50% of the active ingredient is release within 12 hours.
[0034] The extended release pharmaceutical composition of the present invention is in a solid dosage form as a monolithic system, multi-particulate system, matrix system, matrix with coating system and the likes thereof.
[0035] Throughout this specification and the appended claims it is to be understood that the words “comprise” and include” and variations such as “comprises”, “comprising”, “includes”, “including” are to be interpreted inclusively, unless the context requires otherwise. That is, the use of these words may imply the inclusion of an element or elements not specifically recited.
EXAMPLE
[0036] The present invention has been described by way of example only, and it is to be recognized that modifications thereto falling within the scope and spirit of the appended claims, and which would be obvious to a person skilled in the art based upon the disclosure herein, are also considered to be included within the scope of this invention. The above said invention can be illustrated by but not limited to following example(s):
Example 1
[0037]
[0000]
Sr. No
Ingredients
% w/w
1
Paliperidone
1.93
2
Lactose
44.8
3
HPMC K-4M
32.1
4
Povidone K-30
3.85
5
Isopropyl alcohol
Qs
6
Purified water
Qs
7
HPMC K 100 LV
12.3
8
Stearic acid (60#)
0.97
9
BHA
0.19
Functional Coating
1
PEG 4000
0.52
2
Isopropyl alcohol
Qs
3
Dichloromethane
Qs
4
Eudragit RSPO
3.34
Process for Preparation
A) Intragranular Application of Matrixing Agent
[0038] 1) Weigh and sift Paliperidone, Lactose and HPMC K-4M trough 40#.
[0039] 2) Mix step 1) carefully and ensures geometric mixing.
[0040] 3) Dissolve Povidone K-30 in isopropyl alcohol: purified water mixture.
[0041] 4) Granulate step 2) with binding solution of step 3).
[0042] 5) Dry the granules and pass the dried granules through 20#.
B) Extragranular Application of Matrixing Agent
[0043] 6) Weigh and sift HPMC K 100 LV, Stearic acid (60#) and BHA through 40#.
[0044] 7) Lubricate step 5) with step 6). Mix well for 5 minutes.
[0045] 8) Compress the resultant blend of step 7)
C) Coating by pH Independent Polymer
[0046] 1) Dissolve PEG 4000 in isopropyl alcohol: dichloromethane solution with stirring.
[0047] 2) Add Eudragit RSPO in step 1) with stirring.
[0048] 3) Mix the solution for 10-20 minutes with stirring.
[0049] 4) Pass the solution through 200#.
[0050] 5) Perform the coating with the coating solution of step 4)
Example 2
[0051]
[0000]
Sr. No
Ingredients
% w/w
1
Paliperidone
3.73
2
Lactose
41.61
3
HPMC K-4M
31.06
4
Povidone K-30
3.73
5
Isopropyl alcohol
Qs
6
Purified water
Qs
7
HPMC K 100 LV
11.92
8
Stearic acid (60#)
0.93
9
BHA
0.19
Functional Coating
1
PEG 4000
0.86
2
Isopropyl alcohol
Qs
3
Dichloromethane
Qs
4
Eudragit RSPO
0.78
5
Titanium dioxide
0.86
6
Ferric oxide red
0.12
Process for Preparation
A) Intragranular Application of Matrixing Agent (as Per Example 1)
B) Extragranular Application of Matrixing Agent (as Per Example 1)
C) Coating by pH Independent Polymer
[0052] 1) Dissolve PEG 4000 in approx 75% quantity of isopropyl alcohol: dichloromethane mixture with stirring.
[0053] 2) Add Eudragit RSPO in step 1) with stirring.
[0054] 3) Disperse the titanium dioxide and ferric oxide red in remaining quantity of isopropyl alcohol: dichloromethane mixture.
[0055] 4) Mix the solution of step 2) and 3) for 10-20 minutes with stirring.
[0056] 5) Pass the solution through 200#
[0057] 6) Perform the coating with the coating solution of step 5)
Example 3
[0058]
[0000]
Sr. No
Ingredients
% w/w
1
Paliperidone
5.59
2
Lactose
39.76
3
HPMC K-4M
31.01
4
Povidone K-30
3.73
5
Isopropyl Alcohol
Qs
6
Purified Water
Qs
7
HPMC K l00 LV
11.93
8
Stearic Acid (60#)
0.93
9
BHA
0.19
Functional Coating
1
PEG 4000
0.78
2
Isopropyl alcohol
Qs
3
Dichloromethane
Qs
4
Eudragit RSPO
5.07
5
Titanium dioxide
0.74
6
Ferric oxide yellow
0.27
Process for Preparation
A) Intragranular Application of Matrixing Agent (as Per Example 1)
B) Extragranular Application of Matrixing Agent (as Per Example 1)
C) Coating by pH Independent Polymer
[0059] 1) Dissolve PEG 4000 in approx 75% quantity of isopropyl alcohol: dichloromethane mixture with stirring.
[0060] 2) Add Eudragit RSPO in step 1) with stirring.
[0061] 3) Disperse the titanium dioxide and ferric oxide yellow in remaining quantity of isopropyl alcohol: dichloromethane mixture.
[0062] 4) Mix the solution of step 2) and 3) for 10-20 minutes with stirring.
[0063] 5) Pass the solution through 200#
[0064] 6) Perform the coating with the coating solution of step 5)
Results for Dissolution Profile Studies for Example 1, 2 and 3
[0065]
[0000]
% Dissolved
Time
Example
Example
Example
(hr)
1
2
3
2
0
5
1
8
24
57
32
12
53
82
61
18
85
98
89
24
97
101
96
Example 4
[0066]
[0000]
Sr. No
Ingredients
% w/w
1
Paliperidone
3.77
2
Lactose monohydrate
42.14
3
HPMC K-4M
31.45
4
Povidone K-30
3.77
5
Isopropyl alcohol
Qs
6
Purified water
Qs
7
HPMC K 100 LV
12.08
8
Stearic Acid (60#)
0.94
9
BHA
0.19
Functional Coating
1
Triethyl citrate
0.28
2
Isopropyl alcohol
Qs
3
Dichloromethane
Qs
4
Ethylcellulose 7cps
3.96
5
HPMC E3LV
1.42
Process for Preparation
A) Intragranular Application of Matrixing Agent (as Per Example 1)
B) Extragranular Application of Matrixing Agent (as Per Example 1)
C) Coating by pH Independent Polymer
[0067] 1) Dissolve HPMC E3LV in Isopropyl alcohol with stirring.
[0068] 2) Dissolve ethylcellulose and triethyl citrate in dichloromethane with stirring.
[0069] 3) Mix the solution of step 1) and 2) for 10-20 minutes with stirring.
[0070] 4) Pass the solution through 200#
[0071] 5) Perform the coating with the coating solution of step 4).
Example 5
[0072]
[0000]
Sr. No
Ingredients
% w/w
1
Paliperidone
0.92
2
Lactose monohydrate
43.99
3
HPMC K-4M
30.67
4
Povidone K-30
3.68
5
Isopropyl Alcohol
Qs
6
Purified Water
Qs
7
HPMC K 100 LV
11.78
8
Stearic Acid (60#)
0.92
9
BHT
0.06
Functional Coating
1
Eudragit RSPO
3.87
2
PEG 4000
1.66
3
Iso Propyl Alcohol
Qs
4
Dichloromethane
Qs
Color Coat
1
HPMC E5 cps
1.58
2
PEG 4000
0.20
3
Titanium dioxide
0.39
4
Talc
0.25
5
Iron oxide Yellow
0.01
6
Iron oxide Red
0.04
7
Purified Water
Qs
Process for Preparation:
[0073] A) Intragranular application of matrixing agent
[0074] 1) Weigh and sift paliperidone, lactose and HPMC K-4M trough 40#.
[0075] 2) Mix step 1) carefully and ensures geometric mixing.
[0076] 3) Dissolve Povidone K-30 in isopropyl alcohol: purified water mixer.
[0077] 4) Granulate step 2) with binding solution of step 3).
[0078] 5) Dry the granules and pass the dried granules through 20#.
B) Extragranular Application of Matrixing Agent
[0079] 6) Weigh and sift HPMC K 100 LV, stearic acid (60#) and BHT through 40#.
[0080] 7) Lubricate step 5) with step 6). Mix well for 5 minutes.
[0081] 8) Compress the resultant blend of step 7)
C) Coating by pH Independent Polymer
[0082] 1) Dissolve PEG 4000 in Isopropyl alcohol: dichloromethane solution with stirring.
[0083] 2) Add Eudragit RSPO in step 1) with stirring.
[0084] 3) Mix the solution for 10-20 minutes with stirring.
[0085] 4) Pass the solution through 200#.
[0086] 5) Perform the coating with the coating solution of step 4)
D) Color Coating
[0087] 1) Dissolve HPMC E5 and PEG 4000 in half qty of purified water with stirring
[0088] 2) Disperse titanium dioxide, talc, iron oxide red and iron oxide yellow in remaining qty of purified water in homogenizer.
[0089] 3) Add step 2) in step 1) with stirring.
[0090] 4) Pass the solution through 200#.
[0091] 5) Perform the coating with the coating solution of step 4)
Example 6
[0092]
[0000]
Sr. No
Ingredients
% w/w
1
Paliperidone
3.68
2
Lactose monohydrate
41.10
3
HPMC K-4M
30.67
4
Povidone K-30
3.68
5
Isopropyl alcohol
Qs
6
Purified water
Qs
7
HPMC K 100 LV
11.78
8
Stearic acid (60#)
0.92
9
BHT
0.06
Functional Coating
1
Eudragit RSPO
3.87
2
PEG 4000
1.66
3
Isopropyl alcohol
Qs
4
Dichloromethane
Qs
Color Coat
1
HPMC E5 cps
1.58
2
PEG 4000
0.20
3
Titanium dioxide
0.39
4
Talc
0.25
5
Iron oxide Yellow
0.03
6
Iron oxide Red
0.01
7
Purified water
Qs
Process for Preparation: (As per Example 5)
[0093] Results of Dissolution Profile Studies for Examples 4, 5 and 6
[0000]
% Dissolved
Time
Example
Example
Example
(hr)
4
5
6
2
0
0
2
8
23
14
29
18
71
75
81
24
84
92
92
|
The present invention relates to an extended release composition of paliperidone for oral administration comprising paliperidone and at least one matrixing agent. The said extended release composition maintains desired therapeutic drug effect over a prolonged period of time and thereby reduces the side effects resulting due to excess drug blood plasma concentration. Further, the invention also relates to process for the preparation of an extended release oral composition of paliperidone.
| 0
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BACKGROUND OF THE INVENTION
This invention relates to apparatus for facilitating the machining or grinding of predetermined regions of workpieces.
In particular, the present invention is concerned with the grinding of the side faces of hard material tips mounted to the teeth of saw blades.
Machines are known for the grinding of the side faces of such tips whether on circular or linear i.e., band saws in which both side faces are ground in a single operation.
Generally, after the side faces of a tip have been ground the tooth tip is broadest at its leading i.e., cutting edge and diminishes in width from the leading edge to the rear face of the tip. In addition, the side face grinding is such that the tip tapers from the top face of the tip towards the bottom of the tip.
As is well known, the purpose of the side face grinding is to produce side faces which are mutually inclined at predetermined angles to the planes of the side faces of the blade body and teeth. In addition, generally speaking the grinding must be such that the side faces are symmetrically ground with respect to the blade body so that corresponding points on the both side faces of a tip are equidistant from the medial plane of the blade body, except where the grinding is intended to produce an asymmetrical arrangement. To achieve this it is important, during the grinding of the tips on the teeth on the blade, that the blade/tooth should not deflect from the required correct grinding position. Firmly clamping the blade against displacement with respect to the grinding wheels is necessary.
Following completion of the machining/grinding of each saw tip blade tooth, successively indexing the saw blade to bring the next tip to be machined to the location of the machine at which the side grinding wheels are able to grind the side faces is required. This position can be termed the grinding station. During this indexing operation the clamping of the blade has to be released so that the blade is free to be moved by an indexing finger or the like which is arranged to advance the next tooth whose tip is to be machined/ground to the grinding station. Indexing involves pushing against the tooth in question while at the same time guiding the blade through the blade clamping means. At the completion of the indexing operation the blade is reclamped to prevent movement of the blade.
In known machines the usual practice involves clamping the body blade well below the gullets of the teeth so that the clamping arrangements when released do not impede the indexing operation, and so that they do not impede operational movements of the grinding wheels themselves. This mode of clamping relies upon the strength of the blade body, assuming that grinding wheel pressures upon a tip will not distort the tooth with respect to the blade body. However, in practice distortion can occur, leading to an incorrectly machined tip.
A further difficulty arises in relation to the known clamping arrangements because with known machines it is necessary to remove the clamping arrangements from one side of the blade to enable a blade to be removed. In this connection it is convenient to bear in mind that some blades, especially band saw blades, can be twenty or more centimetres deep so that blade changing is a relatively complex and time consuming operation, particularly if it is not possible conveniently to remove the blade clamping arrangements.
As indicated above, an important requirement for the machining of saw blade tips is that their side faces should be machined or ground so that the resulting ground side faces are symmetrically positioned with respect to the medial plane of the saw blade body. In other words, it is usually required that each tip should project to the same extent to either side of this medial plane.
Hitherto it has been presumed that with the known machines and their associated blade clamping arrangements that this conditon of symmetry (when required) is always achieved even though before the grinding operation the tips may have projected unequally to opposite sides of a tooth tip. In other words, it has been assumed without respect to initial individual widths of the tips in relation to the saw blade body, after grinding the required dimensions and angles for the side faces had been achieved.
Industrial users of, for example, band saw blades, have been demanding thinner and thinner saw blades and associated tips so that the amounts of wood wasted during sawing operations such as reducing a tree trunk to planks is reduced. In addition, since one of the most effective materials for the production of saw blade tips, namely the material known under the trade name Stellite, is comparatively expensive, further consequence of thinner blades is that the tips will also be small/thinner in size, reducing the amount of Stellite required for each tip.
It has been found that the presently available clamping arrangements are not adequate for holding a saw blade during the side face grinding of tips on the teeth of saw blades which are thinner than those conventionally contemplated. Whenever a tip on such thin saw blades is not initially symmetrically positioned with respect to the medial plane of the blade body, the pressures exerted by the grinding wheels during grinding distorts the tooth with respect to the clamped blade body medial plane. Consequently where such distortion has occurred the tip remains effectively offset with respect to the medial plane of the blade body and the face angles may well be incorrectly formed since the grinding operation has not removed the excess thickness to one side of the blade. The use of such saw blades whose side faces are not ground to the correct angles and size are very inefficient in operation and become rapidly damaged.
OBJECT OF THE INVENTION
It is therefore an object of the present invention to reduce the changes of incorrect machining of tips on the teeth of saw blades.
SUMMARY OF THE INVENTION
Broadly, according to a first aspect of the invention there is provided a saw blade clamp unit for tools or apparatus for the machining of the side faces of hard material tips provided upon the teeth of saw blades, including clamp means for clamping the actual tooth whose tip is adjacent, or next to the tip to be machined, against displacement with respect to the machining tool(s) of the apparatus.
Preferably, the means for clamping the adjacent tooth whose tip is the next tip to be machined includes means for setting a reference position for the tooth to be machined whereby the tooth is automatically set during a clamping operation to the required grinding position.
Preferably, the clamp means also includes means for clamping the blade whose teeth tips are to be machined against displacement during the machining of a tip at a location in the immediate vicinity of the tooth whose tip is next to be ground.
Conveniently, pivotable means are provided for supporting the clamp means in such manner that the clamp means is pivotable to a location clear of the blade and its teeth, the arrangement being such as to facilitate the mounting and removal of a blade with respect of said machine.
In accordance with a further aspect of the invention a saw blade clamp unit for apparatus for the machining of the side faces of hard material tips provided upon the teeth of saw blades, includes first means for clamping the actual tooth whose tip is the next tip to be machined, against displacement with respect to the machining tool(s) of the apparatus and a second means for clamping the blade at a location in the vicinity of the teeth of the blade.
Preferably, the clamping means are also mounted from the remainder of the apparatus so that at least a part of the clamping means can be moved between its blade clamping position and a second position in which the clamping means at least to one side of the blade are clear of the blade and its tipped teeth thereby to facilitate the mounting of the blade to the apparatus for the purposes of the machining of the tips and the subsequent removal of the blade from the machine after the machining of the tips thereof.
The various features and advantages of the invention will become more apparent to those skilled in the art upon consideration of the following detailed description of a preferred embodiment exemplifying the best mode of carrying out the invention as presently perceived. The detailed description particularly refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention and to show how to carry the same into effect reference will now be made to the accompanying drawings in which:
FIG. 1 is front view of a first embodiment of apparatus incorporating the features of the invention;
FIG. 2 is a plan partially in section view of the apparatus of FIG. 1;
FIG. 3 is a sectional view along the line III--III of FIG. 2;
FIG. 4 is a side view partially in section of a clamping member for use in an apparatus incorporating the features of the invention.
FIG. 5 is side view partially in section of another clamping member.
FIG. 6 is an end view of the clamping member shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and in particular to FIGS. 1, 2 and 3, in which a fragmentary portion of a main frame of a grinding apparatus/machine is shown at 1. A positionally adjustable guide means 2 is provided on the machine frame 1 generally to position a blade 3 for movement along a predetermined path through the machine at the location shown in the Figures and thus relative to the frame 1. As will be discussed hereinafter the guide means 2 has a further function over and above that of a simple blade guide means.
The blade 3 has teeth 4 with tips 5 each comprising a hard material such as the material known under the Trade Name Stellite.
In the figures only a fragmentary portion of a blade 3 whose tips 5 are to be ground is shown.
The apparatus/machine incorporates a plurality of suitably positioned support rolls (not shown) for the blade and upon which the blade rests. An indexing mechanism including an indexing finger (not shown) which engages with a tooth during indexing is provided for indexing the blade 3 so that the next tooth tip to be ground i.e., that on the tooth 4A is located at a so-called grinding position at which grinding wheels 6, of which one is schematially shown, can be caused to grind the side faces of the tips 5.
As has been mentioned the blade 3 is required to be firmly clamped against movement relative to the remainder of the machine and thus the grinding wheels 6 during the side face grinding operation by a hydraulically/pneumatically operable blade clamping assembly generally indicated at 7.
In general, the clamping assembly 7 includes an arm 8 connected at one end 9 to the ram rod 10 of a hydraulic ram/cylinder unit 11 whose cylinder 12 is connected by means of bolts 13 to the main frame 1.
The ram unit 11 is so positioned that the ram rod 10 is axially transverse to the direction of advance of the blade along its predetermined path through the machine and bridges the saw blade 3 to allow the arm 8 to be positionable adjacent to the toothed region of the outer side of the blade blade as may be seen from FIG. 2. The inner side of the blade is regarded as that surface thereof that faces towards the machine frame 1.
As will be discussed later the ram unit 11 incorporates arrangements whereby the ram rod 10 can be rotated within the cylinder 12 thereby to make it possible to rotate the lever arm 8 between an operational position in which it is in the full line position shown in FIGS. 1 and 2 i.e., adjacent to the outer face of the blade 3 and a non-operational or retracted position which is shown in FIG. 1 in phantom. In this latter position it will be noted that the arm 8 has been moved to a position in which it is effectively totally above the teeth and tips the blade. In operation the arm 8 is moved to this retracted position to allow a saw blade 3 to be mounted to the side face grinding machine and to be removed therefrom after grinding has been completed, and returned to the position shown in the Figures in full lines after the blade has been mounted.
The arrangements provided for enabling such rotation will be briefly discussed hereinafter.
The ram rod 10 is associated with a piston 14 which is so resiliently loaded by a spring 15 that the rod 10 is drawn inwardly of the cylinder 12 and in so doing moves the arm 8 towards the blade 3.
The arm 8 carries at its free end 16 a clamping member 17 which is intended pressurewise to cooperate with the guide member 2 which latter thus additionally serves as the anvil part of a blade clamping means.
The guide member 2 and the clamping member 17 are located below the level of the tips on the blade and serve to cooperate with the blade in the immediate vicinity of the root regions of the teeth 4.
The resilient loading of the rod 10 is such that the member 17 presses lightly against the blade 3 and essentially serves to guide the blade body when subjected solely to the spring force.
A duct 18 for pressurized hydraulic/pneumatic fluid extends lengthwise of the ram rod 10 and has a first fluid connection 19 with the underside 20 of the piston 14 (as shown in the drawings) whereby the application of fluid pressure to the underside 20 of the piston 14 pulls the ram rod 10 inwardly and thus causes the member 17 to cramp the blade 3 between the member 2 and the member 17 thereby to prevent displacement of the blade 3 relative to the machine frame 1.
The arm 8 is provided with a second blade clamping arrangement 21 which is so positioned as to be able to clamp against the actual tooth 4A whose tip is the next tip to be machined against displacements arising from the action of the grinding wheels 6.
This second blade clamping arrangement 21 includes a second hydraulic/pneumatic ram unit 22 having a piston 23 slidable within a cylinder 24. This second piston 23 is resiliently loaded by spring 25 away from the blade 3.
This is necessary so as to allow the blade to be indexed.
The end face 24A of the cylinder 24 lies in the same plane as the end face 17A of the clamping member 17 and forms a clamping face co-planar with that of the member 17.
In other words the rest position of the second clamping means 21 is spaced away from the blade 3 at a position allowing for sufficient clearance for free movement of the blade.
A second blade clamping member 26 is connected to the free end of the ram rod 27 connecting with the piston 23 movable within the cylinder 24. This second clamping member 26 is of an elongate shape and is so aligned with respect to the arm 8 that it effectively lies lengthwise of the tooth 4A whose tip is the next tip to be ground/machined. The clamping member 26 extends substantially up to the base of the tip 5 so that the complete length of the tooth 4A is clamped thereby preventing any undesired movements of the tooth 4A during a machining operation.
A further clamping arrangement 30 complementary to the member 25 is mounted from the main frame 1. This second arrangement is conveniently formed by a further ram unit 31 of construction generally similar to that of ram unit 22 carried by the arm 8, but in this case ram unit 31 is mounted from the main frame 1.
That is to say the further clamping arrangement incorporates a further clamping member 32 of form and orientation similar to the clamping member 26. In view of the similarity of the two clamping arrangements further consideration of the arrangement 30 and its clamping member 32 is not thought necessary.
The clamping arrangements 21 and 30 thus provide a means whereby the tooth 4A can be very firmly clamped against movement during the machining operation.
In order to provide for an accurately repeatable reference position for the clamping surfaces of the above discussed clamping arangements the travel of the piston 14 within the cylinder 12 is limited by a stop surface 34 in such manner that by the time the piston has contacted the stop surface 34 the two clamping members 17 and 26 have pressed against the blade and have clamped the blade in the position in which the medial plane thereof is correctly positioned with respect to the machine frame 1.
The fluid duct 18 passing through the ram rod 10 fluidwise connects with the rear (lower end) of the piston 23 by way of a connection duct forming link 18A so that when the ram unit 10 is pressurized to advance the arm 8 and the member 25/17 towards the blade 3 and after the piston 14 has abutted the associated stop surface 34 the second clamping arrangement is subjected to pressure sufficient to press clamping member 26 against the tooth. As before the piston 23 will cooperate with an associated stop surface 35 so as accurately to define the reference position for the tooth itself.
At the same time the clamping means 31 will be subjected to pressure such as to hold the tooth firmly against the reference surface formed by the displacement of the ram rod 10, the arm 8, and its associated clamping arrangements.
With this arrangement the tooth is firmly restrained against any movements that could result from grinding wheel pressures.
After the side grinding of the tip faces of the tooth 4A has been completed the clamping effect of the clamping arrangements are released by removal of the pressurized fluid, which allows the resilient loading on the various pistons to take effect thereby to retract the clamping members from their respective clamping positions.
At this stage the blade 3 can be indexed as above discussed.
As has been mentioned to facilitate the mounting and removal of a saw blade 3 the ram rod 10 and the associated arm 8 are rotatable about the axis X through arc A relative to the main ram unit cylinder 12 from the position shown in solid lines in FIGS. 1 and 2 to the position shown in dashed lines in FIG. 1.
The ram rod 10 is held in the position shown in FIG. 1 by a release pin 36 engaging in a bore 37 in the ram rod 10, the position of the release pin being controlled by the action of pressurized fluid on the pin.
To release the ram rod 10 for pivoting, the release pressurized fluid is used to displace the pin release 36 to withdraw it from locking the piston against rotation within the cylinder and thereby to allow the relative rotation of the ram rod 10 within its cylinder 12.
The structure of the release pin 37 is such that returning the crank-like lever 8 to the position shown in FIG. 1, the release pin automatically moves to the ram rod locking position against rotation.
FIGS. 4 to 6 are concerned with a particular construction of the clamping members 30 and 21. For convenience those components which have already been mentioned in connection with FIGS. 1 to 3 will be identified with the same reference numerals.
The clamping arrangement of the FIGS. 4 and 5 effectively corresponds to the clamping arrangement 21 and includes a ram unit 21 with a piston 23 movable within a cylinder 24, the piston 23 being connected with a ram rod 27 which is slidably supported within the cylinder by an inwardly directed guide flange 24A.
The piston 23 at its free end mounts wing like clamping means 37 which is intended to press against the blade in the vicinity of the tooth 4A. The ram rod 27 slidably mounts a secondary piston 38 which in turn mounts the elongate blade clamping means 26 which is intended to engage along the length of a tooth 4A so that the slightly tapered end thereof is located very close to the actual location to which the tip is secured to this tooth.
The piston 23 is resiliently loaded by the spring 25 so that the clamp member 26 is effectively urged towards a retracted position, i.e., that shown in the drawing, Arrangements are provided for ducting pressurized hydraulic/pneumatic fluid into the cylinder 24 in such manner when the pressurized fluid is so introduced the piston 23 is displaced against its resilient loading by the spring 25 into a position in which it is able to cause the piston to cooperate with the stop surface 35. At this position the wing members 35 effectively define the reference position for the blade 3.
As has been mentioned the travel of the piston is limited by the stop surface 35. Once the piston reaches this stop surface 35 the pressurized fluid is able to exert sufficient pressure on the secondary piston 38 to cause it firmly to press the elongate member 26 towards and against the tooth 4A thereby to hold the latter firmly against the clamping arrangements located to the other side of the blade.
The clamp arrangement disclosed in FIG. 4 is effectively similar to the arrangement 30 and in practice has the same function.
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A saw blade clamp unit for holding saw blade in a manner to permit machining of side faces of hard material tips provided upon the teeth of the saw blades. The saw blade clamp unit clamps a saw blade tooth adjacent to a saw blade tooth tip being machined, holding the saw blade. The clamping mechanism of the clamp unit is arranged to form a lateral reference position for the tooth to be machined, with the tooth being set to the required grinding position during the clamping operation.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of applicant's application Ser. No. 10/309,607, filed Dec. 3, 2002 now U.S. Pat. No. 6,696,670.
BACKGROUND OF THE INVENTION
The field of the invention is glow plugs and the invention relates more particularly to a high performance glow plug for use in state of the art engines, particularly in model car engines.
Internal combustion model cars have been refined to an extent that tethered model cars can substantially exceed 200 mph. In such extreme environments the glow plugs are heated to a temperature where conventional glow plugs will leak and fail. Various improvements in glow plug construction have been made. One such improvement is shown in U.S. Pat. No. 6,346,688 having the same applicant as the present application. This patent is incorporated by reference herein.
Temperatures at the lower end of a glow plug can reach in excess of 1000° F. The combination of the pressure in the cylinder of the engine and the high temperature of the lower end of the glow plug can result in the formation of leaks which reduce the compression within the cylinder which is highly detrimental to the performance of the engine. A better seal against leaking can result when the crimping downward force is increased. However, the amount of force is limited by the strength of the plug body. Increased crimping force can deform the base of the plug and cause it to deform outwardly. Various attempts at improving the crimping at the top of the glow plug have reduced, but not eliminated, the problem. A better seal against leaking can result when the crimping downward force is increased. However, the amount of force is limited by the strength of the plug body. Increased crimping force can form the base of the plug and cause it to move outwardly.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a glow plug which can withstand state of the art high performance temperatures and pressures without leaking.
The present invention is for a glow plug construction which has a larger than a conventional base to spread the crimping force over a greater area, thereby reducing the force per unit of base area. The glow plug body has a circumferential groove formed around the hexagonal portion of the body to permit the temporary attachment of an igniter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a cross-sectional view of the glow plug of the present invention prior to being crimped together taken along line 1 — 1 of FIG. 4 .
FIG. 2 is a cross-sectional view of the glow plug of the present invention after crimping.
FIG. 3 is an exploded perspective view of the glow plug of FIG. 1 .
FIG. 4 is a side view of the plug of FIG. 1 .
FIG. 5 is a side view of a plug of the prior art.
FIG. 6 is a bottom view of the plug of FIG. 4 .
FIG. 7 is a bottom view of the plug of FIG. 5 .
FIG. 8 is a cross-sectional view taken along line 8 — 8 of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
A glow plug assembly prior to crimping is shown in FIG. 1 and indicated generally by reference character 10 . Glow plug 10 has a body 11 which has an outer shell portion 12 , which surrounds an inner cavity 13 . The base of body 11 has a threaded portion 14 , which would be screwed into an engine block in a conventional manner. Body 11 has a central axis 15 along which an inner electrode 16 is positioned.
Inner electrode 16 has a frusto-conical wall length 17 , which extends upwardly from a base 18 to a washer 19 . Washer 19 extends outwardly with respect to connector shaft 20 . Washer 19 is preferably integrally formed with inner electrode 16 .
Connector shaft 20 terminates in a connector for attachment to a source of electrical energy.
Inner electrode 16 is held centrally in body 11 by a pair of insulated rings. Insulating ring 22 is fabricated from an electrically non-conductive material. One such material is hard anodized aluminum. All surfaces of ring 22 are anodized so that it does not conduct any electricity between inner electrode 16 and body 11 . Similarly, an upper washer 23 is electrically non-conductive. It may also be made from hard anodized aluminum. Washer 23 is part of a pressure-applying portion of the assembly of FIG. 1 . As shown in FIG. 2 , upper ring 24 may be crimped against a frusto-conical portion 25 , which is at an angle of, for instance, 30° with respect to central axis 15 . The result is a continuous downward pressure formed by the contact between the crimped upper ring 26 and the frusto-conical portion 25 of upper washer 23 .
As shown in FIG. 1 , on initial assembly there is an upper gap 27 and a lower gap 28 between insulating ring 22 and washer 19 and lower floor 29 , respectively. These gaps disappear during the crimping step as shown in FIG. 2 . Preferably, castor oil is applied between the outer frusto-conical surface 30 and the inner cavity 13 , as well as between the inner frusto-conical surface 31 of ring 22 and the frusto-conical wall length 17 . Also, a light oil, such as that sold under the trademark “W-D 40,” is preferably applied to the outer surface of upper washer 23 to help lubricate the downward compression movement of the parts to provide a glow plug such as that shown in FIG. 2 . The glow plug in FIG. 2 has no gaps between the upper and lower surfaces of ring 22 .
The heating element 32 is welded between the base of inner electrode 16 and body 11 . The outer body is preferably fabricated from steel and the upper ring thereof 24 is moved inwardly by a crimping tool 33 , which has a frusto-conical wall portion 34 , and a connector opening 35 . A downward pressure of 2500 to about 3000 pounds is preferably exerted, as shown in FIG. 2 , which squeezes the inner electrode and the insulating ring downwardly until there is no significant gap above and below insulating ring 22 , as shown in FIG. 2 .
The frusto-conical angles relating to insulating ring 22 should be small enough so that they provide a locking taper. That is, when pressure is exerted downwardly on ring 22 in cavity 13 , the angle is small enough so that the ring is locked into the cavity rather than simply falling out. This angle should be between 6° and 12°, and preferably about 8°. The presence of lubricant 36 and 37 helps to facilitate the elimination of gaps 27 and 28 during the crimping step. Also, it is believed that the use of castor oil at the area indicated by reference character 36 is further beneficial to prevent the escape of gases between ring 22 and either the body or the inner electrode. Castor oil, when sufficiently heated, will form a gummy residue which is believed to further enhance the sealing effect of the assembly under high temperatures.
As can be seen in the prospective view of FIG. 3 , glow plug 10 has a hexagonal portion 38 which extends from an upper end 39 to a base 40 . The hexagonal portion is interrupted by a circumferential groove 41 . Threaded portion 14 extends downwardly from base 40 . Glow plug 13 , after crimping is shown in side view in FIG. 4 . A prior art glow plug 42 is shown in side view in FIG. 5 . Glow plug 42 also has a hexagonal portion 43 and has a decorative circumferential groove 44 . There is a substantial difference between grooves 41 and 44 . As is visible from comparing FIGS. 4 and 5 , circumferential groove 41 extends completely around the hexagonal portion. For instance, by viewing FIG. 8 , it can be seen that groove 41 has a depth “d” in the middle of the hexagonal face in which it is located. In contrast, groove 44 shown in FIG. 5 has no depth at all in the center portion of the hexagonal faces. This groove 41 permits the attachment of an igniter. For a glow plug having a 5/16″ hex, a groove having an inside diameter of 0.275″ provides an appropriate depth for affixing of an igniter.
Hexagonal portion 43 extends from an upper end 45 to a lower end 46 . A lower cylindrical portion 47 extends from lower end 46 to base 48 . This forms a shelf 49 adjacent lower end 46 . When the top of the plug is crimped, a downward force is exerted on the crimped portion of the plug, as shown in FIG. 2 of the drawings. An analogous force is placed on crimp 50 of plug 42 . If the force reaches a sufficient level, base 48 is forced outwardly, as indicated by phantom line 51 . This distortion prevents the exertion of additional force on crimp 50 and can limit the effectiveness of the sealing of the elements of the plug into a leak-free assembly.
In order to decrease the tendency of the deformation indicated by phantom line 51 , the area of the base has been increased, as shown best by comparing FIG. 6 with FIG. 7 . In FIG. 6 , the area for support of the plug during crimping is cross-hatched in FIG. 6 and exists essentially from the outer hexagonal portion 38 to the inner threaded portion 14 . This cross-hatched area 48 is less than half of the area 40 shown in FIG. 6 . It is, therefore, possible to exert a far greater crimping force without any distortion of the base of the plug. The present embodiments of this invention are thus to be considered in all respects as illustrative and not restrictive; the scope of the invention being indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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A glow plug having an outer body with an inner cavity having tapered sidewalls. An insulating ring having outer tapered walls is held within the body and has an inner opening also having tapered walls. A central electrode, having a tapered wall section, fits tightly in the inner opening of the insulating ring. The insulating ring and central electrode are forced under pressure in the cavity of the glow plug to provide a glow plug capable of withstanding high temperature and pressure applications without leaking.
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FIELD OF THE INVENTION
[0001] The present invention relates to a novel injection mold, injection molding machine and an injection molding method for producing over-molded articles that can be made of one or more moldable materials. The invention is suitable for use with plastic resins, but can also be applied to glass, ceramics, powders or to combinations of them.
BACKGROUND OF THE INVENTION
[0002] Machines and molds for producing injection molded plastic articles of two or more layers of one or more different resins are well known. Such composite articles can be used in a wide variety of applications. Multi-materials can include materials with different molding properties, such as PET and PEN, the same material with various additives such as dyes, or combinations of these. For example, multi-layer multi-material articles which are injection molded include the keys used in personal computer keyboards, wherein the indicia of the function assigned to the key is formed from a different colored material than the remainder of the key and components such as multi-colored lenses used for the stop and turn signal indicator lights in automobiles.
[0003] Another common use is in the manufacture of multi-layer, multi-material articles for the packaging of food wherein, for example, U.S. FDA regulations require that only virgin plastic materials be employed in locations which contact the food. Generally, it is desired to reduce the amount of virgin material which is employed in such packages for both environmental reasons (wherein it is preferred to use recycled materials) and for cost reasons (as virgin material is more expensive than recycled plastic materials). Accordingly, multi-layer multi-material packages have been produced which include a first, thin, layer of virgin plastic material which contacts the food and a second, thicker, layer of recycled or otherwise less expensive material which is laminated to the first layer during injection molding to provide strength to the package.
[0004] One area where such multi-layer packaging is employed is in bottles and other vessels manufactured from PET or other materials. PET bottles and vessels are commonly blow molded from “preforms” in a well known manner, the preforms having been manufactured by injection molding to form a thread on the neck portion of the bottle to receive a bottle closure. It is known to form a multi-layer preform of PET, the inner most layer of which is virgin plastic and at least some portion of the remainder of the preform being recycled plastic material. In such cases, when the bottle or vessel is blow molded from the preform, the virgin material forms a continuous inner layer within the vessel and the recycled or other material surrounds the outside of the inner layer to increase the overall strength of the vessel to an acceptable level.
[0005] In other circumstances, the layers employed in multi-layer articles can have properties other than, or in addition to, being different colors and virgin and recycled materials, for example layers can have different chemical properties, etc. Also, more than two layers can be employed, if desired. It is known, for example, to produce a multi-layer preform for blow molding PET bottles and vessels wherein a layer of barrier material is located between the inner layer of virgin material and the recycled material, the barrier layer inhibiting take-up of CO 2 gas from carbonated beverages stored in the blown bottle by the PET materials behind the barrier.
[0006] Various systems and techniques for molding multi-layer, multi-material plastic articles are known. Generally, such systems are based on either co-injection, over-molding and/or insert-molding systems. In all co-injection methods, the mold remains closed until the cavity is filled by the injection of two or more plastic materials into the cavity, either simultaneously or sequentially.
[0007] In sequential co-injection, a measured amount of a first material is injected into the cavity and an amount of a second material is then injected into the first material within the cavity. Due to a “skin” effect, the first material maintains its contact with the cavity walls and the second material pushes the first through the cavity, such that the materials fill the cavity with the second material sandwiched between inner and outer layers of the first.
[0008] In simultaneous co-injection, both materials are injected into the cavity at the same time, for at least part of the injection operation, and the differing viscosity, skin effects and other characteristics of the materials and the injection process result in the desired formation of layers of the materials within the cavity.
[0009] In the majority of co-injection methods, the article is made of maximum three different materials displaying difficult characteristic or/and functions. For example, one material can be a virgin, the second one can be a recycled version of same or different resin and the third can be a chemical barrier layer (such as EVOH, Nylon, MXD6) formed between them, or as a first layer. In common applications using two materials, article can be formed having three or five layers ( 2 WL or 2 M 5 L). If three materials are used, the article can have either three ( 3 M 3 T) or five layers ( 3 MSL).
[0010] Sequential co-injection systems for preforms are discussed in U.S. Pat. No. 4,781,954 to Krisnakumar et al. and U.S. Pat. No. 4,717,234 to Schad et al., the contents of each of which arc incorporated herein by reference. A more recent co-injection system shown in U.S. Pat. No. 5,582,788 to Collette et al., shows the use of a turret injection molding machine for co-injection which allows for improved cooling of molded articles.
[0011] Simultaneous co-injection systems for preforms are discussed in several U.S. Patents, such as those assigned to American National Can. Of interest Us this regard is U.S. Pat. No. 5,523,045 to Kudert et al. which shows a multi-material co-injection nozzle design suitable for multi-layer preforms.
[0012] An innovative mold design capable of performing either simultaneous or sequential molding is described in U.S. patent application Ser. No. 712,481 to Bertschi et al. and assigned to the assignee of the present invention. This application hows the first mold design wherein hot runner injection nozzles are located on the opposite sides of cavity to inject two or more different resins. This approach simplifies the mold and allows for injecting into cavities which are arranged in a more compact, denser manner, as the nozzles for a single cavity are not on the same side of the mold.
[0013] While conventional co-injection methods offer some advantages as they use a single cavity and all the injection units are on one side of the injection molding machine, they also have several significant drawbacks. One of them is that it is difficult to obtain continuous and uniform layers of the different materials as they interact in a complete molten state and proper metering of the materials is often difficult. This is especially true when three materials are to injected. Further, the mold design and the hot runner design become very complicated as a single manifold or a single nozzle must be able to work with different materials having different processing parameters. These problems are further exacerbated for high cavitation molds, such as 48 or 96 cavity molds. Another difficulty is cooling, wherein thick articles require longer residence time in the mold close position, which affects the cycle time.
[0014] Some of the disadvantages of the co-injection systems are overcome by overmolding systems, where each injection operation is performed in a different mold cavity. Generally, the first injection operation is performed in a mold cavity to create the first layer of an article and the cavity is then changed to increase the volume and, commonly, to alter the geometry of the cavity space. Usually this is accomplished by changing the cavity and using the same core that holds the molded article. A second molding operation is then performed with the first layer of the article, which is retained by the core, being placed in the changed cavity. During the second injection the new molded material bonds to the previously molded layer in the mold to form the multi-layer article. As will be apparent, while the second cavity has a larger volume than the first, it will be understood by those of skill in the art that the actual cavity volume which must be filled in the second injection operation can be less than the volume filled in the first injection operation, with the balance of the volume being occupied by the first layer.. As will also be apparent, over-molding can include more than one over molding operation to form articles using more than two resins and/or with more than two layers, if desired.
[0015] While good results can be obtained by over-molding, the necessity to open the mold to move a previously molded layer of an article to a second mold cavity for molding of the next layer has been difficult to achieve in a cost effective and reliable manner, especially if there are geometrical profile differences between the over-molded layers. U.S. Pat. No. 3,914,081 to Aoki shows an early attempt to perform over-molding employing a rotary stripper plate which is used to extract, hold and transfer a molded first layer of an article to a second mold cavity, wherein a second layer of resin of a different color is injected. U.S. Pat. No. 3,947,176 to Rainville shows a split mold design that allows ejection of the article after the molding of a threaded neck portion of the article by splitting the mold laterally. Rainville-type molds have proven to be difficult to manufacture, need more “real estate” to allow opening of the mold walls, present sealing problems over a greater area and tend to leave injection marks on the molded article.
[0016] Attempts to produce a more suitable over-molding system include U.S. Pat. No. 4,744,742 and U.S. Pat. No. 4,830,811 to Aoki which shows a two cavity mold design for preforms which is used with a rotary injection blow-molding machine. In these systems, the core enters a first cavity in which the first, inner, layer of a preform to molded. The core is then removed from the first cavity with the molded layer still in place and is inserted into a two portion second cavity, the lower portion of which is a single piece cavity of a larger diameter than the first and the upper portion of which is a two-part, split, cavity which defines threads for the neck portion of the preform. The second layer is then injected into the two portion cavity and the core is removed from within the cavity. The upper, threaded, portion of the cavity extracts the molded preform from the lower portion of the cavity and moves it to a blow molding station. After blow molding, the upper portion of the cavity is split to allow removal of the finished bottle.
[0017] The system taught by Aoki suffers from a number of disadvantages. First, the design is not readily applicable to forming more than two preforms per cycle, due to the complexity of the transfer platen used to move articles and the upper portions of the molds. Also, after the second injection operation is performed, the core is removed from the molded article prior to its transfer to the blow-molding station, preventing cooling of the interior of the preform by the core during the transfer. Thus, the bulk of the cooling must be performed before removal of the core, resulting in a relatively long cycle time.
[0018] A more recent attempt to produce over-molded preforms having a thread on the neck portion is shown in published European Patent Application 715,937 A1 to Massano. This reference teaches an injection mold to perform two-layer over-molding of a two-material PET preform wherein the mold comprises a stationary cavity plate, a moveable stripper/cavity and core plates. The cavity plate comprises adjacent pairs of single piece cavities of two different diameters and the stripper/cavity plate includes adjacent pairs of two-part cavity portion elements which can be split laterally. One cavity portion of each pair, which is aligned with the smaller diameter cavity in the cavity plate, has a smooth bore of the same diameter as the smaller diameter cavity and the other cavity portion of each pair, which is aligned with the larger diameter cavity, includes a thread to define the threaded neck portion of the preform.
[0019] The core plate has rotatable pairs of adjacent cores and molding is performed by inserting the pairs of cores into the pairs of cavities with the stripper/cavity plate contacting the cavity plate so that the cavity portions on the stripper/cavity plate form part of the cavity for the injection operation.
[0020] A complete injection operation is performed by injecting a first layer of material into the smaller diameter cavity and cavity portion, then the core and cavity/stripper plates are each moved away from the cavity plate until the end of the molded preform has been completely removed from the cavity, after which the core plate continues to move away from the cavity plate while the stripper/cavity plate remains in place. The core plate moves away from the now stationary stripper/cavity plate to remove the molded first layer, which remains on the core, from the smooth-bored cavity portion on the stripper/cavity plate. Just prior to the core being completely removed from the cavity portion, the two parts defining the pair of cavity portions are separated to allow the completed preform (commenced in the previous injection cycle) to fall from the threaded cavity portion, having been removed from the core by the engagement of the molded threads with the threaded cavity portion.
[0021] The molded first layer remains on the other core, being pulled through the smooth-bored cavity portion. Once the core and the molded first is completely removed from the smooth-bored cavity portion, the pair of cores are rotated one hundred and eighty degrees on the cavity plate so that the core with the molded first layer can now be inserted into the larger diameter cavity, through the threaded cavity portion on the stripper/cavity plate, and the now-empty other core can be inserted into the smaller diameter cavity through the smooth-bored cavity portion to commence another injection molding cycle.
[0022] The core plate and the stripper/cavity plate are closed to the cavity plate and the second layer is injected into the larger diameter cavity and the threaded cavity portion to complete the molding of the preform on this core (a first layer is injected into the other cavity with the smooth-bored cavity portion to commence the molding of the perform on that core). The cavity plate and stripper/cavity plate are then moved away from the cavity plate, as described above, to eject the completed preform and to rotate the cores for the next portion of the cycle.
[0023] The Massano system described above suffers from several disadvantages. In particular, the core plate must be moved away from the cavity plate for a distance exceeding at least twice the length of the molded articles while the stripper/cavity plate must be moved away from the cavity plate for a distance exceeding the length of the molded articles to allow ejection of the molded articles. These opening requirements result in a slower cycle time, while the plates move the required distances, and in a machine which requires a relatively large amount of floor space in which to operate. Also, the molded first layer is pulled through the smooth-bored cavity portion at the end of the first injection operation and this can result in damage to the molded first layer. Further, the requirement to rotate each pair of cores increases the expense of manufacturing the machine and can lead to leaking of cooling fluid from the cores, etc.
[0024] Published PCT patent application WO 97/02939 to Collette et al. shows two other injection molding machines for over-molding. The first machine shown is a turret machine with a number of cores mounted on each of a pair of opposed sides of the turret and a pair of cavity plates, each with a set of a corresponding number of cavities, facing each turret face. The first set of cavities is used to form the first layer of the molded article and the second set of cavities each including cavity extension portions to define the threads of a preform neck. One cavity plate and the turret move relative to the other cavity plate, and the turret rotates to move cores with a first molded layer from the first set of cavities to the second set of cavities where the second layer is molded with the cavity extension portions closed. The turret mold shown in Colette is used in conjunction with a conventional three platen injection molding machine. As shown in FIG. 2 a of Colette, the second injection station unit (more exactly the second cavity plate) is located opposite the first one and in front of the clamping unit (not shown). The clamping unit thus prevents the injection unit from being located perpendicular to the mold plate, and instead it must be located at 90° to the stroke of the clamping unit. This results in Collette's machine having a large total foot-print. Further, Collette system requires an additional ejection system on the core plate to eject the molded articles from the cores which have been retracted from the second set of cavities. Such ejections systems are expensive and/or difficult to provide and can introduce other problems in the molding operation, such as core shift.
[0025] The second machine taught in Collette is a shuttle-type system wherein the cavity plate has two sets of first cavities surrounding a set of second cavities and two sets of cores are mounted to a core plate which shuttles the cores between a first position wherein the first set of cores is aligned with one set of first cavities and the second set of cores is aligned with the second set of cavities, and a second position, wherein the first set of cores is aligned with the second set of cavities and the second set of cores is aligned with the other set of first cavities. The core plate is laterally “shuttled” between the first and second positions each time the mold is opened to sequentially insert a core in one of the first sets of cavities, where a first layer is molded, and then in one of the second set of cavities where the second layer is molded. This machine suffers from disadvantages in that it requires an extra set of cavities, i.e.—three sets of cavities produce two sets of articles, which increases the expense of the mold.
[0026] Multi-layer articles can also be formed by insert-molding wherein an insert, formed by extrusion, injection molding, thermoforming, etc., is placed into a mold cavity and a layer of another material is then injected to fill the cavity. In fact, insert-molding can be combined with over-molding or co-injection to encase the insert between multiple layers of different materials, if desired.
[0027] It is desired to have an efficient, reliable and cost-effective injection molding machine and mold therefore to form multi-layer molded articles.
SUMMARY OF THE INVENTION
[0028] It is an object of the present invention to provide a novel injection molding method, machine and mold therefore to produce multi-layer molded articles.
[0029] According to a first aspect of the present invention, there is provided an injection mold for producing over-molded articles, comprising:
[0030] a cavity plate having first and second cavities mounted thereon;
[0031] a core plate having a core mounted thereon;
[0032] a cavity extension comprising a pair of cavity elements located about said core;
[0033] cavity extension operating means on said core plate to move said pair of cavity elements between an open position wherein said core can be inserted into said first cavity between said pair of cavity elements and a closed position wherein said pair of cavity elements are combined with said second cavity to form a composite cavity of greater volume than said first cavity; and
[0034] a mold clamping unit operable with said cavity operating means to close said mold by in said core into said first cavity when said cavity extension elements are in said open position and to close said mold by inserting said core into said composite cavity when said cavity elements are in said closed position.
[0035] According to another aspect of the present invention, there is provided an injection molding machine for producing over-molded articles, comprising:
[0036] a cavity plate having first and second cavities mounted thereon, said second cavity having a cavity depth less than the cavity depth of said first cavity;
[0037] a core plate having a core mounted thereon, said core plate being movable relative to said cavity plate;
[0038] a cavity extension comprising a pair of cavity elements located about said core, said cavity extension having a depth substantially equal to the difference between the cavity depths of said first cavity and said second cavity and defining a geometric configuration different from that of said first cavity; and
[0039] cavity extension operating means on said core plate to move said pair of cavity elements between an open position wherein said core can be inserted into said first cavity between said pair of cavity elements and a closed position wherein said pair of cavity elements are combined with said second cavity to form a composite cavity which receives said core.
[0040] According to another aspect of the present invention, there is provided an injection mold for producing over-molded articles comprising:
[0041] a cavity plate having first and second cavities mounted thereon, said second cavity having a cavity depth less than the cavity depth of said first cavity;
[0042] a core plate having a core mounted thereon, said core plate being movable relative to said cavity plate;
[0043] a cavity extension comprising a pair of cavity elements located about said core, said cavity extension having a depth substantially equal to the difference between the cavity depths of said first cavity and said second cavity and defining a geometric configuration different from that of said first cavity; and
[0044] cavity extension operating means on said core plate to move said pair of cavity elements between an open position wherein said core can be inserted into said first cavity between said pair of cavity elements and a closed position wherein said pair of cavity elements are combined with said second cavity to form a composite cavity which receives said core.
[0045] According to yet another aspect of the present invention, there is provided a method of injection molding an over-molded article, comprising the steps of:
[0046] (i) moving a cavity extension associated with a core to a disengaged position;
[0047] (ii) inserting said core into a first cavity having a defined volume and a first geometrical configuration;
[0048] (iii) performing a first injection operation into said first cavity to form a first layer of said article;
[0049] (iv) removing said core from said first cavity with said first layer of said article on said core;
[0050] (v) moving said cavity extension to an engagement position;
[0051] (vi) inserting said core and said first layer into a second cavity, said second cavity and said cavity extension engaging to form a composite cavity having a larger volume than said defined volume and defining a second geometrical configuration;
[0052] (vii) performing a second injection operation into said composite cavity to overmold said fit layer to form an article;
[0053] (viii) separating said core and cavity extension from said second cavity to remove said article therefrom; and
[0054] (ix) moving said cavity extension relative to said core to remove said article from said core.
[0055] According to yet another aspect of the present invention, there is provided an injection molding machine for producing over-molded articles, comprising:
[0056] a cavity plate having first and second cavities mounted thereon said second cavity having a cavity volume greater than the cavity volume of said first cavity, each of said first and second cavities having means to receive an injection nozzle;
[0057] at least one injection unit to perform an injection operation into said first and second cavities;
[0058] a core plate having a core mounted thereon;
[0059] a cavity extension adjacent said core;
[0060] cavity extension opening means on said core plan to move said cavity extension between a disengaged position, wherein said cavity extension is distal said first cavity, and an engaged position, wherein said cavity extension combines with said second cavity to form a composite cavity; and
[0061] a mold clamping unit operable with said cavity operating means to close said mold by inserting said core into said first cavity when said cavity extension is in said disengaged position and to close said mold by inserting said core into said composite cavity when said cavity extension is in said engaged position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0062] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
[0063] [0063]FIG. 1 shows a schematic representation of section through the turret of an injection molding machine and a mold in accordance with a first embodiment of the present invention;
[0064] [0064]FIG. 2 shows a schematic representation of a section through a portion of the core plate, stripper plate, cavity plate and a pair of slide operators of an injection molding machine and a mold in accordance with another embodiment of the present invention;
[0065] [0065]FIG. 2 a shoes the center portion of the machine of FIG. 2 with two cores and two cavities;
[0066] [0066]FIG. 3 shows the injection molding machine of FIG. 2 a with the core and stripper plate separated from the cavity plate with the slide operators in a first position;
[0067] [0067]FIG. 4 shows the injection molding machine of FIG. 3 with the stripper plate separated from the core plate;
[0068] [0068]FIG. 5 shows the injection molding machine of FIG. 4 wherein the stripper plate has been moved back to the core plate with slide operators in a second position;
[0069] [0069]FIG. 6 shows the injection molding machine of FIG. 5 after the core plate has been rotated with respect to the cavity plate;
[0070] [0070]FIG. 7 shows the injection molding machine of FIG. 6 after the cavities have been closed;
[0071] [0071]FIG. 8 shows a cross section through a core, cavity extension and first cavity in accordance with another embodiment of the present invention;
[0072] [0072]FIG. 9 shows a cross section through the core and cavity extension of FIG. 8 and a second cavity;
[0073] [0073]FIG. 10 shows a cross section through an article produced in the mold of FIGS. 8 and 9; and
[0074] [0074]FIG. 11 shows a top view of the article of FIG. 10.
DETAILED DESCRIPTION OF THE INVENTION
[0075] In FIG. 1, an injection molding machine in accordance with an embodiment of the present invention is indicated generally at 20 . As shown, machine 20 is a turret mold that can be advantageously operated on an innovative two-platen injection molding machine, similar to that described in co-pending U.S. patent application Ser. No. 08/772,474, filed Dec. 23, 1996 to Koch et al. and assigned to the assignee of the present invention, and the contents of which arc included herein by reference. This two platen injection molding machine is not only faster then than three platen machines, but also allows placing of various molding stations at any location around the turret mold, which saves space and provides manufacturing flexibility.
[0076] Machine 20 includes, for example, a four-sided turret 24 which can be rotated about axis 28 (that can be vertical, horizontal, etc.), in the direction indicated by arrow 32 . As will be apparent to those of skill in the art, turret 24 is rotated as desired to move four mold core assemblies 36 a, 36 b, 36 c and 36 d between four different molding operation stations 40 , 44 , 48 and 52 . In the FIG. 1, and in the following discussion, similar components on each side of turret 24 are identified with like reference numerals to which an “a”, “b”, “c” or “d” is appended to identify the particular station the component illustrated is located at.
[0077] Further, FIG. 1 shows a partial cross-section through turret 24 so that only one core assembly 36 per side is visible. However, as will be apparent to those of skill in the art, turret 24 can include multiple core assemblies 36 on each side with corresponding numbers of components being located at each station 40 , 44 , 48 and 52 as needed. In a presently preferred embodiment of the invention, each side of turret 24 includes forty eight core assemblies 36 on each side of turret 24 .
[0078] In FIG. 1, station 40 is an ejection station, station 44 is a first molding station, station 48 is a second molding station and station 52 is a cooling station. As shown in FIG. 1, each mold core assembly 36 includes a mold core 56 , a stripper plate 60 , a pair of cavity extension elements 64 , each of which is attached to a slide means 68 , 68 ′. While not shown in the Figure, core 56 is provided with suitable means for circulating cooling fluid within core 56 and turret 24 is provided with suitable means for moving stripper plate 60 , which movement is described below in more detail.
[0079] Each slide means 68 , 68 ′ is connected to a respective one of a pair of slide operators 72 via a tierod 76 and slides 68 , 68 ′ can move toward or away from core 56 under the control of a respective slide operator 72 . Slide operators 72 operate as cavity extension operating means, as further described below. It should be noted that, for clarity, only one of the two slide operators 72 and one of the two tierods 76 of each core assembly 36 is shown in FIG. 1 but in practice two slide operators 72 are provided on each side of turret 24 .
[0080] Each slide means 68 extends longitudinally along the side of turret 24 with each cavity extension element 64 on a fist side of each core 56 being mounted to slide means 68 adjacent that first side and each cavity extension element 64 on a second side of each core 56 being mounted to slide means 68 adjacent tat second side such that, movement of a slide means 68 by its respective slide operator 72 results in all the cavity extension elements on a side of cores 56 moving in unison toward or away from core 56 .
[0081] In the embodiment of FIG. 1, each slide operator 72 comprises a cam support 80 mounted to turret 24 , each cam support having a cam track 84 therein with two legs 86 and 86 ′ in which a cam follower 88 can move. Each cain follower 88 is connected to a respective slide means 68 by a respective tierod 76 and cam follower 88 moves with slide means 68 and with stripper plate 60 . At the extremity of cam track 84 distal turret 24 , there is a cam director 92 which operates to switch cam follower 88 between a leg 86 and a leg 86 ′ via a gate 96 . As shown in the Figure, each leg 86 and 86 ′ includes an inclined portion adjacent cam director 92 and a straight portion adjacent the side of turret 24 .
[0082] Cam director 92 is rotatable to move gate 96 into communication with the inclined portion of either leg 86 or 86 =, as described below in more detail. Cam director 92 can be rotated by any suitable means as will occur to those of skill in the art, and in a presently preferred embodiment is rotated by pneumatic means.
[0083] The process of creating a multi-layer injection molded article with machine 20 will now be described, by discussing the operations performed at each station in turn. It will be apparent to those of skill in the art that, while the following discussion relates to the molding of a single article on a single side of turret 24 , in operation of machine 20 multiple articles are being molded and/or operated on each side of turret 24 , at each station 40 , 44 , 48 and 52 .
[0084] The injection molding operation for a multi-layer article commences with a core assembly 36 a at station 40 . As shown in the Figure, core 56 a is empty, a previously formed multi-layer article 100 (if any) having been stripped from core 56 a by stripper plate 60 a moving away from turret 24 as will be described further below. Cam followers 88 a in each cam operator 72 arc located in gate 96 a so that tierods 76 a have slides 68 in a half-open position, allowing previously molded article 100 (if any) to be ejected. Cam directors 92 a are then rotated to bring gate 96 a into alignment with leg 86 ′ and turret 24 is rotated ninety degrees in the direction indicated by arrow 32 .
[0085] At station 44 , the second step of the process is shown wherein stripper plate 60 b is moved adjacent turret 24 . Stripper plate 60 b is moved toward or away from turret 24 in any suitable manner as will occur to those of skill in the art and, in a presently preferred embodiment of the invention, is performed via hydraulic cylinders. As stripper plate 60 b moved toward turret 24 , cam followers 88 b move along the inclined portions of legs 86 ′ to the straight portions adjacent turret 24 , moving tierods 76 b away from core 56 b and thus moving slides 68 b and cavity extension elements 64 b mounted thereon, to a fully opened position. As will be apparent to those of skill in the art, the movement of stripper plate 60 can be performed simultaneously with the rotation of a side of turret 24 to station 44 from station 40 to reduce total cycle time, or can be performed once that rotation is complete.
[0086] A first cavity 104 is then brought into engagement with core 56 b, extending between cavity extension elements 64 b, and a first injection operation is performed. As shown in the Figure, the base of core 56 b directly engages cavity 104 via corresponding inclined surfaces 108 and 112 with aid in sealing cavity 104 . First injection operation can be performed with a single material or can be a co-injection operation, either simultaneously or sequentially, as will be apparent to those of skill in the art.
[0087] When the first injection operation is complete, cavity 104 is retracted from core 56 b and stripper plate 60 b is moved away from turret 24 to move cam followers 88 into gates 96 b. Cam directors 92 are then rotated to align gates 96 b with the inclined portions of legs 86 while turret 24 is rotated to move core 56 with the molded article thereon to station 48 .
[0088] At station 48 , or while rotating to station 48 , stripper plate 60 c is moved to a position adjacent tune 24 , thus moving cam followers 88 along the inclined portions of legs 86 to the straight portions of leg 86 proximal turret 24 . As cam follower 88 is moved along the inclined portion of legs 86 , tierods 76 and slides 68 are moved towards core 56 c, bringing the two halves of cavity extension element 64 c into engagement about core 56 c. As stripper plate 60 c continues to move toward turret 24 , cam follower, 88 moves along the straight portion of leg 86 and the inclined surface 116 c of the engaged cavity extension elements 64 c engages the inclined surface 108 c at the base of core 56 c.
[0089] A second cavity 120 is then moved into engagement with cavity extension elements 64 c, second cavity 120 having an inclined surface 124 complementary to an inclined surface 128 on engaged cavity extension elements 64 c.
[0090] As will be apparent, cavity 120 has a shorter length and a greater diameter than cavity 104 . As will also be apparent, cavity 120 is combined with the cavity formed by cavity extension elements 64 c to obtain the required total length of the cavity. As will also be apparent, the portion of the combined cavity formed by cavity extension elements 64 c defines different geometric features for a portion of the article to be molded in the combined cavity. In the illustrated embodiment, these different geometric features comprise threads for the neck portion of a preform, although any other features of differing geometries can be provided as will occur to those of skill in the art.
[0091] A second injection molding operation is then performed at station 48 to fill the combined cavity comprising cavity 120 and cavity extension elements 64 c. The second injection operation can be performed with a single material or can be a co-injection operation, either simultaneous or sequential, as will be apparent to those of skill in the art.
[0092] When the second injection molding operation is completed, cavity 120 is removed, leaving molded article 100 on core 56 c and turret 24 is rotated to move core 56 c, with article 100 still thereon, to station 52 . At station 52 , article 100 is cooled, both by cooling fluid circulated within core 56 d and by cooling air blown over article 100 .
[0093] Next, turret 24 is rotated to bring core 56 d, and article 100 thereon, to station 40 to complete the molding operation. At station 40 , stripper plate 60 a is moved away from turret 24 , moving cam followers 88 a along legs 86 . Cavity extension elements 64 c are still engaged with each other and with article 100 and force article 100 along core 56 a as stripper plate 60 a moves away from turret 24 . As stripper plate 60 a approaches the limit of its movement away from turret 24 , each cam follower 88 engages the inclined portion of legs 86 , moving tierods 76 to disengage cavity extension elements 64 a from each other and from article 100 . As article 100 is substantially free of core 56 a at this point, article 100 is ejected from machine 20 and can be removed from the vicinity of machine 20 by any suitable means such as a conveyor. Each cam follower 88 enters a respective gate 96 a, movement of stripper plate 60 a ceases and the molding cycle is complete and machine 20 is ready to commence another cycle.
[0094] While the description above discusses a single molding cycle, it will be apparent to those of skill in the art that, in fact, four molding cycles are performed simultaneously, with each station 40 , 44 , 48 and 52 performing its respective operations on a different one of four different cycles.
[0095] While in the embodiment of FIG. 1 machine 20 includes the above-mentioned four stations, it will be apparent to those of skill in the art that the number of stations and the corresponding number of sides of turret 24 can be selected as required by the molding operation to be performed. Further, while machine 20 of FIG. 1 includes the above-mentioned four different molding stations, it will be apparent to those of skill in the art that all the stations need not be different. For example, if eight stations are provided, they can comprise two repeated sets of the four stations described above to allow to complete articles to be produced on each half of a complete rotation of turret 24 . In either case, the number of simultaneous machine cycles which can be performed can be selected as desired. Also, it is contemplated that in some circumstances it may be desired to have a second cavity extension, formed from a second pair of extension elements, which can be used to form a composite cavity with a third cavity for a third injection operation. In such a case, the second pair of extension elements can move between their open and closed positions in a direction perpendicular to the pair of cavity elements for the first cavity extension, such that either both sets can be open at the same time or either set can be closed, as desired.
[0096] One of the significant problems which must be faced when injection molding articles is that the material, or materials, which are injected can be damaged by a slow transition from liquid to solid states as the article is cooled. The present inventors have determined that this damage, commonly referred to as the crystallinity problem, is mitigated or eliminated if adequate cooling and short cavity residence times can be obtained, As will be apparent, overmolding can aggravate the crystallinity problem in two aspects, the first being that the first layer acts as an insulator between the core and the second layer, inhibiting the transfer of the heat from the second layer to the core and the second being that the first layer is reheated, to some extent, by the injection of the second layer, thus enabling the formation of crystalline areas in the first layer during the second injection. In an over-molded article, this crystallinity problem can lead to failure of the inner layer, for example allowing food to contact the second layer of recycled material, or even total failure of the article.
[0097] Accordingly, as determined by the present inventors, the provision of cooling station 52 in the embodiment of FIG. 1, which allows both internal cooling of the article from the core and external cooling from the blown air or other cooling fluid at station 52 , is believed to provide significant advantages in allowing the reduction of crystallinity in over-molded articles. It is further contemplated that another cooling station can be provided in some circumstances, between station 44 and station 48 , to provide external cooling to the first layer between injection operations. In such a circumstance, turret 24 can have more than four sides or one or more stations, such as station 40 and station 52 , can be combined.
[0098] If it is desired to produce an article which is over-molded over an insert, it is contemplated that, in the situation wherein the insert is pre-formed by a separate process, an insert loading operation can be combined with the ejection operation at station 40 , and the insert placed on core 56 a after ejection of a completed article 100 , or can combined with the machine operation at any other appropriate station. In the situation wherein the insert is to be molded in place by machine 20 , an appropriate additional station can be added at an appropriate location, as will also occur to those of skill in the art. In the situation wherein it is desired to mold over an insert between the injection operations, an appropriate additional station to load the insert onto a first, or subsequent, layer of the molded article can be provided between injection stations.
[0099] A second embodiment of the present invention will now be described with reference to FIGS. 2 and 2 a through 8 wherein another molding machine in accordance with the present invention is indicated generally at 200 and similar components to those of the embodiment of FIG. 1 are identified with like reference numerals, although in these Figures the letters “a” and “b” are appended to distinguish between two sets of components. As described below, machine 200 is a rotary machine.
[0100] Machine 200 comprises a core plate 204 which includes a series of identical core assemblies 36 including cores 56 , a stripper plate 60 and a set of slides 68 , each of which has one or more cavity extension elements 64 mounted thereon. Machine 200 includes a pair of slide operators 72 which are mounted to core plate 204 and cam followers 88 in each slide operator 72 move with stripper plate 60 , as described above with respect to machine 20 . Each cam follower 88 is directly connected to the slide means 68 closest to it via a tie bar 76 and the remaining slides 68 are connected to alternating remaining slides via additional tierods 76 extending between slides 68 such that every second slide means 68 is operated by one slide operator 72 and the remainder of slides 68 are operated by the other slide operator 72 . For example, in FIG. 2 a slides 68 b and 68 a are operated by slide operator 72 b while slide means 68 c is operated by slide operator 72 a.
[0101] In a preferred aspect of the present invention, cooling fluid is circulated to slides 68 , and thus to cavity extension elements 64 , via tierods 76 which are hollow, providing closed conduits between slides 68 through which cooling fluid is circulated. This use of tierods 76 to circulate cooling fluid to slides 68 is believed to be particularly advantageous and eliminates the need for cooling fluid hoses to be provided each slide 68 .
[0102] Machine 200 also includes a manifold plate 208 and a mold cavity plate 212 to which a plurality of pairs of cavities 216 and 220 are mounted. As shown, cavity 216 has a smaller diameter than cavity 220 and has a greater depth than cavity 220 . As is indicated in FIG. 2 a, only a portion of core plate 204 , stripper plate 60 and cavity plate 208 are shown for clarity and, in use, machine 200 can include forty-eight or more core assemblies 36 on core plate 204 and a corresponding number of cavities, arranged as adjacent pairs of cavities 216 and 212 on cavity plate 208 . Accordingly, core plate 204 and mold cavity plate 212 have like numbers of cores and cavities, respectively, which can be arranged in a square, rectangular or other shaped array, as desired.
[0103] Core plate 204 is rotatable about central axis 224 and cavities 216 and 220 are arranged in the array on mold cavity plate 208 such that rotation of core plate 204 through one hundred and eighty degrees will result in each core 56 which was axially aligned with one of cavities 216 and 220 before the rotation, being axially aligned with the other of cavities 216 and 220 after the rotation. In a presently preferred embodiment, rotation of core plate 204 is reciprocating, i.e.—turning one hundred and eighty degrees in a first direction and then turning one hundred and eighty degrees in the opposite direction. While reciprocal rotation simplifies the various connections which must be effected to core plate 204 and the components mounted thereon, reciprocal rotation is not required and continuous rotation in a single direction is also possible.
[0104] The operation of machine 200 will now be described. For clarity, the molding of a single article on a single core 56 a will be described although it will be apparent to those of skill in the art that each core 56 is identical to each other core 56 and that an article is generally always being molded on each core 56 , albeit at one of two different stages, except at start up or shut down of machine 200 .
[0105] In FIG. 2 a, a molding cycle is commenced with core 56 a inserted into cavity 216 . A shown, cam followers 88 a and 88 b are located in the straight portions of legs 86 of cam tracks 84 and slides 68 a and 68 c are thus moved away from each other, allowing cavity 216 to be inserted therebetween to engage the base of core 56 a As shown, the base of core 56 a includes an inclined surface 108 a which engages a complementary inclined surface 112 a on cavity 216 to assist in sealing cavity 216 . A first injection operation is then performed into cavity 216 to form a first layer of a molded article.
[0106] Next, core plate 204 is moved away from mold cavity plate 208 , as shown in FIG. 3 and the first layer molded onto core 56 a in cavity 216 remains on core 56 a Next, as shown in FIG. 4, stripper plate 60 is moved away from core plate 204 and, as can be seen, cam followers 88 a and 88 b move with stripper plate 60 and enter gates 96 a and 96 b respectively, moving slides 68 to the mid-points of their range of movement with respect to each other.
[0107] As will be apparent to those of skill in the art, the movement of stripper plate 60 will remove a finished article, if present, from core 56 b until cam followers 88 a and 88 b enter the inclined portions of leg 86 , moving the pair of cavity extension elements 64 b away from each other, allowing the completed article to fall, or be otherwise removed, from machine 200 .
[0108] Next, as shown in FIG. 5, cam directors 92 a and 92 b are rotated to bring gates 96 a and 96 b into alignment with legs 86 ′ and stripper plate 60 is moved toward core plate 204 . As cam followers 88 a and 88 b ride on the inclined portion of legs 86 ′, tierods 76 a and 76 b move slides 68 b and 68 c away from each other and slides 68 c and 68 a toward each other, thus closing the pair of cavity extension elements 64 a about the article formed on core 56 a in the first injection operation and opening the pair of cavity extension elements 64 b about core 56 b as shown. Closed cavity extension elements 64 a define an inclined surface 116 a which is complementary to and engages inclined surface 108 a.
[0109] Next, as shown in FIG. 6, core plate 204 is rotated about center axis 224 to align core 56 a with cavity 220 and core 56 b with cavity 216 . As will be apparent to those of skill in the art, cavities 216 and 220 can be arranged in a variety of manners on cavity plate 212 . For example, all of cavities 220 can be on one side of central axis 224 and all of cavities 216 can be on the other. Alternatively, cavities 216 and 220 can be arranged in repeating sets of pairs on either side of center axis 224 , with the ordering of the pairs being reversed on either side of center axis 22 . Other arrangements of cavities 216 and 220 , including mixtures and combinations of those mentioned above, will occur to those of skill in the art.
[0110] Next, core plate 204 is moved toward cavity plate 208 to close the mold, as shown in FIG. 7, and a second injection operation is performed in cavity 220 , over-molding the first layer previously formed on core 56 a with a second layer. As shown in FIG. 7, closed cavity extension elements 64 a define a second inclined surface 128 a which is complementary to and engages inclined surface 124 of cavity 220 .
[0111] When the second injection operation of FIG. 7 is complete, machine 20 is in the same state as that shown in FIG. 2 a, albeit with the two cores in a reversed configuration, and the another molding cycle commences with the machine repeating the steps discussed above with respect to FIGS. 3 through 7.
[0112] As was the case for machine 20 , either or both of the injection operations of machine 200 can be injections of single materials or can be co-injection operations, either simultaneous or sequential, as desired.
[0113] While each of machines 20 and 200 have been described as having cavity extension elements 64 on the cavity used for the second injection operation, it will be apparent to those of skill in the art that this can be reversed, if desired, to allow creation of features of different geometries on the first layer which are then covered by the second layer. For example, the jeweled diffraction areas of an automotive indicator light lens can be molded in a first cavity having cavity extension elements to define the jeweled area and then inserted into a larger, second cavity in which a second layer of material is over-molded on the lens to form a smooth outer layer. The first layer can be molded in red translucent material, for example, and the second layer in transparent material.
[0114] It is also contemplated that the present invention can by employed in circumstances wherein a single, common, cavity is employed with different cores. In such an embodiment, the molded article is formed by a first injection operation into the cavity with a large core in place The large core is then removed and replaced with a smaller core, while the article remains in the cavity, and a second injection operation is then performed to complete the article. The article is then ejected from the cavity and the cycle is repeated. In over-molding processes wherein the article remains on the core for each molding operation, there can be difficulty in providing adequate cooling through the core after the injection molding operation. This is because the first layer formed on the core acts to some extent as an insulator, inhibiting heat transfer between subsequent layers and the core. In the common cavity-multiple core embodiment of the present invention, this difficulty can be avoided by changing the core between injection operations.
[0115] [0115]FIG. 8 shows another embodiment of the present invention comprising a core 300 and a first cavity 304 and a cavity extension 308 . In FIG. 8, core 300 and first cavity 304 form a mold cavity 312 and cavity extension 308 is in a disengaged position, as shown. When an injection operation is performed, through inlet 316 , a first layer of an article is formed in cavity 312 . Core 300 is then removed from cavity 304 , with the firs layer of the article on it.
[0116] As shown in FIG. 9, core 300 is then inserted into a second cavity 320 with the first layer of the article 324 on core 300 and a composite cavity 328 is formed by moving cavity extension 308 into an engaged position with cavity 320 . In this example, composite cavity 328 overlaps only a portion of article 324 and it will be apparent to hose of skill in the art that the present invention is not limited to the complete over-molding of a first layer of an article and can instead be employed to over-mold only portion of a first layer.
[0117] An injection operation is performed through inlet 332 to fill cavity 328 and core 300 and cavity extension 308 are separated from cavity 320 with the over-molded article on core 300 . Cavity extension 308 can then be moved along core 300 , toward overmolded article 324 , to eject article from core 300 . As will be apparent to those of skill in the art, cavity extension 308 engages only a portion of cavity 320 in this embodiment to form composite cavity 328 and cavity extension 309 is a single part.
[0118] [0118]FIGS. 10 and 11 show an example of the irregular geometry of article 324 which can be obtained with the present invention. Further, while in this example both the first and second injection operations employed the same materials, resulting in article 324 having a homogenous structure, it will be apparent to those of skill in the art that the first and second injection operation can employ different materials and can in fact be co-injection operations, if desired.
[0119] While the description above only specifically refers to turret and rotary machines, it will be apparent to those of skill that the present invention is not so limited and can be employed with shuttle-typo or other machine types.
[0120] The above-described embodiments of the invention are intended to be examples of the present invention and alterations and modifications may be effected thereto, by those of skill in the art, without departing from the scope of the invention which is defined solely by the claims appended hereto.
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This invention relates to a mold design, injection molding machine and a method for forming a multi-layer plastic article by over molding where the second layer of the article includes a portion having a different geometrical profile than the first one. The novel injection mold and injection molding machine for producing over-molded articles comprises an array of one or more cores which engage arrays of one or more first cavity and arrays of one or more composite cavities. Each composite cavity is formed from the combination of a second cavity and a cavity extension which carries at least a portion of the different geometrical profile, such as a thread. In one embodiment, the cavity extension comprises a pair of cavity portions which are mounted adjacent the core to laterally moveable slides on a movable plate, that can be a stripper plate. During molding of the first layer, the cavity extension elements are moved “out” of alignment with the first cavity and during molding of the second layer the cavity extension elements arc moved “in” to form the composite cavity with the second cavity so that only the second layer replicates the geometrical profile of the composite cavity. In another embodiment of the invention, the cavity extension is a single element which is moved between a disengaged position wherein the core can be inserted into the first cavity and an engaged position wherein the core is inserted into the composite cavity.
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CROSS-REFERENCES TO RELATED APPLICATIONS
None.
BACKGROUND OF THE INVENTION
Manufacturers of consumer goods, specifically, manufacturers of food products annually devote a substantial amount of time, effort and resources to improving the products they offer. These improvements can take the form of improved taste or texture, reduced calories or fat content and the like. More recently, and as the population matures, food companies are looking more and more into food products, food components or ingredients that deliver a particular health or nutritional benefit. That is, food products that may assist the consumer in living a healthier life in that the food product aids in reducing high cholesterol levels, mitigating the risk of heart diseases, diminishing the risk of some cancers and many other illnesses and diseases, which become more prevalent as society ages or dietary patterns are modified to meet the changing lifestyles of today's population.
One health claim that has received a lot of interest lately is the effect of using sterols/stanol, steryl esters and other fatty acid derivatives and combinations thereof to reduce unhealthy or high cholesterol levels. In this regard, a number of internationally known food manufacturers have successfully manufactured and marketed starch-containing food products that have certain levels of sterols and steryl esters in order to deliver a product that provides this health benefit. Such starch-containing food products include ready to eat (RTE) cereals, dough based products, RTE meals and the like.
It is well known that cholesterol in humans comes from primarily two sources, the body's own production of cholesterol (endogenous) and dietary cholesterol (exogenous). Typically, the average person consumes between 350-400 milligrams of cholesterol daily, while the recommended intake is around 300 milligrams. Increased dietary cholesterol consumption, especially in conjunction with a diet high in saturated fat intake, can result in elevated serum cholesterol. Elevated serum cholesterol is a well-established risk factor for heart disease and therefore there is a need to mitigate the undesired effects of cholesterol accumulation. High cholesterol levels are generally considered to be those total cholesterol levels at 200 milligrams per deciliter and above or LDL cholesterol levels at 130 milligrams per deciliter and above.
Lipoproteins contain specific proteins and varying amounts of cholesterol, triglycerides and phospholipids. There are three major classes of lipoproteins and they include very low density lipoproteins (“VLDL”), low density lipoproteins (“LDL”) and high density lipoproteins (“HDL”). The LDLs are believed to carry about 60-70% of the serum cholesterol present in an average adult. The HDLs carry around 20-30% of serum cholesterol with the VLDL having around 1-10% of the cholesterol in the serum. To calculate the level of non-HDL cholesterol present (find the level of LDL or VLDL levels), which indicates risk, the HDL is subtracted from the total cholesterol value. By lowering the total system LDL cholesterol level, it is believed that certain health risks, such as coronary disease and possibly some cancers, that are typically associated with high cholesterol levels, can be reduced.
Numerous studies relating to modifying the intestinal metabolism of lipids have been done to illustrate that such effects can reduce a high cholesterol level. This may be done by hampering the absorption of triglycerides, cholesterol or bile acids. It is believed that certain plant sterols, steryl esters, stanols fatty acid derivatives and combinations thereof lower serum cholesterol levels by reducing the absorption of dietary cholesterol and/or bile acids from the intestines.
Sterols occur in natural fats and oils, particularly in vegetable oils. Unsaturated vegetable oils and non-animal fat oils, such as soybean oil, wheat germ oil, cottonseed oil, safflower oil, peanut oil, rice oil, canola oil and the like are well known sources of β-sitosterol, stigmasterol, ergosterol and campesterol as well as various other materials such as higher aliphatic alcohols. Tall oil is also a significant source of β-sitosterol and campesterol.
Stanols (β-sitostanol, campestanol, stigmastanol and fatty acid derivatives thereof) are the 5 alpha saturated derivatives of plant sterols and may be derived from similar sources set forth above.
Natural plant sterols are similar structurally to cholesterol except in the arrangement of the basic side chains. Absorption of plant sterols in the intestines is believed to be minimal at best and sterols/steroids are generally excreted in the stool. Thus, the levels of plant sterols in the serum are relatively low since they are not absorbed by the body and are relatively quickly excreted. Where the amount of sterols is increased in an effort to obtain greater beneficial or health effects, the sterols still do not increase significantly in amount in the blood serum as the absorption capability, however limited it may be, is quickly exceeded. Hence, the interest in including sterol related or containing compounds in food products, food ingredients and food components (the presumed health benefit stated above) is directly related to the manufacturer's interest in sterol inclusion into such products.
In manufacturing products that contain certain health claims, such as a RTE cereal, i.e. TOTAL® or CHEERIOS® available from General Mills, Inc. of Minneapolis, Minn., it is important that the product not only be able to support or substantiate the health claim for regulatory reasons but also that the product must actually contain the amount of the effective ingredient stated in the nutritional information provided with the package. One of the problems associated with making foods having sterol related or containing compounds is determining or verifying the actual level of sterol related or containing compounds in the end product to be consumed.
Thus, there is a need for food manufacturers to be able to accurately calculate or quantify the amount of the sterols and steryl esters in a food product so that the proper amount is delivered in each of the suggested serving or portion sizes in order that the claims of the food product are supported by the contents.
Heretofore, a number of methods using a variety of internal standards have been developed to attempt to calculate the amount of sterol related or containing compounds in the food product. However, these methods while possibly being relatively quick and inexpensive to use can in fact be detrimental to both the manufacturer from both a cost and a regulatory standpoint as well as the consumer of the product from a health related aspect.
With respect to prior methodologies employed by the food product manufacturer, readings related to determining the level of sterol based or containing compounds provided by these methods often resulted in a reading that was substantially lower than the actual amount of sterols or steryl esters that may have been added to the food products during the manufacturing process, that is, that amount added to provide or obtain the health or nutritional benefit. Often, it was found that readouts from these prior test methods would be from twenty-five to fifty percent (25-50%) lower than the actual amount of the ingredient or component that was added. Such readings would then result in the manufacturer adding even more of the ingredient or component to insure that the food product would be supported by the claims and nutritional information provided with the package, that is in the present example, to insure that enough of the sterol based compound is present. While this is a simple solution, it has significant economic disadvantages in that sterol related compounds are relatively expensive ingredients when compared on a relative weight basis with other ingredients present in the product, i.e. the grain (wheat, oat, barley), sugar, macro and micro nutrients, etc. There are also other significant disadvantages to having excessive amounts of sterol containing compounds in the food products. As used herein, the term “food products” includes food components (such as dough, flakes), food intermediates (a transitional step used in making a product or component) and a food ingredient. Where the term “food product” is used in connection with a manufacturer or manufacturing, the term is intended to imply an entity, which makes, fabricates, processes or produces food products as defined above.
It is important to insure that the right amount of the ingredient is available in each serving or portion size, not only from a manufacturing but also a regulatory standpoint. From a manufacturing point of view, cost of manufacture is a significant factor in determining profit levels. However, from a regulatory standpoint, providing an amount of sterols and steryl esters beyond an acceptable threshold can be detrimental to the health of the consumer. As such, there is a maximum amount of the ingredient that cannot be exceeded in order to qualify for the generally recognized as safe (“GRAS”) status of such sterol related compounds. As used herein, the term sterol related or containing compound refers to such compounds as β-sitosterol, stigmasterol, ergosterol, campesterol, stanols β-sitostanol, campestanol, stigmastanol and fatty acid derivatives thereof.
It is believed that the prior testing methods, which used an internal standard of cholestane, produced unacceptable results in part due to the fact that cholestane did not sufficiently chemically simulate the compounds that were being assayed to compensate for degradation or matrix binding. The problem of getting an accurate reading using current methods is that the steryl esters and sterols are bound by the starch (most probably amylopectin) during the cooking process, which is inherent in most food product manufacturing steps. Using such internal standards prior test methods were ineffectual in releasing the starch bound sterols and steryl esters resulting in readings being off by as much as fifty percent (50%) from the known amount of ingredient or component that was added to the food product or food component initially.
What is needed therefore is an accurate method for determining or quantifying the level of the sterol related or containing compounds in a particular starch containing or consumer food product or component which has a health claim or benefit associated with it so as to insure compliance with self-affirmed GRAS status as well as to maintain manufacturing economies in scale with target projections.
SUMMARY OF THE PRESENT INVENTION
The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.
In a presently preferred embodiment of the present invention, the invention comprises an extraction method to be able to quantify the amount of sterol based compounds in starch-containing food product, which includes the steps of providing an amount of a steryl ester, preferably cholesterol oleate, and then initially hydrating a polysaccharide matrix of a starch-containing food product. Then mixing the matrix with an organic solvent. The organic phase is separated from an aqueous phased which was created by the mixing process. The organic phase is then subject to a drying step in order that the level or amount of sterol based compounds in the starch containing food product can be determined.
A still further preferred embodiment of the present invention sets forth an assay for determining quantities of sterols, stanols, steryl esters, fatty acid derivatives and combinations thereof in a cereal based product using a steryl ester as an internal standard. Preferably, the steryl ester is cholesteryl oleate.
A additional preferred embodiment of the present invention relates to an assay for determining quantities of sterols, stanols, steryl esters, fatty acid derivatives and combinations thereof in which more than 90%, preferably closer to 100%, of the sterols, stanols, steryl esters, fatty acid derivatives and combinations thereof are recovered for quantification.
Another embodiment of the present invention includes a method for substantiating the presence or absence of sterol based compositions that are found in a consumer food product. This method comprises the steps of, initially obtaining a consumer food product and then separating the consumer food product into certain fractions. Once the fractions are separated, at least one of the fractions are hydrated. Next, an organic solvent is added to the hydrated fraction. This hydration creates an organic phase which is sequestered from the organic phase of the hydrated fraction. Using an internal standard of a sterol related compound the amount of sterol based compounds in the consumer food product is determined. Once the amount of sterol based compound is determined that result is communicated to deliver a particular health message related to the presence of the sterol based compound.
A still further embodiment of the present invention relates to a method of reporting a health benefit of a consumer food product. This method comprises the steps of initially manufacturing a food product that is intended for human consumption. (Although only human consumption is referenced herein, this embodiment as well as the other embodiments provided in this application may include food products that are intended for animal consumption as well.) In order to determine the presence or absence of a sterol related compound in the food product, an internal standard of a sterol related compound is provided as a reference. The food product is then hydrated to create a matrix through the addition of an organic solvent. An organic phase of the matrix is separated and analyzed to obtain a level of sterol related compounds found in the hydrated food product. Finally, once the amount of sterol related compounds in the food product is known, a health benefit of the food product containing sterol related compounds is advertised to potential consumers of the health product.
Publications, patents and patent applications are referred to throughout this disclosure. All references cited herein are hereby incorporated by reference. All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise stated.
These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:
FIG. 1 is a gas chromatograph illustrating sterol standards; and
FIG. 2 is a graph showing the correlation of the level of sterol determined by the prior method to the amylopectin content of cooked doughs.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is now illustrated in greater detail by way of the following examples, but it should be understood that the present invention is not to be construed as being limited thereto.
In the preferred embodiment, a starch containing food product, such as an RTE cereal is prepared in a conventional manner. This exemplary RTE cereal is in the form of flakes that are created by preparing a cooked cereal dough through known methods and then forming the cooked cereal dough into pellets that have a desired moisture content. The pellets are then formed into wet flakes by passing the pellets through chilled roller and then subsequently toasting or heating the wet cereal flakes. The toasting causes a final drying of the wet flakes, resulting in slightly expanded and crisp RTE cereal flakes. The flakes are then screened for size uniformity. The final flake cereal attributes of appearance, flavor, texture, inter alia, are all affected by the selection and practice of the steps employed in their methods of preparation. For example, to provide flake cereals having a desired appearance feature of grain bits appearing on the flakes, one approach is to topically apply the grain bits onto the surface of the flake as part of a coating that is applied after toasting.
In the following example, the assay is based on using an internal standard of cholestryl oleate instead of cholestane, which has been perceived as producing unacceptable results as typified in the graph illustrated in FIG. 2 . As set forth previously, it is believed that cholestane did not sufficiently, chemically simulate the compounds that were being assayed to compensate for degradation or matrix binding which further exacerbates the problem of getting an accurate reading in that the steryl esters, stanols and sterols are bound by the starch (most probably amylopectin) during the cooking process. By using the following process substantially all, that is greater than 90%, but typically closer to 100% of the sterol related compounds that is added to the sample product is recovered.
Example A Extraction of Steryl Esters/Sterols/Stanos from Cooked Cereal Products:
1. Add Cholesterol Oleate (0.1 mg) to a clean 20 ml glass scintillation vial with phenolic foil lined cap (“Vial”). 2. Weigh out 0.1000 gram of sample into the Vial. 3. Add 2.0 ml of Solution 0.1 M Acetic Acid with 0.7% (w/v) KCl to hydrate the polysaccharide matrix of the sample. 4. Heat Sample at 95° C. for 30 minutes. 5. Cool sample to room temperature. 6. Add 10 ml of HPLC grade chloroform to the sample. Alternatively, add 10 ml of 2:1 Chloroform:MeOH. Seal cap tightly. Incubate at 37° C. for 12-16 hours with constant shaking at 250 rpm. 7. Focus organic and aqueous phase by centrifuging for 10 min at 5000 rpm separating the organic phase from the aqueous phase. 8. Withdraw bottom layer (chloroform or chloroform:MeOH) from the vial with a 10 ml gas tight syringe. Avoiding the aqueous layer during the draw. Transfer to a clean flask and dry down. 9. Transesterify using Alltech MethPrep II (Alltech Associates, Inc., Deerfield, Ill. 60015, USA) or sodium methoxide. Alternatively, saponify samples. 10. Silanate samples and inject on to GC with FID detector (Hewlett Packard 5890 Gas Chromatograph; Agilent Technologies Palo Alto, Calif. 94303 USA ) or Mass Spec detector(Hewlett Packard Model 5970 MSD; Agilent Technologies Palo Alto, Calif. 94303 USA) to quantify or determine the amount or level of sterol related compounds that are found in sample.
The following example uses enzymes to digest the carbohydrate and protein matrix and is thought to obtain substantially all, that is greater than 90%, but typically closer to 100% of the sterol/stanol/steryl ester that is added to the sample product is recovered.
Example B Extraction of Steryl Esters/sterols/stanols from Cooked Cereal Products
1. Add Cholesteryl Oleate (0.1 mg) to a clean 20 ml glass scintillation vial with phenolic foil lined cap (Vial). 2. Weigh out 0.1000 gram of sample into Vial. 3. Add 2.0 ml of Solution A-2 to hydrate the polysaccharide matrix of the sample (see below). 4. Heat Sample at 95° C. for 30 minutes. 5. Cool Sample to 50° C. then add 400 ul of Enzyme Solution 1 (see below). Incubate at 50° C. for 3 hours. Vortex occasionally. 6. Add 100 ul of Enzyme Solution 2 (see below). Incubate at 50° C. for 1 hour. Vortex occasionally. 7. Add 20 ul of 50% Acetic acid (Final Conc. ˜0.1 M Acetic Acid). 8. Add 10 ml of HPLC grade chloroform. Seal cap tightly. Incubate at 37° C. for 12-16 hours with constant shaking at 250 rpm. 9. Focus organic and aqueous phase by centrifuging for 10 min at 5000 rpm separating the organic phase from the solution. 10. Withdraw bottom layer (chloroform) from the vial with a 10 ml gas tight syringe. Be sure not to draw any of the aqueous layer into the syringe. Transfer to a clean flask and dry down. 11. Transesterify using Alltech MethPrep II (Alltech Associates, Inc., Deerfield, Ill. 60015, USA) or sodium methoxide. Alternatively, saponify samples to determine the amount or level of sterol related compounds in the food product sample. 12. Silanate samples and inject on to GC with FID(Hewlett Packard 5890 Gas Chromatograph; Agilent Technologies Palo Alto, Calif. 94303 USA) detector or Mass Spec detector.
Solution A2:
20 mM KH 2 PO 4 , pH 7.2 150 mM NaCl 50 mM KCl
Enzyme Solution 1: (make just prior to use)
2 grams α-Amylase 4 ml Amyloglucosidase (volume to 500 ml with Solution A2—above)
Enyme Solution 2: (make just prior to use)
1 gram Papain 0.6 grams Dithiothreitol (19.5 mM) volume to 200 ml with Solution A2 (above)
In order to determine the amount of sterols, stanols, steryl esters, fatty acid derivatives or combinations thereof which have been recovered by using one of the aforementioned examples, the sample is subjected to gas chromatography. FIG. 1 , illustrates the standard peaks for sterols.
Cooked starch-containing dough samples with increasing concentrations of amylopectin and fixed amounts of added steryl esters were assayed using one of the above referenced processes but having cholestane as the internal standard. FIG. 2 , illustrates that the assay using the internal standard of cholestane underestimates the amount of steryl ester in a well correlated manner (r 2 =0.993) to the total amount of amylopectin present in the sample.
The following table lists the results of exemplary RTE cereal samples, which were tested after using the process described in the above referenced examples. Example A lists values obtained using the process contained herein whereas Example B lists values obtained using cholestane as an internal standard over which the method of the present invention is an improvement over.
TABLE 1
Sterol Determinations
Sample Name
Sterol Target
Example A
Example B
Batch Flake
2.00
2.05 ± 0.16
1.49 ± 0.10
Clinical James Flake
4.10
3.93 ± 0.2
2.87 ± 0.07
James Flake 1715
3.00
3.04 ± 0.12
1.75 ± 0.23
James Flake 1915
3.20
3.14 ± 0.05
1.92 ± 0.14
HSE Flake 11001
2.50
2.53 ± 0.01
1.56 ± 0.09
LSE Flake 12501
2.00
2.09 ± 0.05
0.87 ± 0.18
In conducting a comparison of standard steryl esters processed in the absence of a cereal matrix by the process set forth above using either an internal standard of cholesteryl oleate or cholestane the following results were reported in Table 2. These results demonstrate that the cholestane is being recovered in higher yield relative to the silated sterol standards resulting in a lower value for the measured sterols that use the cholestane internal standard. Unlike cholesteryl oleate, cholestane is unesterified during the initial extraction steps and will therefore have different affinity for compounds and/or matrices that may irreversibily bind steryl esters. Following the saponification or transesterification, cholesteryl oleate and the other steryl esters will yield a free sterol with a hydroxyl group at the 3 position of the sterol ring. This hydroxyl group can cause the free sterol to irreversibly bind to glassware being used in the assay. Cholestane lacks the hydroxyl at the 3 position. This may also explain its higher yield relative to the measured sterols.
TABLE 2
Sterol Determinations
Sample Name
Sterol Target
Example B
Sterol Stds (cholestane)
100.00
89.96 ± 0.64
Sterol Stds (cholesteryl oleate)
100.00
98.41 ± 1.58
In table 3, the first column represents the sample being tested. In this table, in addition to RTE cereals (batch flake and clinical test), a dough, which may be used for breads, muffins and other baked goods is also tested. The second column represent the sterol related compound based target, the third column using the process described herein and the fourth column represents the percent difference of second and third columns.
TABLE 3
Sterol Determinations
Sample Name
Sterol Target
Test A
% Difference
Brabender Var 1
2.32
2.38 ± 0.03
2.6
Brabender Var 2
3.08
3.08 ± 0.14
2.0
Brabender Var 3
3.71
3.98 ± 0.21
7.2
Barbender Var 4
4.46
4.50 ± 0.06
0.8
James Flake
2.94
3.09 ± 0.16
5.1
It is believed that each of the foregoing tables illustrate the significant improvement of recovery of sterol related compounds from starch-containing food products or food components, when compared with previous methods that have used cholestane as the internal standard have not hydrated the starch matrix prior to extraction.
As can be seen from the tables, by using the novel assay of the present invention significantly more of the sterol related compounds are recovered when compared with previous or prior art methods.
In practicing the method embodiments of the present invention applicants the resultant reports are then provided in a manner that enables the communication or advertising of the benefit of having various levels or amounts of sterol related compounds in the food products. This advertising or communication can take any number of forms including the printing of the benefit of sterol compounds for the reduction of cholesterol levels on the packaging of the food product, through the use of audiovisual devices such as television, computer enabled devices and printed indicia such as newspapers, magazines, newsletters and the like.
The methods of the present invention as well as the assay itself is useful in the determination of the levels of sterol related compounds in ready to eat food products. Ready to eat food products (RTE) for the purposes of this invention include baked goods, salted snacks, specialty snacks and confectionary snacks as well as dairy products. Many of the aforementioned products can be dough based products, that is a dough is created, usually from a mixture of flour, water and other ingredients to necessary for the finished product.
It will thus be seen according to the present invention a highly advantageous test methodology has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent processes, methodologies and assays.
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The present invention relates to an assay for determining the levels of sterols, stanols, steryl esters, fatty acid derivatives and combinations thereof in a starch-containing food product. The assay is particularly useful in supporting product health and/or nutritional claims in manufacturing products intended for human or animal consumption. The present invention describes a method for extracting sterols related compounds and uses as an internal standard a steryl ester, preferably cholesterol oleate. By using the present extraction technique the process enables the recovery of substantially all of the sterol related compound in the sample.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claimst he benefit of U.S. Provisional Application No. 61/884,519, filed Sep. 30, 2014.
BACKGROUND
[0002] Systems for cutting, wedging or slicing food including fruits, vegetables, meats or cheese, especially devices for cutting apples into sections have existed for many years. Unfortunately, a drawback to many conventional food slicing devices, and in particular, apple slicing devices, is that such apple slicers are not easily portable.
[0003] Conventional apple slicers do not enclose a food item for sanitary travel, and they do not provide the user a sanitary surface on which to place the food item during the cutting process. A user has to provide a separate cutting surface such as a plate. Conventional apple slicers also do not protect the user from the cutting blade during travel, storage of the food item in the slicer apparatus and during the cutting process.
[0004] Not all individuals can eat food items, such as an apple or pear in their whole form, but do desire the whole, unprocessed food nutrition. For example individuals trying to eat a healthy diet, but who do not enjoy eating a whole apple may still enjoy eating a sliced apple. Also, people of all ages with dental problems may have difficulty eating an apple in its whole state, but they may still be able to eat a sliced apple. For example, people with chipped teeth, children with loose or missing teeth, people with dentures, and the elderly.
[0005] Many people also desire whole, unprocessed food nutrition on the go. For example, at sports activities, school, work, or while traveling, etc. Additionally, parents and caregivers often struggle to find snacks that kids like to eat, are healthy, economical, and do not include common allergens banned from many schools.
[0006] Packaged pre-cut apples are available, but these contain preservatives, may not be available as an organic product, and come in a very limited variety. Packaged pre-cut apples also have shorter shelf life than whole apples, they still require refrigeration and do not taste as fresh. Accessibility is also a problem with packaged pre-cut apples. Packaged pre-cut apples are not as readily available and easily accessible as whole apples; not all stores that carry apples also carry packaged pre-cut apples.
SUMMARY
[0007] The problems with storing food items for travel and for cutting and serving food items on the go may be addressed by the exemplary systems and methods described herein. For example, the exemplary systems and methods are able to protect and store a food item during travel, the storage system incorporating both a cutting apparatus and sanitary surface on which to cut and serve the food item, all in one elegant system. Furthermore, no decoupling of the components of the system may be required to transition from storing, to cutting, to serving the food item.
[0008] One exemplary system for storing a food item prior to cutting, for cutting the food item, and for supporting the food item after it has been cut may include a cutting apparatus comprising an outer frame defining an interior cutting region, wherein the interior cutting region comprises one or more blades being supported by the outer frame. The collapsible apparatus may include a base configured to support the food item during the cutting process, an open end portion (e.g., a rigid ring or frame), and a collapsible region, wherein the collapsible region extends (e.g., spans the space or distance) between the base and the open end portion. The cutting apparatus may be removably couplable to the open end portion of the collapsible apparatus.
[0009] In at least on embodiment, the blades include a sharpened end (e.g., chamfered edge) facing the base of the collapsible apparatus (e.g., direction of collapsible region) in any or all of a food storage configuration, a food cutting configuration, and a food serving configuration.
[0010] In at least one embodiment, the system is configured to operate while maintaining the coupling (e.g., fixed or substantially fixed coupling) between the cutting apparatus and the open end portion of the collapsible apparatus in all of a food storage configuration, a food cutting configuration, and a food serving configuration.
[0011] One exemplary system for storing a food item prior to cutting, for cutting the food item in a cutting process, and for supporting the food item after it has been cut may include a cutting apparatus including an outer frame defining an interior cutting region. The interior cutting region may include one or more blades being supported by the outer frame. The exemplary system may further include a collapsible apparatus including a base configured to support the food item during the cutting process, an open end portion, and a collapsible region. The collapsible region may extend between the base and the open end portion, and the collapsible region is configured to collapse during the cutting process. The system is couplable such that the cutting apparatus is removably couplable to the open end portion of the collapsible apparatus. The coupled system including a first configuration having a first volume and a first height, and a second configuration having a second volume and a second height, such that the first volume is greater than the second volume, and the first height is greater than the second height. In addition, when the cutting apparatus is coupled to the collapsible apparatus, the cutting apparatus may be closer to the base in the second configuration than in the first configuration.
[0012] In one or more embodiments, the first configuration may be a food storage configuration and the second configuration may be a food serving configuration and further wherein the transition between the first configuration and second configuration may be a food cutting configuration.
[0013] In one or more embodiments, the open end of the collapsible apparatus comprises at least a portion of a coupling mechanism configured to allow coupling of the cutting apparatus to the collapsible apparatus.
[0014] In one or more embodiments, the base of the collapsible apparatus of the base may include one or more projections. The projections may include a height extending from a top surface of the base towards the open end of the collapsible apparatus, and when the cutting apparatus and the collapsible apparatus are in the fully collapsed configuration, the blades occupy the space in between, but the blades may not come into contact with the protrusions.
[0015] In many embodiments, the second height is at least 51% less than the first height. In some embodiments, the second height may be further defined to be at least 65% less than the first height.
[0016] In one or more embodiments, a cross section of the collapsible apparatus in the second configuration taken along a plane perpendicular or substantially perpendicular to the plane of the base perpendicular or substantially perpendicular to the plane of the open end the collapsible apparatus includes a zig-zag portion.
[0017] In one or more embodiments, at least one of the blades may include a sharpened end (e.g., edge) facing the base of the collapsible apparatus in all of the food storage configuration, the food cutting configuration, and the food serving configuration.
[0018] In one or more embodiments, at least one of the blades comprises a chamfer (e.g., knife-like) on the edge of the blade facing the base when the cutting apparatus is coupled to the collapsible apparatus.
[0019] In or more embodiments, the cutting apparatus does not move relative to the open end of the collapsible apparatus in all of a food storage configuration, a food cutting configuration, and a food serving configuration.
[0020] In one or more embodiments, the cutting apparatus does not move relative to the open end portion of the collapsible apparatus during the cutting process.
[0021] In one or more embodiments, the cutting apparatus comprises handles configured to receive and transfer the force to cut the food item, and further wherein the handles also provide at least a partial covering of the interior cutting region.
[0022] In one or more embodiments, the collapsible apparatus is made of a resilient material, including, but not limited to, silicone.
[0023] In one or more embodiments, a gap is maintained between the blades and the collapsible region when the cutting apparatus is coupled to the collapsible apparatus in any or all of the food storage configuration, the food cutting configuration and food serving configuration.
[0024] In one or more embodiments, the base comprises a food retention feature configured to receive, pierce and retain the food item in the food storage configuration.
[0025] One or more exemplary methods for storing a food item prior to cutting the food item, for cutting the food item, and for supporting the food item after it has been cut may include providing a collapsible apparatus comprising a base configured to support the food item during a cutting process. The collapsible apparatus may include an open end portion, a base, and a collapsible region. The collapsible region may be coupled or affixed to and extend (e.g., span the space or distance) between the base and the open end portion (e.g., from the base to the open end portion, or from the top surface of the base (e.g., the surface opposite the bottom surface which supports the food item), to the proximal surface (bottom) of the open end portion. Prior to placing the food item into the collapsible apparatus, the collapsible apparatus may be expanded. Once the collapsible apparatus is expanded the food item may be placed into the collapsible apparatus (however, it may be possible for the food item to be placed into the collapsed collapsible apparatus, and then expand the collapsible apparatus afterward). Then, a cutting apparatus including an outer frame defining an interior cutting region may be coupled to the collapsible apparatus. The interior cutting region may include one or more blades (or wires, etc.) being supported by the outer frame. Then, the collapsible apparatus may be collapsed such that collapsing the collapsible apparatus results in the food item being cut and passing at least a portion of the food item through the interior cutting region and out of (e.g., mostly out of or substantially out of, the collapsible apparatus. Collapsing the collapsible apparatus results in the system being reduced from a first configuration having a first height and first volume to a second configuration having a second height and second volume, the first height may be greater than the second height, and the first volume may be greater than the second volume.
[0026] In one or more embodiments, the cut food item may be presented to a user when the collapsible apparatus is in a collapsed configuration without de-coupling the cutting apparatus from the collapsible apparatus.
[0027] In one or more embodiments, the food item may be pierced with a food retention feature of the base when placing the food item into the collapsible apparatus. Piercing the food item with the food retention feature may retain the food item (e.g., in a desired orientation) during travel.
[0028] In one or more embodiments of a method, when collapsing the system, the second height is at least 51% less than the first height. In one or more embodiments of the method, the second height is at least 65% less than the first height. A range of reduction in heights and volumes is possible depending on the characteristics of the embodiment. The range of reduction in heights and volumes is further described herein.
[0029] Exemplary systems and methods for storing a food item prior to cutting, for cutting the food item, and for supporting the food item for serving to a user after it has been cut are described herein. The exemplary system may include a cutting apparatus removably couplable to an open end of a collapsible apparatus having a collapsible region between the open end and a base. The system may be configured to store the food item until cut. Upon application of a sufficient compressive force, the collapsible apparatus collapses and causes the food item to be cut and be moved out of the collapsible apparatus passing through and out of or mostly (e.g., substantially) out of the cutting apparatus. The system is configured to operate while maintaining the coupling between the cutting apparatus and the collapsible apparatus in all of a food storage configuration, a food cutting configuration and a food serving configuration, and all transitions therebetween.
[0030] The above summary is not intended to describe each embodiment or every implementation of the present disclosure. A more complete understanding will become apparent and appreciated by referring to the following detailed description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1A is a side view of an exemplary system for storing, cutting and serving a food item in an expanded or food storage configuration. Note: Portions within the outer frame are depicted with hidden lines, and portions of the collapsible apparatus are shown translucent, for the sake of clarity. A food item is also depicted in the system.
[0032] FIG. 1B is a side view of the system of FIG. 1A in a collapsed or food serving configuration. Note: the entire food item is not shown.
[0033] FIG. 1C is a top view of the cutting apparatus of the exemplary system of FIG. 1A .
[0034] FIG. 1D is an side view of the system of FIG. 1A in a de-coupled configuration.
[0035] FIG. 1E is a example of a sectional view of a sharpened blade taken along line A-A in FIG. 1C .
[0036] FIG. 2 is a top view of another exemplary cutting apparatus.
[0037] FIG. 3A is a de-coupled assembly side view of another exemplary system for storing, cutting and serving a food item in an expanded or food storage configuration with handles in a storage position or food covering orientation. Note: portions of the embodiment are shown translucent, and a food item is depicted in the system for the sake of clarity.
[0038] FIG. 3B is a side view of the coupled system of FIG. 3A with the handles in a food cutting configuration or opened orientation.
[0039] FIG. 4A is perspective view of another exemplary system for storing, cutting and serving a food item in an expanded and de-coupled configuration.
[0040] FIG. 4B is a sectional view of the collapsible apparatus of the exemplary system of FIG. 4A in the expanded and de-coupled configuration taken along a diameter line passing through the central axis of the collapsible apparatus.
[0041] FIG. 4C is a sectional view of the collapsible apparatus of FIG. 4A in a collapsed configuration taken along a diameter line passing through the central axis of the collapsible apparatus. An exemplary embodiment of a cutting apparatus is also provided.
[0042] FIG. 5 is a sectional view of another exemplary collapsible apparatus in a collapsed configuration taken along a diameter line passing through the central axis of the collapsible apparatus including an alternate base design. Note: the cutting apparatus of FIG. 4C is also provided, for the sake of clarity.
[0043] FIG. 6A is a close-up perspective view of an embodiment of a base of a collapsible apparatus of an exemplary system.
[0044] FIG. 6B is a close-up perspective view of another embodiment of a base of a collapsible apparatus of an exemplary system.
[0045] FIG. 7 is a flow chart of a exemplary method for storing, cutting and serving a food item.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0046] In the following detailed description of illustrative embodiments, reference is made to the accompanying figures of the drawing which form a part hereof, and in which are shown, by way of illustration, specific embodiments which may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from (e.g., still falling within) the scope of the disclosure presented hereby.
[0047] Exemplary embodiments shall be described with reference to FIGS. 1-7 . It will be apparent to one skilled in the art that elements (e.g., apparatus, structures, parts, portions, regions, configurations, functionalities, method steps, materials, etc.) from one embodiment may be used in combination with elements of the other embodiments, and that the possible embodiments of such apparatus, systems and methods using combinations of features set forth herein is not limited to the specific embodiments shown in the figures and/or described herein. Further, it will be recognized that the embodiments described herein may include many elements that are not necessarily shown to scale. Still further, it will be recognized that the size and shape of various elements herein may be modified but still fall within the scope of the present disclosure, although certain one or more shapes and/or sizes, or types of elements, may be advantageous over others.
[0048] Exemplary systems for storing a food item, cutting a food item and supporting a food item for serving are described herein. Generally, the exemplary apparatus may include a cutting apparatus and a collapsible apparatus that may be configured to contain, store and protect a food item until the user decides to cut it. For example, the food may be stored (e.g., in transit from home to work or school, while traveling, en route to a picnic or sports events, etc.) in its whole, or mostly whole form inside the system until the user wishes to cut the food item. When the user decides to cut the food item, the user may do so by applying a compressive force to the system, collapsing the collapsible apparatus, and in the process of collapsing, causing the food item to be cut and move out (e.g. completely, mostly or substantially move out) of the system/collapsible apparatus through the cutting apparatus.
[0049] The exemplary system and apparatus may be described in terms of various configurations or states. As described, the states of the system may also apply to the individual structures thereof. For example, when the food item is stored inside the system and the collapsible container in its expanded state (e.g., fully, mostly or substantially expanded state), it may be described herein that the system is in, or is configured in, a food storage configuration (e.g., expanded, non-collapsed, uncollapsed, substantially expanded, or mostly expanded configuration).
[0050] When the food item is stored inside the system, and the food item is in the process of being cut with the collapsible container in an intermediate cutting configuration, (e.g., partially collapsed, partially expanded), it may be described herein that the system (or structures thereof) is in, or is configured in, a food cutting configuration.
[0051] Finally, when the collapsible apparatus, or structures of the system are in the fully, mostly or substantially collapsed state, and the food item has been cut and most of the food item has traveled out of the system, it may be described herein that they system is in, or is configured in, a food serving configuration (e.g., fully, mostly or substantially collapsed, etc.).
[0052] As shown in FIGS. 1A-1E , the system 10 includes a cutting apparatus 20 and a collapsible apparatus 60 . The cutting apparatus 20 is removably couplable to the collapsible apparatus 60 . The system 10 may also include a cover 80 which may be coupled to the cutting apparatus 20 by cover retention feature 96 . The cutting apparatus 20 and the collapsible apparatus 60 include features that may be used separately rather than as part of the system 10 , but will be described herein as part of a system.
[0053] The cutting apparatus 20 includes an outer frame 30 that may be formed in a ring or circular shape defining an interior cutting region 31 . Blades 40 may span interior cutting region 31 . Outer frame 30 has an outer surface 30 a and an inner surface 30 b defining a thickness. In some embodiments, the thickness may be substantially even around the outer frame 30 , in other embodiments the thickness may vary. The outer frame 30 may also be a rectangle, polygon, square, octagon, irregular or any other suitable shape, depending on the food item F intended to be cut.
[0054] Outer frame 30 may include an entrance surface 38 on the surface of the outer frame 30 or cutting device 20 that may be the surface most proximal to the collapsible apparatus 60 (e.g., bottom surface) when the outer frame 30 is coupled to collapsible apparatus 60 . The entrance surface 38 may be intersected by entrance plane 28 . Entrance surface 38 may also be the surface of the outer frame 30 or cutting device 20 that is closest to a cutting end portion 46 (e.g., edge) of blades 40 as discussed herein. Entrance surface 38 and entrance plane 28 may be perpendicular to or substantially perpendicular to outer surface 30 a and/or inner surface 30 b , and/or central axis 29 .
[0055] Outer frame 30 may also include an exit surface 37 (e.g., top surface) opposite or distal from entrance surface 38 and may be intersected by exit plane 27 . Exit surface 37 may also be the surface of outer frame 30 that is closest to a trailing end portion 48 , or upper end 50 of blades 40 . The exit surface 37 may be or the surface of outer frame 30 that is most distal a cutting end e portion 46 , as discussed herein. Exit surface 37 may be perpendicular to or substantially perpendicular to outer surface 30 a and/or inner surface 30 b and/or central axis 29 . The height of the outer frame 30 may be defined as the distance from the entrance surface 38 to the exit surface 37 .
[0056] Outer frame 30 may be rigid and formed from plastic, stainless steel, other metals, ceramic, a combination of materials, a composite, or any other material of sufficient strength and durability to withstand the force required to pass the blades through the food item F. As shown in FIGS. 1A , 1 B, 1 D, 3 A and 3 B, the food item F may include foods such as an apple, but may also be any suitable food including, but not limited to, pears, citrus fruits including lemons, limes grapefruit and oranges, cheese, meat, potatoes, jicama, mango, sweet potatoes, tomatoes, radishes, water chestnut, carrots, peppers, banana and pineapple etc.
[0057] The cutting apparatus 20 includes one or more blades 40 . In some embodiments, such as those directed to cutting apples or pears, the cutting apparatus 20 may include a central blade 42 (e.g., may be a ring shape or other suitable shape) which may be centrally located within the outer frame 30 . The central blade 42 may serve to core the food item F. Extending blades 44 may extend away from the central blade 42 (e.g., radially or otherwise). In other words, the extending blades 44 may span the distance between the ring blade 42 and the outer frame 30 . Each of the extending blades 44 may be identical or substantially similar to one another and may divide the annular space between the outer frame 30 and the central blade 42 into equal or unequal open portions 94 . In some embodiments extending blades may extend across the outer frame 30 or between each other instead.
[0058] FIG. 1E shows a sectional view of one embodiment of a blade 40 ( 42 , 44 ) taken along line A-A in FIG. 1C . The cross section of both central blade 42 and extending blade 44 may be the same or similar. Thus for the sake of brevity, the sectional view of the blade will be discussed in relation to extending blades 44 herein, but features discussed may be applied to blade 42 as well. Each or any of the blades 44 may have a longitudinal length along the longitudinal axis 49 of the blade 44 . Each of blades 44 extends a length from the first end 43 to the second end 45 along longitudinal axis 49 and may span a portion of the interior cutting region 31 of the outer frame 30 . Each blade 44 may lie in respective blade planes 41 .
[0059] Each or any of blades 40 has a thickness 97 from a first surface 97 a to a second surface 97 b . Blades 40 may include the cutting end (e.g., edge) portion 46 , which may include a sharpened end (e.g., edge) portion 47 that may initiate the cutting process by penetrating food item F. The cutting end portion 46 may terminate at lower end 51 . Blades 40 may also include the trailing end portion 48 , terminating at upper end (e.g., edge) 50 . The cutting end portion 46 of each or any of blades 40 , may be sharpened, or knife-like (e.g., beveled, angled, chamfered, or narrowing in thickness towards the cutting end 46 ) to decrease the compressive force required to cut a food item F, allowing for easier cutting. As shown in FIG. 1E , the trailing end portion 48 (edge that may not initiate cutting) is located distal (e.g. opposite) to the cutting end portion 46 and may be unsharpened. However, in some embodiments, either or both of the cutting end portion 46 or the trailing end portion 48 may be sharpened, only one may be sharpened, or neither may be sharpened, or they may be sharpened to different degrees. The height of blades 40 may be defined as the distance from the upper end 50 to the lower end 51 .
[0060] In one or more embodiments, when the cutting device 20 is coupled to collapsible device 60 , the sharpened end(s) 47 of one or more blades 40 may face the base 70 of collapsible apparatus 60 . In this configuration, the user is protected from sharpened ends 47 of the blades 40 .
[0061] The cutting end portion 46 , the sharpened end portion 47 , or the lower end 51 may be proximate, adjacent, terminate at, or intersect a cutting plane 26 , or alternatively at the entrance plane 28 of the cutting apparatus 20 . The cutting plane 26 may defined by the plane, that when the food item crosses it, the blades 40 penetrate the food item, initiating the cutting process. Cutting plane 26 may perpendicular to, or substantially perpendicular to the central axis 29 and/or a surface of the outer frame 30 ( 30 a , 30 b ). Cutting plane 26 may be parallel to or substantially parallel to any of the entrance plane 38 , the exit plane 37 , or base 70 , including a top surface 72 or a bottom surface 74 , or a plane intersection base 70 and perpendicular to or substantially perpendicular to central axis 29 .
[0062] As depicted in FIG. 1E each or any of the blades 44 may have a respective blade plane defined by plane 41 , although blades 44 need not be completely straight (e.g., may be wavy or non-linear). Blade plane 41 passes, or substantially passes through the blade 44 extending from a first end portion 43 to a second end portion 45 , and from the cutting end portion 46 to the trailing end portion 48 . Blade plane 41 may be perpendicular or substantially perpendicular to any of the exit plane 22 , the coupling plane 24 , and/or the entrance plane 26 of the cutting device 20 (although in some embodiments the blade plane 41 may not be perpendicular). Blade plane 41 of the extending blades 44 may also be perpendicular, or substantially perpendicular to central axis 28 of the outer frame 30 (although in some embodiments the blade plane 41 may not be perpendicular). The blades may be formed of metal, such as stainless steel, but may also be formed from ceramic, plastic, composites, or any other suitable material. In some embodiments, such as an embodiment for cutting foods such as cheese, wires (e.g., metal, plastic, etc.) may be provided in place of blades 40 .
[0063] The cutting apparatus 20 is configured to be removably couplable to the collapsible apparatus 60 , and/or vice-versa. The collapsible apparatus 60 may be attached to the cutting apparatus 20 at mating and force transfer surfaces 499 a , 499 b which are intersected by one or more mating and force transfer planes 25 . The mating and force transfer surfaces (not shown in FIGS. 1A-1E , but shown in FIG. 4C as 499 a , 499 b provide a mating surface at which the compressive forces may be transmitted from the cutting apparatus (e.g., as in 420 ) to the collapsible apparatus (e.g., as in 460 ). The system may store the food item F within the system 10 in a cutting orientation. The collapsible apparatus 60 may also protect the user from the cutting end portions 46 of blades 40 when the collapsible apparatus 60 and the cutting apparatus 20 are coupled to each other in any of the food storage, food cutting or food serving configurations. The collapsible apparatus 60 and cutting apparatus 20 may be removably coupled via coupling mechanism 92 a , as shown in the embodiment of FIGS. 1A-1D as engaging with an coupling mechanism 92 b (the proximal end 64 b of the open end portion 64 (e.g., frame, ring) of the collapsible apparatus). As shown in FIGS. 1A , 1 B and 1 D, a snap fit connection (e.g., tongue and groove type retention feature) may be engaged and disengaged along pivot path R.
[0064] Cutting apparatus 20 may further include handles 32 of sufficient strength and size to enable a user to apply a compressive pressure to the system 10 , to cut the food item F.
[0065] Collapsible apparatus 60 (e.g., foldable apparatus) may be configured to completely or partially contain (hold, enclose, house, surround, cover receive, protect) a food item F when the food item F is placed into reservoir 61 of the collapsible apparatus 60 via open end portion 64 (e.g., frame, ring). Collapsible apparatus 60 may be a bowl, a cup, or any other suitable container, a flexible bag or enclosure for storing and/or supporting a food item and/or providing and integral and/or sanitary surface, via base 70 , on which to cut the food item.
[0066] Collapsible apparatus 60 includes a collapsible region 62 . Collapsible region 62 may extend all or a portion of the region between the open end portion 64 and base 70 . Collapsible region 62 may include a variety of formations to facilitate collapsing, including, but not limited to living hinges or thin walled sections. In other embodiments, flexible materials with no formations may facilitate the collapsing mechanism. Any other suitable collapsing mechanism as is known in the art may be incorporated.
[0067] Base 70 may be configured to support food item F in all or any of the food storage configuration, a food cutting configuration, and a food serving configuration. Base 70 may include a bottom surface 74 most distal from the open end portion 64 , and a top surface 72 opposite the bottom surface 74 . The top surface 72 may be closer to the open end portion 64 than the bottom surface 74 when the collapsible apparatus 60 is in the expanded or food storage configuration.
[0068] Base 70 may be made of a material that is harder or more resistant to cutting than the collapsible region 62 . Base 70 may be made of nylon, polypropylene, metal, ceramic, composites, glass, a combination of materials, or any other suitable material. In some embodiments, the material may be selected such that it is hard enough to withstand contact with the blades 40 without being damaged or is resistant to damage (e.g., contact without substantially affecting the structural integrity of the base 70 ). In one or more embodiments, the top surface 72 of base 70 may be made of a harder material than the bottom surface 74 of base 70 . The bottom surface 74 of base 70 may further include grippy feet or high friction surfaces or features to prevent the base 70 of collapsible apparatus 60 from slipping during use. Base 70 may also be made of resilient or elastomeric material, and further may be integrally formed with collapsible region 62 .
[0069] In one or more embodiments, at least a portion of base 70 may be formed as a condiment reservoir removably couplable to the system (e.g., to the collapsible apparatus). In some embodiments, at least a portion of the base 70 may be configured to hold and contain a condiment (e.g., carmel or other dip). All or a portion of base 70 may be configured to be removable (e.g., via threads or snap-fit attachment, or other suitable attachment), allowing the user to remove and access a condiment container in a portion of base 70 . Alternatively, cover 80 could be configured as a removable condiment reservoir.
[0070] In one or more embodiments, as shown in FIGS. 1A-1D , the open end portion 64 of the collapsible apparatus 60 may be made of a material that is more rigid than the material of the collapsible region 62 (although in some embodiments, the open end portion 64 may be made of the same material as the collapsible region 62 or an altered version of the same material). The open end portion 64 may provide a variety of coupling surfaces or coupling features for connection with the cutting apparatus 20 . The open end portion 64 may also provide stability to the collapsible region 62 , both in static stability and/or during collapsing of the system. As shown in FIGS. 1A , 1 B and 1 D, the distal surface 64 a (e.g., top surface, surface of open end portion 64 more distal from base 70 ) of open end portion 64 may be in contact with the coupling plane of the cutting device 20 when coupled. The proximal surface 64 b (bottom surface, surface of open end portion 64 more proximal to the base 70 than the distal surface 64 a ) of the open end portion 64 may be proximate, adjacent to, affixed, coupled to, or directly coupled to the collapsible region 62 . Proximal surface 64 b may also provide a portion of the coupling mechanism 92 b , as shown with the snap fit connection provided by coupling mechanism 92 a when in contact with coupling mechanism 92 b (e.g., proximal surface 64 b ) as shown in FIG. 1A . The coupling mechanism 92 a , 92 b may be release along release path R. Any suitable feature, including a separate feature for coupling to mechanism 92 b , other than bottom surface 64 b may be provided on open end portion 64 .
[0071] Collapsible apparatus 60 may be reduced in size (e.g., height, volume) from a first configuration, or food storage configuration in which collapsible apparatus 60 is expanded and may store the food item F, to a second configuration or food serving configuration in which the collapsible apparatus 60 is collapsed and has cut the food item F and is configured to support a food item F and present it to a user for consumption. The food serving configuration can also be the same or similar to a non-use configuration (e.g., for storing the system 10 in a drawer or cabinet).
[0072] The food cutting configuration or intermediate configuration may include the range of sizes in between the food storage configuration and the food serving configuration (e.g., post-cut configuration), when the food item F is in the process of being cut.
[0073] In particular, collapsible apparatus 60 may accomplish this change in size by being collapsible or foldable (e.g., upon itself, pleated) in at least the collapsible region 62 . In one or more embodiments all or a portion of the collapsible apparatus 60 or collapsible region 62 may be formed of a resilient or elastomeric material(s) such as silicone or silicone composites. In other embodiments, collapsible region 62 may be formed of woven or non-woven textiles, plastic, rubber, composites, or any other suitable material, or any combination of materials. The materials used in manufacturing of any or all components of the system 10 may be food grade materials, and may be reusable or disposable.
[0074] The collapsible apparatus 60 or system 10 may be collapsed (e.g., reduced in height and/or volume) from the food storage configuration to the food serving configuration. The food serving configuration may include a height or volume at least 75% less than the storage configuration. The food serving configuration may also include a height and/or volume at least 10% less, at least 20% less, at least 30% less, at least 40% less, at least 50% less, at least 55% less, at least 60% less, at least 70% less, at least 80% less, at least 85% less, at least 90% less or at least 95% less than the storage configuration, depending on which features and geometries are included in the system. In theory, the more the height and volume can be collapsed, the better, for the sake of compact storage. However, the reduction of height and/or volume must be within reason to allow for the following: sufficient blade 40 height for cutting, appropriate coupling of the cutting apparatus 20 to the collapsible apparatus 60 , sufficient strength to outer frame 30 , and to prevent contact of the blades 40 with the collapsible region 62 when the collapsible apparatus 60 is in the food serving configuration. In some embodiments a height or volume reduction of more than 50%, for example, 51% to 90% may be preferred to meet these criteria or even 55% o 90%, with a height or volume reduction of 65% to 90% being more preferable, and a height or volume reduction of at least 65% being sufficient, but a height or volume reduction of at least 75% being more preferable, and a height or volume reduction of at least 80% being even more preferable.
[0075] The height of the collapsible apparatus may be defined as the distance from the bottom surface 74 of the base 70 (which is the base surface most distal from the open end portion 64 ) to the distal surface 64 a (top surface) of the open end portion 64 . The height of the system 10 being defined as the distance from the bottom surface of the base 74 to the exit surface 37 of the outer frame, and may exclude any height contributed by handles 32 .
[0076] The volume of the collapsible apparatus may be defined as either or both of an internal volume of the collapsible apparatus 60 and an external volume occupied by collapsible apparatus 60 .
[0077] The external volume of the system 10 may be defined as the external volume occupied by the system 10 , and may exclude handles 32 . The internal volume of the system 10 may be defined as the internal volume contained within the system 10 from the top surface of the base 72 up to the exit surface 37 , when the cutting apparatus 20 and the collapsible apparatus 60 are coupled.
[0078] The cutting apparatus 20 may be removably couplable to the open end portion of the collapsible apparatus 64 such that when the cutting apparatus 20 is coupled to the collapsible apparatus 60 , the cutting apparatus 20 may closer to the base in the food serving configuration (e.g., second configuration) than in the food storage configuration (e.g., first configuration). In many embodiments, the cutting apparatus 20 does not move relative to the open end portion 64 of the collapsible apparatus 60 in any or all of a food storage configuration, a food cutting configuration, and a food serving configuration. However, in some embodiments, the cutting apparatus 20 may move relative to the open end portion 64 of the collapsible apparatus 60 .
[0079] As shown in FIG. 2 , other blade geometries are possible. In one or more embodiments, the cutting apparatus 220 may be substantially similar to cutting apparatus 20 in most respects other than blade arrangement. Cutting apparatus 220 may include an outer frame 230 and a central blade 242 as previously described. However, the remaining blades 244 need not necessarily radially extend from the central blade 242 . For example, the blade configuration shown in FIG. 2 includes a right angled grid which may be provided with or without the central blade 242 . In order to cut rectangular prisms (e.g., french fry shaped pieces), extending blades 244 may span and divide the annular space between the outer frame 230 and the central blade 242 into open portions 294 . The open portions may be square or mostly square sections with some irregular shaped sections. The irregular shaped sections may be located anywhere, but as shown in FIG. 2 , are specifically near or directly adjacent to the central blade 242 and near or directly adjacent to the outer frame 230 . In other words, the extending blades form a grid of blades surrounding the central blade 242 . Other embodiments, a grid including acute and obtuse angles instead of right angles may be provided, resulting in parallelogram, or other polygonal shapes.
[0080] Another exemplary system 310 for storing, cutting and serving a food item F is depicted in FIGS. 3A-3B . Several features and/or portions of the exemplary system 310 may be similar to the exemplary system 10 described herein with reference to FIGS. 1A-1E . For example, the outer frame 330 , blades 340 , planes 325 - 329 , central axis 329 , portions of base 370 , portions of cutting apparatus 320 and collapsible apparatus 360 and subcomponents thereof, may be similar to the outer frame 30 , blades 40 , planes 25 - 28 , central axis 29 , portions of base 70 , portions of cutting apparatus 20 and collapsible apparatus 60 , and subcomponents thereof of the apparatus of FIGS. 1A-1E . Further, for example, the food storage configuration, the cutting configuration and the serving configuration and mechanisms of the exemplary system 310 may be similar to the food storage configuration, the cutting configuration and food serving configuration and mechanisms of the exemplary system 10 . As such, such features and/or portions may not be further descried herein or may not be described in the same level of detail, and it is to be understood that one or more such features and/or portions may be used interchangeably between each and every embodiment described herein.
[0081] As shown in the embodiment of FIGS. 3A-3B , the coupling mechanisms 392 a (depicted by hidden lines), 392 b may include threads 365 . Threads 365 may be arranged in any suitable manner within the structures of the system to facilitate coupling. Threads 365 may be provided as shown, or may be provided in any suitable arrangement. For example, in some embodiments, the threads 365 could be located on the external circumferential surface of the outer frame 30 , and the mating threads could be located on the inner surface of the open end portion 364 of collapsible apparatus 60 .
[0082] FIGS. 3A-3B depict a handle construction that may be incorporated into one or more embodiments, including handles 332 which may be movable between a storage configuration and a cutting configuration. The handles 332 may be more compactly arranged with respect to the cutting apparatus 320 in the storage configuration than in a cutting configuration. The handles 332 of FIGS. 3A-3B may also act as a cover for the food item F and/or blades 340 (not shown) of the cutting apparatus 320 (e.g., during travel). The handles 332 in the depicted embodiment may be pivotable around an axis through point 336 along path O. In other embodiments, the handles 332 may be slidable in/out of slots in outer frame 330 or pivotable about an axis other than an axis through point 336 . For example, in some embodiments, the handle may be pivotable around an an axis passing through the outer frame 330 that is parallel to central axis 329 ). A stop feature 334 may be provided on the outer frame 330 , or on the handle 332 , or any other component of the system to stop the handle 332 from rotating too far to be effective for transferring a compressive force applied to handle 332 to the system 310 to collapse system 310 .
[0083] As shown in FIGS. 3A-3B , in some embodiments, the collapsible region 362 may or may not necessarily include geometric formations to facilitate collapsing apparatus 360 . In these embodiments, the material chosen may have favorable collapsing characteristics, even in the absence of geometric formations to facilitate collapsing.
[0084] Another exemplary system 410 for storing, cutting and serving a food item F is depicted in FIGS. 4A-4C . Several features and/or portions of the exemplary system 410 may be similar to the exemplary system 10 described herein with reference to FIGS. 1A-1E . For example, the outer frame 430 , blades 440 , planes 425 - 428 , central axis 429 , portions of base 470 , portions of cutting apparatus 420 and collapsible apparatus 460 , open end portion 464 and subcomponents thereof, may be similar to the outer frame 30 , 230 , 330 , blades 40 , 240 , 340 , planes 425 - 428 , central axes 29 , 329 , 429 , bases 70 , 370 , open end portions 64 , 264 , 364 , portions of cutting apparatus 20 , 220 , 320 and collapsible apparatus 60 , 360 , and subcomponents thereof of the apparatus of FIGS. 1A-1E , 2 and 3 A- 3 B. Further, for example, the food storage configuration, the cutting configuration and the serving configuration and mechanisms of the exemplary system 410 may be similar to the food storage configuration, the cutting configuration and food serving configuration and mechanisms of the exemplary system 10 , 210 , 310 . As such, such features and/or portions may not be further described herein or may not be described in the same level of detail, and it is to be understood that one or more such features and/or portions may be used interchangeably between each and every embodiment described herein.
[0085] As shown in FIG. 4A , in some embodiments, coupling mechanism 492 a (e.g., a locking pin) and coupling mechanisms 492 b (e.g., a slot) may be used as the coupling method. Locking pin 492 and slot 493 may be arranged anywhere on the system suitable for facilitating removable coupling of the cutting apparatus 420 to the collapsible apparatus 460 . Any other suitable removable attachment feature or method as is known in the art may also be utilized.
[0086] As shown in further detail in the embodiments of FIGS. 4A-4C , the collapsible apparatus 460 has an inner surface 462 and an outer surface 462 b defining a thickness, which may vary. Collapsible apparatus 460 may include geometric formations to facilitate collapsing and expanding of the collapsible apparatus 460 . In one or more embodiments the collapsible region 462 may include one or more hinges 466 a - d (e.g., living hinges or thin walled portions) to enable the collapsible apparatus 460 to collapse and expand.
[0087] In one or more embodiments, the collapsible region 462 may be arranged to expand in a manner that the diameter of each successive layer is larger than the diameter of its preceding layer the further the layer is from the base 470 (e.g.. diameter of 468 a may be larger than diameter of 468 b ; 468 b may be larger than the diameter of 468 c ; and so on and so forth, etc.).
[0088] FIGS. 4C depicts an embodiment of the collapsible apparatus 460 of 4 A and 4 B in the collapsed or folded configuration. As shown in FIGS. 4C , the vertical profile of the collapsible apparatus 460 may be reduced dramatically from the expanded state depicted in FIGS. 4A and 4B . The collapsible region 462 may fold at each of the thin walled sections 466 . In the collapsed configuration, the thin walled sections 466 and thick walled sections 468 form pleated region 467 in the flexible material of the collapsible region 462 . When collapsed, at least a portion of the cross section of the collapsible apparatus 460 in the region of the pleated region 467 exhibits a zig-zag pattern.
[0089] Referring to FIG. 4C , although blades 440 are shown as spanning the height of the outer frame 430 defined as the distance from the entrance surface 438 to exit surface 437 , blades 440 need not span the entire height of the outer frame 430 . In some embodiments, blades 440 may not extend all the way to exit surface 437 , or may not extend all the way to entrance surface 438 . In other words, the outer frame 430 may have a height greater than the blades 440 , (the height of the blades defined as the distance from the cutting end portion 46 to trailing end portion 48 , as shown in FIG. 1E ). In some embodiments, the height of at least a portion of the blade 440 may be greater than the height of the outer surface, or may extend below or above the entrance plane 428 or exit plane 427 .
[0090] In order to protect the collapsible region 462 of the collapsible apparatus 460 from damage due to blades 440 , a gap 498 may be maintained between the cutting end portion 446 of blades 440 and a collapsed plane 469 . Collapsed plane 469 may be defined as a plane through the portion of the collapsible region 462 most distal from the base 470 (e.g., as shown in FIG. 4C as the collapsible region inner surface 462 a , at or near hinge 466 b ). The collapsed plane 469 may also perpendicularly intersect central axis 429 .
[0091] Gap 498 between the blades 440 and collapsible region 460 may also be maintained by the geometric relationship between the coupling surfaces 499 a and 499 b , and the blades 440 . In other words, the mating and force transfer surfaces 499 a , 499 b are intersected by mating and force transfer plane 425 , and may be arranged such when they are coupled together, they are sized, dimensioned and/or placed to prevent the blade from moving too far into collapsible apparatus 460 .
[0092] FIG. 5 , is an embodiment of a system 510 , including cutting apparatus 520 and collapsible apparatus 560 that is substantially the same in all respects as the embodiment of FIGS. 4A-4C , except for the base 570 . In FIG. 5 , the gap 598 may be maintained, at least in part, by the location of the top surface of the base 572 , or the protrusion height 576 of base 570 . As shown in FIG. 5 , in one or more embodiments, the top surface of the base 572 limits travel and prevents the blades 540 from coming into contact with the collapsible region 562 (e.g., living hinges 466 b , etc.) when in the collapsed configuration.
[0093] FIGS. 6A-B depicts embodiments of a base 670 that may be used or included in one or more embodiments, including any of the embodiments disclose herein (e.g., 70 , 370 , 470 , 570 ). Base 670 may include central protrusions 676 and/or general protrusions 678 extending from the top surface 672 in a direction opposite the bottom surface of the base 674 . Central protrusion 676 is a centrally located protrusion with respect to the base. In FIGS. 6A-B , general protrusions 678 are shown surrounding central protrusion 676 , but may be provided in any suitable manner. Protrusions 676 and 678 may be oriented to occupy the open portions (e.g., 94 in FIG. 1C ) and not come into contact with the blades 440 . Protrusions 676 and 678 serving to allow further travel of the blades 640 (not shown) past at least a portion of the base 670 (including protrusions 676 , 678 ) and further with respect to the food item F so as to more completely cut the food item F.
[0094] FIG. 6A further depicts a food retention feature 679 a which is configured to and capable of penetrating or piercing the food item F so as to provide additional support, stability and retention of a food item F. This is especially helpful during travel and/or cutting so that the food item F does not move out of place during travel and/or cutting, keeping the food item F in the desired orientation. In one or more embodiments, the protrusions 676 , 678 and the food retention feature 679 a may all be provided together, or only one or two of the features may be provided in a particular embodiment. These features may be completely independent of one another and may be provided in any combination, including providing the food retention feature 679 a without protrusions 676 and/or 678 and vice-versa, or only protrusions 678 , or only protrusion 676 , etc.
[0095] FIG. 6B is substantially similar in all respects to FIG. 6A , except FIG. 6B depicts another embodiment of a food retention feature 679 b . The food retention feature shown in FIG. 6B may be of a geometry that pierces the food item F over an area of the food item F. As shown, food retention feature 679 b is a circular projection that is hollow in the middle, although in some embodiments, a combination of both food retention features 679 a and 679 b . Any suitable food retention feature, covering any portion of the base 670 may be provided. In some embodiments, the food retention feature 679 a , 679 b occupies an area of the base 670 such that when the collapsible apparatus (e.g., 460 ) is in the collapsed position, the food retention feature 679 does not interfere with the blades 40 (e.g., occupies the space within the diameter of the central blade 42 when the system 10 is in the collapsed position). In one or more embodiments, additional food retention features may be included in the area occupied by projections 678 as shown in FIG. 6B .
[0096] An embodiment of the method of using the present invention will be described with reference to FIG. 7 . FIG. 7 depicts a flow chart of one embodiment of an exemplary method for storing, cutting and serving a food item using any of the systems and features described in FIGS. 1-6 .
[0097] In step 710 , the user provides a system 10 including a cutting apparatus (e.g., 20 ) and a collapsible apparatus (e.g., 60 ). In step 720 , the user places a food item F into the collapsible apparatus 60 . If a food retention feature (e.g., 679 a or 679 b ) is present, the user presses the food item F into the food retention feature 679 a or 679 b.
[0098] In step 730 , the user couples the cutting apparatus 20 to the collapsible apparatus 60 in a first system configuration having a first volume or height. The first system (or collapsible apparatus) configuration may be the storage configuration.
[0099] In step 740 , starting with the system 10 in the storage configuration, and without decoupling the cutting apparatus 20 from the collapsible apparatus 60 , the user applies a compressive force to collapse or fold the collapsible apparatus 60 or system 10 to a second system (or collapsible apparatus) configuration having a second volume or height, simultaneously cutting the food item F during the transition from the first system configuration to the second system configuration. The transition from the first system configuration to the second system configuration may be a cutting configuration.
[0100] In one or more embodiments, collapsing the collapsible apparatus (e.g., 60 ) results in the system (e.g., 10 ) being reduced from a first configuration having a first height and first volume to a second configuration having a second height and second volume, wherein the first height is greater than the second height, and the first volume is greater than the second volume. Any reduction in height or volume discussed with respect to any embodiment herein, may be applied to the method. For example, the second height may be at least 51% less than the first height; or, the second height may be at least 65% less than the first height.
[0101] In step 750 , without decoupling the cutting apparatus 20 from the collapsible apparatus 60 , the system 10 supports the food item F via the collapsible apparatus 60 in the second system configuration. In the second system configuration the user may access the cut food item F and may access the cut food item F without having to access any interior volume within the bounds of the structure of the system 10 to remove at least a portion of the cut food item F. The second system configuration may be a food serving configuration.
[0102] In some embodiments of the method, in-between step 730 and 740 , steps may be included to open or extend handles (e.g., 332 ) from a storage or covering position as depicted in the system of FIG. 3A , to an open orientation or cutting configuration as depicted in FIG. 3B .
[0103] In some embodiments of the method, a slightly collapsed position may be considered a food storage position depending on the size of the food item F. The food item F may be stored with the collapsible apparatus 20 just slightly collapsed, and/or the blades 40 just partially penetrating the food item F which may hold the food item F in place in the system 10 during transport. This serves to eliminate, reduce or limit, or prevent the food item F from being damaged by rolling around inside the system 10 during travel by holding the food item F in a particular position/location within the collapsible apparatus 20 without actually cutting the food item F into separate pieces.
[0104] Any of the features described in the above embodiments may be combined or eliminated to form additional embodiments that fall within the scope of the present invention.
[0105] Any patents, patent documents, and references cited herein are incorporated in their entirety as if each were incorporated separately. This disclosure has been provided with reference to illustrative embodiments and is not meant to be construed in a limiting sense. As described previously, one skilled in the art will recognize that other various illustrative applications may use the techniques as described herein to take advantage of the beneficial characteristics of the system and methods described herein. Various modifications of the illustrative embodiments, as well as additional embodiments of the disclosure, will be apparent upon reference to this description.
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Exemplary systems and methods for storing a food item prior to cutting, for cutting the food item, and for supporting the food item for serving to a user after it has been cut are described herein. The exemplary system may include a cutting apparatus removably couplable to an open end of a collapsible apparatus having a collapsible region between the open end and a base. The system may be configured to store the food item until cut. Upon application of a sufficient compressive force, the collapsible apparatus collapses and causes the food item to be cut and moved out of the collapsible apparatus through the cutting apparatus. The system is configured to operate while maintaining the coupling between the cutting apparatus and the collapsible apparatus in all of a food storage configuration, a food cutting configuration and a food serving configuration, and transitions therebetween.
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FIELD OF THE INVENTION
The present invention relates to the art of production of furan-epoxy powder-like binders adapted to be used in the manufacture of spray coatings, laminates, moulding compositions, adhesives, foamed plastics.
BACKGROUND OF THE INVENTION
Known in the art is a process for producing a furanepoxy binder by reacting an epoxy diane resin (a product of polycondensation of epichlorohydrin with diphenylolpropane) with difurfurylideneacetone and a modifying agent, viz. furfuramide, at the temperature of 140° C. at the following proportions of the epoxy diane resin, difurfurylideneacetone and furfuramide, parts by weight:
epoxy diane resin:100
difurfurylideneacetone:50-150
furfuramide:95-100;
The resultant product is cooled to a temperature of at most 30° C. and disintegrated to a powder-like condition.
The binder produced by this prior art process has an increased clogging (becomes clogged after 30 days) and cannot be stored for long periods (more than 3 months) without loss of its initial properties (solubility and meltability). Vicat heat-resistance of polymeric materials prepared from said furan-epoxy polymeric powder-like binder does not exceed 208° C. Moreover, polymeric materials prepared on the basis of said binder are inflammable. These disadvantages restrict the field of application of the furan-epoxy polymeric binder.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide such a process which would make it possible to prepare a furan-epoxy powder-like binder which would feature an increased non-clogging ability.
It is another object of the present invention to provide such a process which would make it possible to prepare a furan-epoxy powder-like binder which would be capable of being stored for long periods without alteration of its initial properties.
It is a further object of the present invention to increase the strain heat-resistance of polymeric materials based on a furan-epoxy powder-like binder.
Still another object of the present invention is to impart, to polymeric materials on the basis of a furan-epoxy powder-like binder, the property of inflammability of selfextinction.
These and other objects of the present invention are accomplished by a process for producing a furan-epoxy powder-like binder by way of reacting an epoxy diane resin with a ketone of the furan series and a modifying agent upon heating, followed by cooling the resulting product to a temperature of at most 30° C. and disintergration to a powder-like condition, wherein, in accordance with the present invention, as the ketone of the furan series use is made of monofurfurylideneacetone, difurfurylideneacetone, difurfurylidenecyclohexanone, a mixture of monofurfurylideneacetone and difurfurylideneacetone at a weight ratio therebetween of from 1:1 to 1.4:1 (parts by weight); 1,9-di-(α-furyl)-nonantetraene-1,3,6,8-one-5 or 1,5-di-(α-furyl)-2,4-dimethylpentadiene-1,4-one-3; as the modifying agent use is made of a phenol-formaldehyde resin or anhydrides of dibasic carboxylic acids; the interaction is effected at a temperature within the range of from 130° to 180° C. and at the following proportions of the above-mentioned components, parts by weight:
epoxy diane resin:100
ketone of the furan series:40 to 50
phenol-formaldehyde resin or anhydrides of dibasic carboxylic acids:60 to 500.
The process according to the present invention makes it possible to produce a furan-epoxy powder-like resin which is not clogged for 60 days and capable of being stored for as long as 12 months without changing its initial properties. Strain heat-resistance of polymeric materials prepared on the basis of said binder is as high as 320° C. (according to Vicat).
It is advisable to perform the interaction of said components in the presence of trifurylborate at a ratio thereof to the epoxy diane resin (expressed in parts by weight) equal to 10-30:100 respectively. In this case there is obtained a furan-epoxy binder which imparts, to polymeric materials, based thereon, the property of inflammability or self-extinction.
The process according to the present invention is simple in both technology and equipment employed. It enables the preparation of the desired product at a high yield of up to 95%.
DETAILED DESCRIPTION OF THE INVENTION
Into a reactor provided with a heating means, a reflux condenser, thermometer and a stirrer there are charged specified amounts of an epoxy diane resin, a ketone of the furan series, a modifying agent and, when required, trifurylborate. The reaction mixture is heated to a temperature within the range of from 130° to 180° C. and the process is conducted for a period of from 1 to 3 hours. Then the resulting furanepoxy binder is poured from the reactor onto a griddle, cooled to a temperature of at most 30° C., for example, to room temperature and ground to a powder with a specified particle size (depending on the end use of the binder). It is undesirable to cool the binder to a temperature above 30° C., since in this case the binder, upon its disintegration, adheres to the parts of the disintegration means.
The mixture of monofurfurylideneacetone and difurfurylideneacetone as used in the process of the present invention may be prepared by condensation of furfural with acetone in the presence of a catalyst, viz. an alkali, at a temperature within the range of from 60° to 90° C. (cf. E. V. Orobchenko "Furan Resins", Kiev, 1963, pp. 64-70).
For a better understanding of the present invention some specific Examples of its particular embodiments are given hereinbelow. Properties of the furan-epoxy powder-like binder and those of polymers prepared therefrom are shown in Tables 1 and 2 respectively which are given after the Examples.
EXAMPLE 1
Into a reactor provided with a heating means, reflux condenser, thermometer and a stirrer there are charged 200 g of an epoxy diane resin (the product of polycondensation of epichlorohydrin with diphenylolpropane) with a number of epoxy groups of 14 to 16%, 80 g of difurfurylideneacetone, 20 g of trifurylborate and 120 g of maleic anhydride. The ratio between the components expressed in parts by weight is equal to 100:40:10:60 respectively. Temperature in the reactor is elevated to 130° C. and the process is conducted at this temperature for 2 hours. The resulting furan-epoxy binder (the yield is equal to 88%) is poured from the reactor, cooled to the temperature of 30° C. and disintegrated to powder with a predetermined particle size.
EXAMPLE 2
Into the reactor described in the foregoing Example 1 there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 16-18%, 200 g of monofurfurylideneacetone, 24 g of trifurylborate and 200 g of phthalic anhydride. Ratio between said components, expressed in parts by weight, is equal to 100:100:12:100 respectively. The process is conducted at the temperature of 160° C. for 2 hours. The resulting product (the yield is equal to 88%) is poured from the reactor, cooled to the temperature of 25° C. and ground to a powder-like condition.
EXAMPLE 3
Into a reactor described in the foregoing Example 1 there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 18-20%, 200 g of a mixture of monofurfurylideneacetone and difurfurylideneacetone at the ratio therebetween of 1:1 and 400 g of a resol phenol-formaldehyde resin (Ubbelohde drop point is 88°-90° C.). Ratio between said components, expressed in parts by weight, is equal to 100:100:200 respectively. The process is conducted at the temperature of 140° C. for 1 hour. The resulting product (the yield is equal to 95%) is poured from the reactor, cooled to the temperature of 20° C. and ground to a powder-like condition.
EXAMPLE 4
Into the reactor described in the foregoing Example 1 there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 20-22%, 200 g of difurfurylideneacetone, 60 g of trifurylborate and 200 g of a novolac phenolformaldehyde resin (Ubbelohde drop point is 105°-115° C.). The ratio between said components, expressed in parts by weight is equal to 100:100:30:100 respectively. The process is conducted at the temperature of 140° C. for one hour. The resulting product (the yield is 95%) is poured from the reactor, cooled to the temperature of 20° C. and ground to a powder-like condition.
EXAMPLE 5
Into the reactor described in the foregoing Example 1 there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 22-24%, 100 g of 1,9-di-(α-furyl)-nonanetetraene-1,3,6,8-one-5 and 460 g of a novolac phenolformaldehyde resin (Ubbelohde drop point is 115°-120° C.). The ratio between said components, expressed in parts by weight, is equal to 100:200:300 respectively. The process is conducted at the temperature of 150° C. for two hours. The resulting product (the yield is 94%) is discharged from the reactor, cooled to the temperature of 25° C. and ground to a powder-like condition.
EXAMPLE 6
Into the reactor described in Example 1 hereinbefore there are charged 100 g of an epoxy diane resin with a number of epoxy groups of 16-18%, 400 g of difurfurylidenecyclohexanone and 460 g of methyltetrahydrophthalic anhydride. The ratio between said components, expressed in parts by weight, is equal to 100:400:460 respectively. The process is conducted at the temperature of 180° C. for three hours. The resulting product (the yield is equal to 88%) is discharged from the reactor, cooled to the temperature of 20° C. and ground to a powder-like condition.
EXAMPLE 7
Into the reactor described in Example 1 hereinbefore there are charged 100 g of an epoxy diane resin with a number of epoxy groups of 20-22%, 100 g of 1,5-di-(α-furyl)-2,4-dimethylpentadiene-1,4-one-3 and 500 g of a novolac phenol-formaldehyde resin (Ubbelohde drop point is 120°-130° C.). The ratio between said components expressed in parts by weight is equal to 100:100:500 respectively. The process is conducted at the temperature of 180° C. for two hours. The resulting product (the yield is equal to 90%) is discharged from the reactor, cooled to the temperature of 25° C. and ground to a powder-like condition.
EXAMPLE 8
Into the reactor described in the foregoing Example 1 there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 18-20%, 200 g of a mixture of monofurfurylideneacetone and difurfurylideneacetone at the ratio therebetween (expressed in parts by weight) of 1.4:1, 60 g of trifurylborate and 120 g of a novolac phenol-formaldehyde resin (Ubbelohde drop point is 95°-105° C.). The ratio between said components, expressed in parts by weight, is equal to 100:100:30:60 respectively. The process is conducted at the temperature of 130° C. for 1.5 hour. The resulting product (the yield is equal to 92%) is discharged from the reactor, cooled to the temperature of 20° C. and ground to a powder-like condition.
EXAMPLE 9
Into the reactor described in Example 1 hereinbefore there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 14-16%, 200 g of a mixture of monofurfurylideneacetone and difurfurylideneacetone at the weight ratio therebetween of 1.2:1 (expressed in parts by weight) and 200 g of phthalic anhydride. The ratio between said components, expressed in parts by weight, is equal to 100:100:100 respectively. The process is conducted at the temperature of 180° C. for 1.5 hour. The resulting product (the yield is equal to 88%) is discharged from the reactor, cooled to the temperature of 30° C. and ground to a powder-like condition.
EXAMPLE 10
Into the reactor described in Example 1, there are charged 100 g of an epoxy diane resin with a number of epoxy groups of 18-20%, 400 g of difurfurylideneacetone, 30 g of trifurylborate and 400 g of a novolac phenol-formaldehyde resin (Ubbelohde drop point is 105°-115° C.). The ratio between said components, expressed in parts by weight, is equal to 100:400:30:400 respectively. The process is conducted at the temperature of 140° C. for two hours. The resulting product (the yield is equal to 95%) is discharged from the reactor, cooled to the temperature of 20° C. and ground to a powder-like condition.
EXAMPLE 11
Into the reactor described in Example 1 hereinbefore there are charged 100 g of an epoxy diane resin with a number of epoxy groups of 18-20%, 400 g of monofurfurylideneacetone, 30 g of trifurylborate and 400 g of a novolac phenolformaldehyde resin (Ubbelohde drop point is 115°-120° C.). The ratio between said components, expressed in parts by weight, is equal to 100:400:30:400 respectively. The process is conducted at the temperature of 140° C. for 1.5 hour. The resulting product (the yield is equal to 92%) is discharged from the reactor, cooled to the temperature of 25° C. and ground to a powder-like condition.
EXAMPLE 12
Into the reactor described in Example 1 there are charged 100 g of an epoxy diane resin with a number of epoxy groups of 20-22%, 200 g of monofurfurylideneacetone and 60 g of maleic anhydride. The ratio between said components, expressed in parts by weight, is equal to 100:200:60 respectively. The process is conducted at the temperature of 150° C. for two hours. The resulting product (the yield is equal to 90%) is discharged from the reactor, cooled to the temperature of 20° C. and ground to a powder-like condition.
EXAMPLE 13
Into the reactor described in Example 1 hereinbefore there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 14-16%, 200 g of monofurfurylideneacetone, 30 g of trifurylborate and 120 g of methyltetrahydrophthalic anhydride. The ratio between said components, expressed in parts by weight, is equal to 100:100:15:60 respectively. The process is conducted at the temperature of 170° C. for two hours. The resulting product (the yield is equal to 88%) is discharged from the reactor, cooled to the temperature of 25° C. and ground to a powder-like condition.
EXAMPLE 14
Into the reactor described in the foregoing Example 1 there are charged 100 g of an epoxy diane resin with a number of epoxy groups of 18-20%, 400 g of 1,9-di-(α-furyl)-nonanetetraene-1,3,6,8-one-5, 30 g of trifurylborate and 200 g of a resol phenol-formaldehyde resin (Ubbelohde drop point is equal to 85°-88° C.). The ratio between said components, expressed in parts by weight, is equal to 100:400:30:200 respectively. The process is conducted at the temperature of 180° C. for two hours. The resulting product (the yield is equal to 88%) is poured from the reactor, cooled to the temperature of 30° C. and ground to a powder-like condition.
EXAMPLE 15
Into the reactor described in Example 1 there are charged 100 g of an epoxy diane resin with a number of epoxy groups of 20-22%, 500 g of 1,5-di-(α-furyl)-2,4-dimethylpentadiene-1,4-one-3, 30 g of trifurylborate and 500 g of phthalic anhydride. The ratio between said components, expressed in parts by weight, is equal to 100:500:30:500 respectively. The process is conducted at the temperature of 160° C. for two hours. The resulting product (the yield is equal to 88%) is discharged from the reactor, cooled to the temperature of 25° C. and ground to a powder-like condition.
EXAMPLE 16
Into the reactor described in Example 1 hereinbefore there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 18-20%, 80 g of difurfurylidenecyclohexanone, 20 g of trifurylborate and 400 g of a novolac phenol-formaldehyde resin (Ubbelohde drop point is 95°-105° C.). The ratio between said components, expressed in parts by weight, is equal to 100:40:10:200 respectively. The process is conducted at the temperature of 160° C. for three hours. The resulting product (the yield is equal to 95%) is discharged from the reactor, cooled to the temperature of 20° C. and ground to a powder-like condition.
EXAMPLE 17
Into the reactor described in the foregoing Example 1 there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 22-24%, 80 g of monofurfurylideneacetone, 20 g of trifurylborate and 120 g of phthalic anhydride. The ratio between said components, expressed in parts by weight, is equal to 100:40:10:60 respectively. The process is conducted at the temperature of 170° C. for two hours. The resulting product (the yield is equal to 88%) is discharged from the reactor, cooled to the temperature of 15° C. and disintegrated to a powder-like condition.
EXAMPLE 18
Into the reactor described in Example 1 hereinbefore there are charged 100 g of an epoxy diane resin with a number of epoxy groups of 18-20%, 500 g of a mixture of monofurfurylideneacetone and difurfurylideneacetone at the ratio therebetween (expressed in parts by weight) of 1.4:1, 30 g of trifurylborate and 500 g of maleic anhydride. The ratio between said components, expressed in parts by weight, is equal to 100:500:30:500 respectively. The process is conducted at the temperature of 160° C. for two hours. The resulting product (the yield is equal to 90%) is discharged from the reactor, cooled to the temperature of 20° C. and disintegrated to a powder-like condition.
EXAMPLE 19
Into the reactor of Example 1 there are charged 80 g of an epoxy diane resin with a number of epoxy groups of 22-24%, 400 g of difurfurylideneacetone and 400 g of a resol phenol-formaldehyde resin (Ubbelohde drop point is 78°-80° C.). The ratio between said components is equal to 100:500:500 respectively (in parts by weight). The process is conducted at the temperature of 150° C. for 1.5 hour. The resulting product (the yield is equal to 92%) is discharged from the reactor, cooled to the temperature of 25° C. and disintegrated to a powder-like condition.
EXAMPLE 20
Into the reactor described in Example 1 hereinbefore there are charged 200 g of an epoxy diane resin with a number of epoxy groups of 16-18%, 80 g of difurfurylideneacetone, 30 g of trifurylborate and 120 g of a resol phenolformaldehyde resin (Ubbelohde drop point is 88°-90° C.). The ratio between the components, expressed in parts by weight is equal to 100:40:15:60 respectively. The process is conducted at the temperature of 160° C. for one hour. The resulting product (the yield is equal to 90%) is discharged from the reactor, cooled to the temperature of 20° C. and disintegrated to a powder-like condition.
EXAMPLE 21
Into the reactor described in Example 1 there are charged 100 g of an epoxy diane resin with a number of epoxy groups of 18-20%, 250 g of difurfurylideneacetone, 30 g of trifurylborate and 250 g of a resol phenol-formaldehyde resin (Ubbelohde drop point is 85°-88° C.). The ratio between said components, expressed in parts by weight, is equal to 100:250:30:250 respectively. The process is conducted at the temperature of 130° C. for 2.5 hours. The resulting product (the yield is equal to 95%) is discharged from the reactor, cooled to the temperature of 15° C. and disintegrated to a powder-like condition.
Properties of the furan-epoxy powder-like binder produced by the process of the present invention in Examples 1 through 21 and by the prior art process are given in the following Table 1.
Table 1__________________________________________________________________________Furan-epoxypowder-likebinderproducedby thePropertiesprocess Stabi-of the lity Non-present Melt- Ubbeloh- Content upon clogg-inven-Appe- ing de drop Solubi- of epo- stora- ing abi-tion, asaran- point, point, lity in xy gro- ge, lity,of ce °C. °C. acetone ups, % months days1 2 3 4 5 6 7 8__________________________________________________________________________Exam-Pow-ple 1der 82 109 Total 2.8 6 35Exam-ofple 2yel- 102 123 " 2.0 10 50Exam-lowple 3to 85 112 " 3.2 9 45Exam-darkple 4brown 80 103 " 4.2 12 60colourExam-ple 5 103 127 Total 2.6 8 40Exam-ple 6 95 118 " 2.1 10 50Exam-ple 7 105 130 " 2.0 12 60Exam-Pow-ple 8der 81 97 " 4.6 7 40Exam-ofple 9yel- 102 127 " 2.3 11 45Exam-lowple 10to 88 109 " 2.4 9 45Exam-darkple 11brown 84 103 " 2.9 8 40colourExam-ple 12 81 101 " 4.1 7 35Exam-ple 13 92 115 " 2.7 12 60Exam-ple 14 106 131 " 2.1 12 60Exam-ple 15 87 108 " 2.1 9 40Exam-ple 16 90 114 " 2.9 12 60Exam-ple 17 94 116 " 4.0 8 35Exam-ple 18 106 131 Total 2.2 12 60Exam-ple 19 98 127 " 1.8 8 60Exam-ple 20 83 109 " 3.9 7 60Exam-ple 21 100 129 " 4.2 7 60Binderdark- 92 114 " -- 3 30producedbrownby thepowderprior artprocess__________________________________________________________________________
Properties of a polymer produced from the furan-epoxy powder-like binder according to the present invention are shown in the following Table 2. The polymer is prepared by curing of the binder according to a step-wise schedule at a temperature within the range of from 140° to 200° C. with the interval of 6 hours after every 20° C.
Table 2______________________________________Properties Value______________________________________Vicat strain heat-resistance, °C. 215-320Ultimate compression strength, kgf/cm.sup.2 800-1,400Ultimate strength at static bending, 350-600kgf/cm.sup.2Resilience, kgf.cm/cm.sup.2 2-8Brinnel hardness, kgf/cm.sup.2 3,000-4,500Coke number, % 35-60Dielectric loss angle at 50 Hz and 25.10.sup.-3 -30.10.sup.-320° C.Chemical resistance:against alkalis Resistantagainst acids ResistantInflammability:of the polymer produced from the binder Inflammableof Examples 3, 5, 6, 7, 9, 12, 19of the polymer produced from the Capable of self-binder of Examples 1, 2, 16, 17 extinguishingof the polymer produced from the Non-inflammablebinder of Examples 4, 8, 10, 11, 13,14, 15, 18, 20, 21______________________________________
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A process for producing a furan-epoxy powder-like binder comprising reaction of an epoxy diane resin (100 parts by weight) with a ketone of the furan series (40 to 500 parts by weight) and a modifying agent (60 to 500 parts by weight). As the ketone of the furan series use is made of monofurfurylideneacetone, difurfurylideneacetone, difurfurylidenecyclohexanone, a mixture of monofurfurylidenacetone with difurfurylidenacetone, 1,9-di-(α-furyl)-nonanetetraene-1,3,6,8-one-5, or 1,5-di-(α-furyl)-2,4-dimethylpentadiene-1,4-one-3. As the modifying agent use is made of a phenolformaldehyde resin or anhydrides of dibasic carboxylic acids. The reaction is carried out at a temperature within the range of from 130° to 180° C. in the presence, when required, of trifurylborate (10 to 30 parts by weight). The resulting product is cooled to a temperature of at most 30° C. and disintegrated to a powder-like condition. The furan-epoxy binder according to the present invention is not clogging for 60 days; it is also capable of being stored for long periods, up to 12 months, without losing its initial properties. Strain heat-resistance of polymeric materials based on this binder is as high as 320° C. according to Vicat. Polymeric materials based on the binder of this invention can be both inflammable and non-inflammable or can have self-extinguishing properties.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to centrifugal gas compressors and, more particularly, to an impeller and shaft assembly used in a high-speed gas compressor in a refrigeration plant or other chiller.
[0002] Centrifugal gas compressors have one or more impellers rotated in a cavity for compressing a gas, such as refrigerant vapor. The one or more impellers are mounted on a pinion shaft that is turned by a motor. In centrifugal gas compressors, it is important that the impellers and pinion shaft mounting arrangements are simple and efficient to manufacture, install and operate. In particular, overly complex attachment arrangements involving the machining of complementary grooves and threads in male and female parts pose a greater burden on highly skilled machinists, a resource that is both finite and costly. More particularly, such arrangements are more likely to be damaged during transport, installation and normal running of the compressor.
[0003] U.S. Pat. No. 4,257,744 describes an impeller and shaft assembly that includes a cap screw, a Belleville washer or spring, a deformable socket machined into the rear of an impeller, a drive shaft with a frusto-conical shaped extremity, and a steel washer. The impeller has an axial bore extending through its center and a counterbored recess at its front. The frusto-conical shaped extremity includes axially extended grooves that are circumferentially spaced and alternate with intervening lands. A high torque applied to the cap screw results in plastic deformation of the lining of the socket in the rear of the impeller.
[0004] The manufacture of the frusto-conical shaped extremity is complex and adds to the cost of the impeller and shaft assembly. In addition, the counterbored recess is sized to accommodate the cap screw. As a result, the protective steel washer and single spring are both sized to correspond to the cross-section area of the counterbored recess and screw cap. Thus, the torque results in a clamping force being directly transmitted from the cap screw, without dissipation, through the single Belleville washer and steel washer. This arrangement may damage the single Belleville washer and cause stress fractures in the front face of the impeller immediately around the counterbored recess, necessitating the costly replacement of the entire impeller. Thus, there is a need for a simple impeller and shaft assembly that minimizes the risk of damage to the front face of the impeller necessitating the costly replacement of the entire impeller.
[0005] Maintenance personnel may use an ordinary wrench when a torque wrench is more appropriate. Dramatic over or under-torquing of pinion shafts in centrifugal impeller configurations leads to increased maintenance and downtime costs. An impeller assembly that is less vulnerable to such problems is needed.
[0006] Additionally, cap screws increase the diameter of the impeller eye. The impeller eye is the terminal area on the cap screw end which is located radially inward of the impeller contour.
[0007] Other factors are the effect of thermal expansion of the aluminum impeller versus the steel drive shaft, and the fretting between the parts.
BRIEF SUMMARY OF THE INVENTION
[0008] Accordingly, an object of this invention is to provide a simpler and improved impeller and shaft assembly.
[0009] Another object is to provide an impeller and shaft assembly that employs an arrangement that more effectively dissipates the clamping load.
[0010] Yet another object is to avoid stress fractures in the front face of the impeller leading to replacement of the entire impeller.
[0011] A further object is to provide an impeller assembly that is less prone to damage resulting from failure to use a torque wrench.
[0012] It is an object, feature and advantage of the present invention to expand the impeller contour into the area of the impeller eye. It is a further object of the invention to provide a contour to the fastener or washer located in that eye area. It is still a further object, advantage and feature of the invention that the contour added in the area of the impeller eye should be continuous with the contour of the impeller itself.
[0013] It is an object, feature and advantage of the present invention to provide a collapsible washer that counteracts the effects of thermal expansion between the aluminum impeller versus a steel drive shaft.
[0014] It is a further object, feature and advantage of the present invention to reduce fretting between the components of a high speed impeller, shaft and fasteners.
[0015] At least one of these objects is addressed, in whole or in part, by the present invention. The invention is a rotatable impeller assembly for a refrigerant compressor. The assembly includes an impeller, a protective washer, a contoured spacer body, and at least one spring. (In this specification, an element introduced with an article “a,” “an,” or “the,” such as “a spring” or “the bore,” should be read to include one or more of the element.)
[0016] The impeller has an axial bore through it, a front face intersecting with the axial bore, and a rear face that is adapted to fit the driving end of a rotatable shaft. The protective washer is seated against the front face of the impeller. The rear face of the protective washer is seated against the front face of the impeller. The protective washer has an aperture registered with the axial bore. The contoured spacer body has a front face, a rear face, a recessed spring bearing surface in its rear face, a spring spacing abutment positioned to seat against the protective washer, and a central bore. At least one spring is seated between the protective washer and the spring bearing surface to provide a spacer assembly. The protective washer is used to keep the at least one spring from damaging the impeller.
[0017] A fastener (such as a bolt), including a headed front end and a rear end, is positioned through the axial and central bores. The rear end of the fastener is connected to the rotatable shaft. The headed front end of the fastener is seated against the front face of the contoured spacer body to provide a clamping load. The front face of the contoured spacer body may further comprise a recess sized to accommodate the headed front end of the fastener.
[0018] An advantage of this invention is that the cross-section area of the headed front end of the fastener does not govern the cross-section area of the protective washer and the at least one spring. Instead, the protective washer and the spring are sized to correspond to the much larger cross-section area of the rear face of the contoured spacer body, which itself closely matches the cross-section area of the front face of the impeller. Hence, the clamping load, after bolt tightening, is dissipated over a relatively large area of the front face of the impeller.
[0019] This arrangement has two immediate and very advantageous consequences. First, the front face of the impeller is less likely to suffer stress fractures. Second, even in the event that the clamping load causes stress fractures in the region immediately around the headed front end, such damage will only require the replacement of the contoured spacer body rather than the replacement of the impeller.
[0020] Another advantage of this invention is that the use of a collapsible washer counteracts the effects of the thermal expansion caused by the difference in materials between an aluminum impeller and a steel drive shaft. The use of the collapsible washer also reduces fretting between the parts since the washer absorbs some of the tension generated in axial directions.
[0021] Yet another advantage of the present invention is that the impeller contour is extended closer to the axis of impeller rotation. This is accomplished by modifying the contoured spacer body to extend the impeller contour over the fastener and washer area.
[0022] A further advantage of the present arrangement is that a maintenance engineer not using a torque wrench is far less likely to damage the impeller shaft assembly by applying too great a clamping load at the headed front end of the fastener. This is because in one aspect of the invention the contoured spacer body includes a spring spacing abutment positioned to seat against the protective washer. Once the spring spacing abutment comes into contact with the front face of the protective washer, the maintenance engineer will notice that it is suddenly harder to tighten the headed front end. This is a signal to stop tightening and hence avoid grossly over-torquing the impeller shaft assembly.
[0023] Yet another advantage is that the impeller shaft assembly is more tolerant to rough treatment. For example, a maintenance engineer who is in the habit of using a hammer or other rough treatment to loosen the fastener is more likely to damage the contoured spacer body rather than the front face of the impeller. Replacing a damaged contoured spacer body is preferable to replacing a damaged impeller.
[0024] Alternatively the contoured spacer body and the headed front end of the fastener can be combined to convert the headed front end into a contoured front end. In this aspect of the invention the contoured front end of the fastener would include at least some of the elements of the contoured spacer body and the headed front end. The contoured front end includes a front face, a rear face, a recessed spring bearing surface in its rear face, and a spring spacing abutment positioned to seat against the protective washer. However, the contoured front end does not require a central bore. The at least one spring is seated between the protective washer and the spring bearing surface of the contoured front end to provide a spacer assembly.
[0025] The above mentioned and other features of this invention and the manner of obtaining them will become more apparent, and the invention itself will be best understood, by reference to the following drawings taken in conjunction with the accompanying description of preferred embodiments.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0026] [0026]FIG. 1 is a block diagram of a chiller showing the major components and the flow of the refrigerant through the chiller.
[0027] [0027]FIG. 2 is a side elevation, cut away to show some of the interior features, of a refrigeration compressor. The refrigerant inlet and outlet are also shown.
[0028] [0028]FIG. 3 is a longitudinal section of the impeller and shaft assembly comprising a contoured spacer body according to one aspect of the invention.
[0029] [0029]FIG. 4 is an enlarged section, in isolation, of the contoured spacer body as illustrated in FIG. 3.
[0030] [0030]FIG. 5 is an enlarged section, in isolation, of the contoured spacer body and Belleville springs employed in an alternative embodiment of the invention.
[0031] [0031]FIG. 6 is an enlarged section in isolation, of the contoured spacer body and Belleville springs employed in another alternative embodiment of the present invention.
[0032] [0032]FIG. 7 is an enlarged section, in isolation, of the contoured spacer body and pair of Belleville springs employed in another preferred embodiment of the invention.
[0033] [0033]FIG. 8 is an enlarged section, in isolation, of the contoured spacer body employed in yet another preferred embodiment of the invention.
[0034] [0034]FIG. 9 is a longitudinal section of the impeller and shaft assembly comprising a contoured front end.
[0035] [0035]FIG. 10 is a longitudinal section of the impeller and shaft assembly comprising a contoured front end according to another preferred embodiment of the invention.
[0036] [0036]FIG. 11 is a longitudinal section of the impeller and shaft assembly comprising a contoured front end according to yet another preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0037] While the invention will be described in connection with one or more embodiments, it will be understood that the invention is not limited to those embodiments. On the contrary, the invention includes all alternatives, modifications, and equivalents as may be included within the spirit and scope of the appended claims.
[0038] [0038]FIG. 1 schematically shows a mechanical chiller 10 including a compressor 12 , a heat exchanger such as a condenser 14 , an expansion device such as an expansion valve 16 , and a heat exchanger such as an evaporator 18 . These components are connected to form a refrigerant circuit by refrigerant conduits 20 , 22 , 24 and 26 . Refrigerant gas enters the compressor 12 from the conduit 20 and is compressed in the compressor 12 , thus raising its temperature. The compressed gas from the compressor 12 enters the condenser 14 via the conduit 22 . In the condenser 14 , the hot, compressed gas is condensed into liquid form and contacted with a heat sink, such as ambient air, ground water, or another cooler medium, to remove heat from the condensing refrigerant. The condensed refrigerant passes through the conduit 24 and through an expansion valve 16 . The expansion valve 16 allows a limited quantity of refrigerant to enter the evaporator 18 , while maintaining the pressure difference between the condenser 14 (at higher pressure) and the evaporator 18 (at lower pressure). The refrigerant entering the evaporator 18 evaporates after contacting a heat load, such as the refrigerator interior or ventilation air that is to be cooled, thus absorbing heat from the heat load. The refrigerant vapor leaves the evaporator 18 via the conduit 20 , returning to the compressor 12 to repeat the cycle.
[0039] Now refer to FIGS. 2 and 3, and specifically to the interior of a centrifugal compressor 12 . The compressor 12 includes an impeller assembly including impellers 40 , 50 mounted on a rotatable shaft 64 . The compressor 12 has a gas inlet 30 , a gas outlet 32 , and internal passages 34 directing refrigerant gas from the inlet 30 , into and through the first stage impeller 40 , the second stage impeller 50 , and to the outlet 32 . The rear end 264 of a fastener 62 such as a bolt (or other device allowing radial rotation while providing axial clamping force) is connected to the rotatable shaft 64 to removably attach the impeller 40 to the rotatable shaft 64 . Although the preferred embodiment of this invention is shown as a gear drive centrifugal compressor, the impeller assembly is generally applicable to all centrifugal compressors as well as to other compressors having an impeller 40 mounted on a terminal end 66 of a rotatable shaft such as rotatable shaft 64 . Exemplary centrifugal compressors are sold under the registered trademark CenTraVac by The Trane Company, a Division of American Standard Inc. having a principal place of business in La Crosse, Wis. Exemplary centrifugal compressors are shown in commonly assigned U.S. Pat. No. 3,805,547 to Eber and U.S. Pat. No. 3,853,433 to Roberts et al., both of which are incorporated by reference herein.
[0040] Referring to FIGS. 2 and 3, a first stage impeller and shaft assembly 90 including the first stage impeller 40 depicting an aspect of this invention is disclosed. The impeller 40 has an axial bore 100 through it, a front face 102 intersecting with the axial bore 100 , and a rear face 104 that is adapted to fit the driving end 66 of the rotatable shaft 64 . FIG. 3 does not show the details of the connection between the impeller 40 and the shaft 64 , which can be conventional. For two examples, either a conventional splined joint or the three-lobed connection described in co-pending U.S. Ser. No. 09/204,867, filed by the present assignee on Dec. 3, 1998 can be used.
[0041] The front face 102 of the impeller 40 is truncated at an end 105 and optionally has a recess 110 to accommodate a contoured spacer body 200 , a protective washer 120 and an expansor such as a spacer assembly 150 . For purposes of this application, a contoured spacer body is a device having an external surface which is aerodynamically contoured and having an internal portion acting as a spacer. The spacer assembly 150 provides a known resistance when compressed.
[0042] The protective washer 120 , preferably a hardened steel washer, has a front face 122 and a rear face 124 . The rear face 124 is seated against the front face 102 (the recess 110 if present) of the impeller 40 . The protective washer 120 has an aperture 126 registered with the axial bore 100 .
[0043] Referring to FIGS. 3 and 4, the contoured spacer body 200 includes a front surface 202 and a rear surface 204 . The contoured spacer body 200 is symmetrical about an axis 206 , and the front surface 202 includes a contoured surface 210 at an angle or a curve relative to the axis 206 . The rear surface 204 includes a spring spacing abutment 220 including a washer contact surface 222 at the end of the abutment 220 . The spring spacing abutment 220 is axially dimensioned relative to the axis 206 so that the spacer assembly 150 deflects at a desired amount. The contoured spacer body 200 includes a center portion 224 having a rear recess 226 arranged in the rear surface 204 about the spring spacing abutment 220 . A central bore 230 runs through the center portion 224 symmetrical about the axis 206 . The washer contact surface 222 engages the protective washer 120 . The recess 226 provides a spring bearing surface 234 for engagement with the spacer assembly 150 . The front surface 202 of the contoured spacer body 200 preferably includes a recess 235 and a forward facing shoulder 236 in the recess 235 . At least one tension providing device such as a spring 232 , which in the illustrated embodiment is a Belleville spring (though another type of spring, or a lock washer, or a compressible gasket or washer can be used instead), is seated between the protective washer 120 and the spring bearing surface 234 to provide the spacer assembly 150 .
[0044] The fastener 62 , including a headed front end 260 , a front face 262 and a rear end 264 , is positioned through the axial bore 100 , the aperture 126 , and the central bore 230 . The rear end 264 of the fastener 62 is connected to the rotatable shaft 64 (here, the rear end 264 is threaded into a cavity 270 in the shaft 64 ), and the headed front end 260 is seated against the front surface 202 of the contoured spacer body 200 , preferably in the recess 234 and against the shoulder 236 , to provide a clamping load.
[0045] After torquing the fastener 62 , the spacer assembly 150 collapses to about 75% of its maximum deflection. The abutment 220 of the contoured spacer body 200 is seated against the protective washer 120 and is spaced by the depth of the spring spacing abutment 220 to control the deflection of the springs 232 in the spacer assembly 150 . At 75% maximum deflection, the clamp load will exceed the axial thrust load imposed upon the impeller 40 .
[0046] [0046]FIG. 4 is an enlarged isolated side elevational view, in section, of the contoured spacer body 200 including the spring spacing abutment 220 as positioned to seat against the protective washer 120 (as shown in FIG. 3). In this embodiment, the surface 222 comes into contact with the front face 122 of the protective washer 120 . At least one spring 232 is sized to fit in the recessed pocket 226 formed between the contoured spacer body 200 and the protective washer 120 . The protective washer 120 is used to keep the at least one spring 232 from damaging the impeller 40 . A skilled mechanic would slack off slightly to avoid over-torquing the impeller shaft assembly in response to the surface 222 seating hard against the protective washer 120 .
[0047] The front surface 202 of the contoured spacer body 200 can desirably be continuous from the front face 102 of the impeller 40 to the central bore 230 . The front surface 202 of the contoured washer 200 optionally has a recess 235 to accommodate the headed front end 260 of the fastener 62 . The recess 235 in the front surface 202 of the contoured spacer body 200 can be sized to ensure that the front face 262 of the headed front end 260 is seated flush across the central bore 230 in order to make a substantially continuous surface (shown in FIG. 3). A substantially continuous surface across the front surface 202 of the contoured spacer body 200 provides improved refrigerant flow during normal operation.
[0048] In one aspect of this embodiment (as depicted in FIG. 3) the truncated end 105 in the front face 102 of the impeller 40 is sized to accommodate the protective washer 120 , the spacer assembly 150 and the contoured spacer body 200 . In this embodiment of the invention, the rear face 124 of the protective washer 120 seats against the recess 110 in the front face 102 of the impeller 40 .
[0049] In an alternative embodiment shown in FIG. 5, the body 224 of the contoured spacer body 200 has an aerodynamic portion 270 extending slightly around the spring spacing abutment 220 but not contacting either the impeller 40 or the protective washer 120 . In this manner, the front face 102 of the impeller 40 need only provide a recess 110 sized to accommodate the protective washer 120 . One advantage of this embodiment is that the front face 102 of the impeller 40 around such a recess would be less vulnerable to stress fractures.
[0050] In another embodiment shown in FIG. 6, the contoured spacer body 200 has an aerodynamic portion 272 which extends around the spring 232 and the protective washer 120 to make contact with the front face 102 of the impeller 40 .
[0051] In still another embodiment, the spring spacing abutment 220 is spaced radially outwardly so that the surface 222 seats against an outer edge 280 of the protective washer 120 (FIG. 7).
[0052] In yet another embodiment, the rear surface 204 of the contoured spacer body 200 provides two shoulder surfaces 274 and 276 (FIG. 8) including an outer shoulder 274 spaced radially outwardly and an inner shoulder 276 spaced radially inwardly. In this embodiment each shoulder, 274 and 276 , seats against the washer 120 to provide a pocket 277 to accommodate the at least one spring 232 .
[0053] Referring to FIG. 9, the contoured spacer body 200 (not shown in FIG. 9) and the headed front end 260 (not shown in FIG. 9) of the fastener 62 are combined to convert the headed front end 260 into a domed front end 300 of the fastener 62 . In this aspect of the invention, the domed front end 300 has a front face 302 , a rear face 304 , a recessed spring bearing surface 306 in its rear face 304 , and a spring spacing abutment 308 positioned to seat against the protective washer 120 . In this arrangement, the spacer assembly 150 is seated between the protective washer 120 and the spring bearing surface 306 .
[0054] As in FIG. 3, the front face 102 of the impeller 40 may comprise a recess 110 in order to accommodate the protective washer 120 . The rear face 304 of the domed front end 300 (including the surface 306 ) can be sized to correspond to the cross section area of the truncated end 105 of the impeller 40 (or to the forward facing area of the recess 110 ). In this arrangement the rear face 124 (and by default, the front face 122 ) of the protective washer is sized to correspond to the cross-section area of the truncated end 105 of the impeller 40 (or the forward facing area of the recess 110 ). Thus, the clamping force is transmitted from the domed front end 300 and through the relatively large surface area of the protective washer 120 . Hence, large torquing may be applied without causing stress fractures in the front face 102 of the impeller 40 or the rear face 304 of the domed front end 300 .
[0055] The fastener's ability to carry more torque results in higher energy yield. In addition, the front face 302 of the domed front end 300 provides a continuous aerodynamic surface 309 across the front face 102 of the impeller 40 . Compressors fitted with a contoured front end will result in higher speeds and higher work rates and a concomitant decrease in compressor size.
[0056] The front face 302 of the domed front end 300 may be designed with indents or holes 320 to allow a suitable tool bit to attach to the aerodynamic surface 309 . This tool bit in turn attaches to a suitable torque wrench. Alternatively, the tool bit might form part of a torquing tool. This would ensure that appropriate tools are used in the installation and removal of the impeller and shaft assembly thus decreasing the likelihood of damage to the impeller and shaft assembly.
[0057] [0057]FIG. 10 schematically shows a different aspect of the arrangement disclosed in FIG. 9. In this aspect of the invention, the rear face 304 of the domed front end 300 makes contact with the front face 102 of the impeller 40 at a shoulder area 312 of the domed front end 300 . The recess 110 in the front face 102 of the impeller 40 is less pronounced compared to that disclosed in FIG. 9.
[0058] In another aspect of the invention, the front face 102 of the impeller 40 has a truncated end 314 which lacks the recess 110 and is essentially flat as shown in FIG. 11. In this embodiment of the invention, the protective washer 120 is sized to correspond more closed to the cross section area of the truncated end 314 of the impeller 40 . The protective washer 120 preferably includes a contoured, radially outward end 318 having an aerodynamic contour matching that of the domed front end 300 and the front face 102 . The domed front end 300 has an additional shoulder 322 . The comparatively large cross section area of the rear face 304 in contact with the protective washer 120 ensures maximum dissipation of the clamping load.
[0059] While the invention is described above in connection with preferred or illustrative embodiments and examples, they are not intended to be exhaustive or limiting of the invention. Rather, the invention is intended to cover all alternatives, modifications and equivalents included within its spirit and scope of the invention, as defined by the appended claims.
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A impeller shaft assembly is disclosed for use in a refrigerant compressor, and more particularly in a commercial high-speed centrifugal impeller shaft configuration. The impeller shaft assembly includes a contoured spacer body. The contoured spacer body includes a front face, a rear face, a recessed spring bearing surface in its rear face, and a spring spacing abutment including a shoulder that is seated against a protective washer. The contoured spacer body functions to prevent the headed front end of a fastener from coming into direct contact with a spring assembly and protective washer. Consequently, the spring assembly and protective washer are not sized to correspond to the cross-section area of the headed front end as disclosed in the prior art. Instead, the protective washer and spring assembly are sized to fit the rear face of the contoured spacer body, which in turn is sized to fit the front face of a first stage impeller. The contoured spacer body ensures that the clamp load is dissipated across the front face of the first stage impeller. The contoured spacer body also provides greater protection to the first stage impeller during installation and maintenance. In another embodiment, the contoured spacer body and headed front head are combined to make a contoured front end.
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BACKGROUND OF THE INVENTION
This invention relates to a vibratory core drill apparatus for applying force to a sampling tube for the recovery of soil and sediment samples.
Recent trends in environment monitoring and pollution control have called for core sampling mechanisms which can deliver large diameter uncontaminated sediment and soil land fill profile cores. The fields of agriculture, engineering and mineral exploration also require large diameter undisturbed soil and sediment profile cores for structure and chemical analysis. Representative soil or sediment samples are often required at depths of up to twenty meters of overburden comprising sediments 25-80% solids.
The use of high frequency vibratory core sampling techniques facilitates the collection of sediment cores with minimal disruption of the circumference layer and without serious compaction or dewatering of the sample. Piston or gravity drive sampling systems including split spoons or shelby tubes often fail to deliver undisrupted and representative sediment or soil samples. Wink discloses a vibratory drill apparatus in Canadian Patent No. 1,163,985, but this apparatus suffers from many drawbacks. The Wink drill is hand held and underpowered, therefore the drill has a very limited penetration depth and is awkward to use. The Wink drill vibrates while it is in operation and, being hand held, the vibration of the Wink drill results in trauma to the arms of the operator. Furthermore, the Wink drill yields soil and sediment samples which are not truly representative due to the fact that the operator cannot apply a uniform downward force onto the drill. This ununiform downward force results in bullnosing or collection of an unrepresentative sample due to temporary blockage of the core tube by stiffer material in the sedimentary sequence.
The Wink drill does not permit the coupling and uncoupling of sampling tubes without first disconnecting the vibrator from a flexible power shaft or hydraulic line. This inability makes the operation of such vibratory drill slow, tedious and awkward. Furthermore, this drawback renders the use of a drill stand for mounting and steadying the vibratory drill, as well as a drive means for driving the sampling tube down into the ground, impractical.
Yet another problem with the prior art rested in the vibrators themselves. The amplitude of the vibrations produced by the said vibrators were not adjustable, furthermore, the frequency of vibration produced was difficult to regulate. Said prior art therefore, could not adjust the nature of the vibrations produced by their vibrators to match the soil or sediment conditions. As a result, said prior art yielded lower quality, less representative, soil or sediment samples.
U.S. Pat. Nos. 3,301,336 and 3,352,160, both to Mount disclose vibratory core sampling apparatus suffering many of the above mentioned drawbacks.
SUMMARY OF THE INVENTION
The present invention discloses a vibratory core drill apparatus for obtaining soil or sediment samples comprising a drill stand, a carriage assembly mounted within the drill stand in a vertically sliding fashion, carriage drive means for driving the carriage assembly up and down, vibratory drive means for applying a vertical vibratory force to the sampling tube, coupling means for coupling and decoupling the sampling tubes to the vibratory drive means without rotation of the vibratory drive means, and support means for supporting and restraining the coupling means and vibratory drive means within the carriage assembly.
The coupling means comprises a fixed member which is rigidly mounted to the vibratory drive means and a revolving member which is rotatably mounted to the fixed member. The revolving member is able to rotate freely in either the clockwise or counter-clockwise direction and is capable of coupling to the sampling tubes.
The vibratory drive means may comprise a pair of eccentric cams mounted to a drive shaft at a variable angle to each other, both being contained within a housing. Such vibratory drive means may be caused to vibrate by the rotation of the drive shaft, and the magnitude of the vibrations may be controlled by varying the angle between the cams. The said drive shaft may be rapidly rotated by a high speed hydraulic motor.
The support means may comprise an annular member having two side arms pivotally connected to the carriage assembly, the coupling means resting within the hollow of the annular member.
The carriage drive means may comprise a hydraulic drive motor connected to a shaft, wherein the rotation of the shaft lowers or raises the vibratory means and coupling means by means of a pair of chains attached to the vibratory means or coupling means. The carriage drive means is adapted to exert a uniform downward force onto the sampling tubes.
The apparatus may further comprise a hydraulic power means providing hydraulic power for the operation of both the carriage drive means and the vibratory drive means, wherein the hydraulic power means comprises a hydraulic pump for pumping hydraulic fluid, a motor for driving the hydraulic pump, a reservoir for storing hydraulic fluid, and a control module all contained as a separate unit capable of being disassembled for easy transportation.
The apparatus herein described is much easier to operate and suffers few of the drawbacks of the prior art. The present invention avoids these drawbacks whilst maintaining the ability to collect large diameter undisturbed and uncontaminated sediment and soil/land fill profile cores.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the apparatus of the present invention.
FIG. 2 is a side view of said apparatus.
FIG. 3 is a front elevational view of a portion of the apparatus of FIG. 1.
FIG. 4 is a cross-sectional view through the coupling means in the apparatus of FIGS. 1 and 2.
FIG. 5 is a cross-sectional view through the vibratory drive means of the apparatus in FIGS. 1 and 2.
FIG. 6a is top view of the support means.
FIG. 6b is a side view of said support means.
FIG. 7 is a front elevation in section of a portion of the apparatus of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A better understanding of the present invention may be had by reference to the following description of the presently preferred embodiment, taken in connection with the drawings. Vibratory core drill apparatus for obtaining soil and sediment samples in accordance with the present invention, is illustrated in FIGS. 1 through 7.
Referring to FIGS. 1, 2 and 3, the apparatus shown therein comprises a vibratory core drill shown generally as 10 and a hydraulic power means shown generally as 14. The vibratory core drill comprises a drill stand shown generally as 12, a carriage assembly 18 mounted within drill stand 12, vibratory drive means 20 and coupling means 22 mounted within the carriage assembly 18, carriage drive means shown generally as 16, and restraining means 48.
Drill stand 12 comprises a pair of vertical side members 26, base plate 28, and head frame 15. Base plate 28 has an opening 31 to permit the travel of sample tube 30. Immediately above opening 31 and mounted to base plate 28 is rod restraining means 48 which serves to support and steady sample tube 30 within drill stand 12, during operation of the drill.
Carriage assembly 18 comprises a frame having side members 34, top member 36, and cross bar 37. Support means 25 is pivotally mounted between the lower inside surfaces of side members 34. Vibratory drive means 20 is mounted atop coupling means 22, adaptor 23 is mounted beneath coupling means 22, and coupling means 22 and adaptor 23 are in turn mounted within support means 25. Snubber 39 is mounted to top frame member 36 and cushions the vibratory drive means 20 from contact with top member 36. Sliders 24 are mounted at one end to the outside faces of side members 34 adjacent the corners of carriage assembly 18. At their other ends, sliders 24 are slidingly mounted to side members 26 of drill stand 12 so as to permit the carriage assembly to slide up and down from a position of full retraction 11 to a position of full extension 13, as shown in FIG. 2.
Carriage drive means 44 comprises shaft 42 mounted within head frame 15 of drill stand 12, hydraulic motor 46 connected to drive shaft 42 and mounted to head frame 15, upper sprockets 40 mounted to shaft 42, lower sprockets 38 mounted near base plate 28, and roller chains 32 which travel between upper sprockets 40 and lower sprockets 38. Roller chains 32 are coupled to the carriage assembly 18 by attachment to sliders 24. Operation of the hydraulic motor 46 causes the spinning of shaft 42 which in turn raises or lowers carriage assembly 18.
With primary reference to FIGS. 2 and 5, vibratory drive means 20 comprises eccentric cams 68 and 69 which are mounted onto shaft 70 within housing 66. Hydraulic motor 71 is connected to shaft 70. Eccentric cams 68 and 69 are positioned on shaft 70 at a variable angle alpha relative to each other. Eccentric cam 69 is thicker and heavier than eccentric cam 68. Threaded lower portion 72 serves to attach vibratory drive means 20 to coupling means 22. The operation of hydraulic motor 71 causes the spinning of shaft 70 and in turn causes vibration due to the revolving of the eccentric cams. The amplitude of the vibration can be varied by changing the variable cam angle alpha. When alpha equals 180° the eccentric cams are counteropposed and, therefore, the spinning of shaft 70 result in minimal amplitude of vibration. Maximal amplitude of vibration results from the lowering of the variable cam angle alpha to 0°.
Referring now primarily to FIG. 4, coupling means 22 comprises fixed member 52 and rotatable member 54 mounted below fixed member 52. Fixed member 52 is attached to the threaded lower portion 72 of vibratory means 20 shown in FIG. 5 by a threaded upper portion 56. The upper portion of rotatable member 54 fits over the lower portion of fixed member 52. A plurality of bearing races 62 are cut along the periphery of the lower portion of fixed member 52 and bearing races 64 are cut along the inside surface of the upper portion of rotatable member 54. Ball bearings 60 ride within the bearing races 62 and 64 between fixed member 52 and rotatable member 54. Ring seal 65 separates the bottom most portion of fixed member 52 from rotatable member 54. Plug 55 shown in FIG. 3 serves to seal an opening (not shown) extending perpendicularly through one wall of rotatable member 54 through which oil or grease may be injected for lubrication of ball bearings 60. Rotatable member 54 has a female threaded lower end having threads 58 which permit male to male adaptor 23 to be screwed into rotatable member 54. Rotatable member 54 is then connectable to sampling tubes by connectioning male adaptor 23 to sampling tubes and then rotating rotatable member 54. Because rotatable member 54 can rotate freely relative to fixed member 52, sampling tubes may be connected to the coupling means without having to rotate fixed member 52.
Referring to FIGS. 1, 6a and 6b, support means 25 comprises an annular portion 29 and side arms 27. Side arms 27 are pivotally mounted directly to the side portions 34 of carriage assembly 18. The inside diameter of annular or ring portion 29 is slightly greater than the outside diameter of the lower portion of rotatable member 54 enabling the lower portion of rotatable member 54 to sit within support means 25. Male adaptor 23 fits within the hollow of annular portion 29.
Support means 25 provides support to coupling means 22 when carriage assembly 18 is being raised. Support means 25 also helps restrain sample tube 30. Furthermore, when in place, support means 25 allows vibratory drive means 20 and coupling means 22 to be angularly displaced relative to carriage assembly 18 by pivoting about the longitudinal axis of side arms 27. This angular displacement of vibratory drive means 20 and coupling means 22 provides for easier attachment of sampling tubes 30.
Referring to FIG. 7, hydraulic power means 14 comprises reservoir 78 for storing hydraulic fluid, hydraulic pump 84 for pumping hydraulic fluid to a high pressure, a prime mover such as engine 86 for operating the hydraulic pump 84, and control module 90 for regulating the hydraulic pressure supplied to hydraulic motor 71 and hydraulic motor 46. Engine 86 may be either a gasoline or diesel engine. Frame 76 mounts engine 86 and hydraulic pump 84 beneath reservoir 78; control module 90 is also mounted to frame 76. Flexible hose 80 transports hydraulic fluid to inlet 82 while outlet 88 permits pressurized hydraulic fluid to be transported via flexible hoses to control module 90. Flexible hoses then carry the pressurized hydraulic fluid from control module 90 to both hydraulic motor 46 and hydraulic motor 71. Other flexible hoses carry depressurized hydraulic fluid back to reservoir 78. Frame 76 may be diassembled for easy transportation into three separate units containing reservoir 78, engine 86 and hydraulic pump 84, and control module 90 respectively.
The operation of the vibratory core drill apparatus of the present invention will now be described. Prime mover 86 is activated, and hydraulic pump 84 pressurizes a quantity of hydraulic fluid which makes its way to hydraulic motors 71 and 46. Control module 90 modulates the flow of pressurized hydraulic fluid to hydraulic motors 71 and 46. The first sampling tube 30 is then coupled to coupling means 22 while carriage assembly 18 is in its fully retracted position and fitted through rod restraining means 48. Vibratory drive 20 is then made to vibrate at approximately 200 hz by the flow of hydraulic fluid through hydraulic motor 71. Carriage drive means 44 is then activated to lower carriage assembly 18 with sufficient force so as to cause the rapidly vibrating sample tube 30 to penetrate the soil, snubber 39 restraining the upward movement of vibratory drive means 20. Rod restraining means 48 and support means 25 guide and steady sample tube 30 as it penetrates the soil. For deeper penetration, sample tube 30 is disconnected from male adaptor 23 extending from coupling means 22 by rotation of rotatable member 54, and the carriage assembly 18 is fully retracted. Then, another sample tube is screwed onto male adapter 23, after pivoting coupling means 22 towards the operator if desired, and the new sample tube is screwed onto the sample tube in the ground by rotation of rotatable member 54. The carriage assembly 18 is then forcibly lowered by operation of carriage drive means 44, so as to drive the additional sample tube section into the soil. This procedure can be repeated several times to obtain penetration depths of up to twenty meters. The samples can be retrieved by reversing the procedure. Very accurate and representative soil core samples may be obtained by regulating the amplitude of vibration and the rate of sample tube penetration.
Many changes could be made in the above disclosed apparatus without departing from the scope thereof. It is therefore intended that all matter contained in the above description, or shown in the accompanying drawings, shall be interpreted as being illustrative only and not limiting.
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A vibratory core drill apparatus for the recovery of soil or sediment core samples. The samples are collected within a rapidly vibrating sample tube which is driven into the ground by the apparatus. The apparatus comprises a drill stand, vibratory drive for imparting a vibratory motion to the sample tubes, coupling for coupling the sample tubes to the vibratory drive, support for supporting and restraining the coupling and vibratory drive, a carriage assembly for mounting the support to the drill stand in sliding up and down fashion, and carriage drive for lifting or lowering the carriage assembly. The invention permits the rapid recovery of representative soil or sediment samples at depths of up to 20 meters without the periodic disassembly of the invention during the drilling operation.
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FIELD OF THE INVENTION
[0001] The present invention relates to chemical compositions and methods for the rapid and sustained prevention, control, and removal of sulfhydryl compounds, such as hydrogen sulfide, and its corresponding corrosion products from industrial process streams. It further relates to the use of chemical compositions and methods for reducing both the oxidant demand by sulfhydryl compounds in industrial process streams as well as the corrosion rates in said systems.
BACKGROUND OF THE INVENTION
[0002] The prevention, removal, and remediation of hydrogen sulfide (H 2 S) and other sulfhydryl compounds from liquid or gaseous industrial process streams is a challenge in a wide range of industries. The presence of H 2 S poses significant environmental and safety concerns to personnel and operators. This is due in part to the fact that H 2 S is highly flammable, highly toxic when inhaled (8 h of exposure at 100 ppm has been reported to cause death while levels of 1,000 ppm can cause death within minutes), highly corrosive, and malodorous. Further, corrosion and scale deposits resulting from the presence of hydrogen sulfide in contact with metallic surfaces, such as carbon steel pipes can further disruption industrial operations via the plugging of pipes, valves, nozzles, and the like.
[0003] In the oil and gas industry, the removal of H 2 S is important for the transport and storage of crude reserves as well as meeting standards for downstream refining, an important consideration due to sulfide poisoning of cracking catalysts and transmission of gas. Further, in both the refining industry and geothermal power industry, cooling tower process water can contain moderate to high levels of H 2 S, both causing significant solids development as well as increasing the level of oxidant demand so as to make oxidants unviable options for microbial control in these systems.
[0004] Nonetheless, the challenge of removing and/or reducing H 2 S from process streams has been addressed with a variety of different technologies. Common techniques utilize either absorption with a solvent or solid phase material with subsequent regeneration of the absorbent, or reaction with a suitable substance or substrate that produces a corresponding reaction product. This reactivity has often involved the reaction of H 2 S with various types of aldehydes. For instance, U.S. Pat. No. 1,991,765 was an early example describing the reaction of formaldehyde with hydrogen sulfide to form an insoluble product, later identified as the sulfur heterocycle 1,3,5-trithiane.
[0005] U.S. Pat. No. 2,426,318 discloses a method of inhibiting the corrosivity of natural gas and oil containing soluble sulfides by utilizing an aldehyde such as formaldehyde.
[0006] U.S. Pat. No. 3,459,852 discloses a method for removing sulfide compounds with α,β-unsaturated aldehydes or ketones such as acrolein or 3-buten-2-one as the reactive compounds. Nonetheless, acrolein is a hazardous, highly toxic chemical limiting extensive use in a wider variety of applications.
[0007] U.S. Pat. No. 4,680,127 describes a method for reducing H 2 S in a neutral to alkaline aqueous medium (pH ˜7-9) with the formation of solids, a problem when using formaldehyde, using glyoxal and glyoxal/formaldehyde mixtures without the formation of solids. However, the glyoxal/formaldehyde mixtures exhibited slower rates of H 2 S scavenging than glyoxal alone.
[0008] European patent application EP 1 624 089 A1 describes the use of mixtures of glyoxal with a metal nitrate compound in conjunction with triazines or N-chlorosuccinimide for preventing H 2 S odor generation, particularly that being microbial in origin, but not being biocidal. This reduction in H 2 S was reported to reduce corrosion as well. The use of the N-chlorosuccinimide was for the purpose of maintaining a particular redox potential and intended to oxidize or consume residual H 2 S. Maintenance of a halogen residual after H 2 S scavenging is not described.
[0009] U.S. Pat. No. 4,978,512 describes a method whereby an alkanolamine and an aldehyde are combined to form a triazine in order to scavenge H 2 S.
[0010] U.S. Pat. No. 5,498,707 describes a composition wherein a diamine and an aldehyde donor are utilized to scavenge H 2 S from liquid or gaseous process streams.
[0011] The composition forms water soluble polymers but does not claim to impact iron sulfide scale.
[0012] U.S. Pat. No. 7,438,877 discloses a method for H 2 S removal utilizing mixed triazine derivatives for improved scavenging. The mixture improves the overall scavenging capacity of triazines, but whether complete removal is achieved for a theoretically stoichiometric amount is not reported. However, it is known that typically triazines, such as hydroxyethyl triazines, do not scavenge H 2 S stoichiometrically (i.e., 3 mol of H 2 S per mol triazine) due to formation of cyclic thiazines that do not further react with H 2 S (Buhaug, J.; Bakke, J. M. “Chemical Investigations of Hydroxyethyl-triazine and Potential New Scavengers”, AIChE 2002 Spring National Meeting).
[0013] In addition, methods and compositions have been described for the treatment of iron sulfide deposits. For instance, U.S. Pat. No. 6,986,358 discloses a method for combining an amine with tris(hydroxymethyl)phosphine in a reaction at a pH of 8 to complex and dissolve deposits of iron sulfide. Similarly, the combination of ammonia with bis-(tetrakis(hydroxymethyl)phosphonium) sulfate forms a tetradentate ligand that complexes iron (Jeffrey, J. C.; Odell, B.; Stevens, N.; Talbot, R. E. “Self Assembly of a Novel Water Soluble Iron(II) Macrocyclic Phosphine Complex from Tetrakis(hydroxymethyl)phosphonium Sulfate and Iron(II) Ammonium Sulfate”: Chem. Commun., 2000, 101-102. Further, WO 02/08127 A1 combines the concept of using an amine, carboxylic acid amine salt, aminophosphonic acid, or ammonia in combination with bis-(tetrakis(hydroxymethyl)phosphonium) sulfate or tris(hydroxymethyl)phosphine to inhibit and reduce the amount of iron sulfide deposits in a water system.
[0014] While multiple methods have been developed for scavenging H 2 S and sulfhydryl compounds from industrial process systems, a high capacity, fast reacting method for reducing hydrogen sulfide, mitigating sources of hydrogen sulfide, such as microbiological sources, and removing products of hydrogen sulfide corrosion, such as iron sulfide, which performs at similar levels over a wide pH range and does reduces solids formation is still desired. Further, it is desirable to be able to use the chemical in industrial process systems that have H 2 S present via either process leaks or influent, such as produced water storage tanks, fracturing fluids, cooling tower refineries, and geothermal cooling towers.
SUMMARY OF THE INVENTION
[0015] In order to address the need to prevent, inhibit, and remediate H 2 S and its scale deposits from multiple sources, the present invention provides a composition obtained by combining at least one aldehyde or aldehyde donor that is not a triazine with the reaction product of an amino acid and a hydroxymethylphosphine or hydroxymethylphosphonium salt and, optionally, a quaternary ammonium salt or amine. Preferably, the pH of the composition is adjusted between about 1 and about 9, more preferably between about 2 and about 7, and most preferably between about 3 and about 6.
[0016] Another aspect of the present invention is a method of preventing the formation of and reducing the amount of iron sulfide in an industrial water or process circuit, such as an oil and gas pipeline or geothermal cooling tower. The inventive method comprises adding the composition described above to inhibit, disperse, and dissolve iron sulfide deposits within an industrial process circuit.
[0017] Another aspect of the present invention is a method of preventing the formation of hydrogen sulfide and, consequently, iron sulfide in an industrial water or process circuit due to microbial contamination. The inventive method comprises adding the composition described above to inhibit or reduce the growth of sulfate-reducing bacteria.
[0018] In one embodiment of the invention, the at least one aldehyde or formaldehyde releasing compound is selected from the group consisting of hydroxymethylhydantoins, bis(hydroxymethyl)hydantoins, imidazolidinyl urea, glyoxal, formaldehyde, glutaraldehyde, and acrolein.
[0019] In one embodiment of the invention, the amino acid is combined with the hydroxymethylphosphine or hydroxymethylphosphonium compound at acidic pH prior to combination with the aldehyde or aldehyde donor.
[0020] The hydroxymethylhydantoins are preferably selected from the group consisting of 1-hydroxymethyl-5,5-dimethylhydantoin, 3-hydroxymethyl-5,5-dimethylhydantoin, 1,3-bis(hydroxymethyl)-5,5-dimethylhydantoin, and mixtures thereof.
[0021] The amino acids may be α-amino acids or other amino acids such as β- or ω-amino acids. With the exception of glycine, α-amino acids can exist in two or more stereoisomeric forms, namely the L -form (which is the form usually found in proteins) and the D -form. For the purpose of this invention all stereoisomers as well as their (racemic or non-racemic) mixtures are suitable and here and in the following the plain names of the amino acids are meant to comprise all stereoisomers as well as their mixtures. Particularly useful amino acids are those selected from the group from the group consisting of glycine, lysine, alanine, histidine, aspartic acid, glutamic acid, serine, threonine, asparagine, glutamine, cysteine, proline, valine, isoleucine, leucine, methionine, phenylalanine, tyrosine, tryptophan, and 12-aminolauric acid.
[0022] In another embodiment of the composition of the present invention, a quaternary ammonium compound or amine can be combined with the amino acid and hydroxymethyl phosphine or phosphonium salt reaction product and aldehyde or aldehyde donor wherein the quaternary ammonium compound has a formula of (R 1 R 2 R 3 R 4 N + ) n X n− wherein R 1 , R 2 , R 3 , and R 4 are each independently an alkyl group having from 1 to 30 carbon atoms or an arylalkyl group having from 7 to 30 carbon atoms, and X n− s a mono- or polyvalent anion such as a halide, a C 2-20 mono- or dicarboxylate, a borate, nitrate, bicarbonate, carbonate, sulfamate, a sulfonate, sulfate, or a phosphate.
[0023] Alkyl groups are any linear, branched or cyclic saturated hydrocarbyl groups having the stated number of carbon atoms. Arylalkyl groups are alkyl groups substituted with an aryl group, preferably with a phenyl group, such as benzyl (phenylmethyl) or phenylethyl.
[0024] Halides are fluorides, chlorides, bromides or iodides, preferably chlorides or bromides.
[0025] C 2-20 mono- or dicarboxylates are anions derived from saturated or unsaturated mono- or dicarboxylic acids having 2 to 20 carbon atoms, such as acetate, propionate, butyrate, pentanoate, hexanoate, octanoate, decanoate, dodecanoate (laurate), tetradecanoate (myristate), hexadecanoate (palmitate), octadecanoate (stearate), oleate, linolate, oxalate, malonate, succinate, glutarate, adipate, 1,8-octanedioate, 1,10-decanedioate, 1,12-dodecanedioate and the like.
[0026] Borates may be monoborates (containing the BO 3 3− anion) or polyborates such as di-, tri-, tetra-, penta-, hexa-, or octaborates.
[0027] Sulfonates may be alkanesulfonates, such as methanesulfonate or trifluoromethanesulfonate, or arenesulfonates, such as benzene- or toluenesulfonate.
[0028] Sulfates may be “neutral” sulfates or “acid” sulfates (hydrogensulfates, bisulfates).
[0029] Similarly, phosphates may be orthophosphates (PO 4 3− ), hydrogenphosphates (HPO 4 2− ) or dihydrogenphosphates (H 2 PO 4 − ).
[0030] The substituted N-hydrogen compound is preferably selected from the group consisting of p-toluenesulfonamide, 5,5-dialkylhydantoins, methanesulfonamide, barbituric acid, 5-methyluracil, imidazoline, pyrrolidone, morpholine, ethanolamine, acetanilide, acetamide, N-ethylacetamide, phthalimide, benzamide, succinimide, N-methyl-urea, acetylurea, methyl allophanate, methyl carbamate, phthalohydrazide, pyrrole, indole, formamide, N-methylformamide, dicyanodiamide, ethyl carbamate, 1,3-dimethylbiuret, methylphenylbiuret, 4,4-dimethyl-2-oxazolidinone, 6-methyluracil, 2-imidazolidinone, ethyleneurea, 2-pyrimidone, azetidin-2-one, 2-pyrrolidone, caprolactam, phenylsulfinimide, phenylsulfinimidylamide, diaryl- or dialkylsulfinimides, isothiazoline-1,1-dioxide, hydantoin, glycinamide, creatine, glycoluril, C 1-20 alkylamines, (C 1-20 alkyl)-alkylenediamines, or (C 1-20 alkyl)-alkylenetriamines.
[0031] The hydroxymethylphosphine or hydroxymethylphosphonium compound is preferably selected from the group consisting of tris-(hydroxymethyl)phosphine, tetrakis(hydroxymethyl)phosphonium chloride, bis-[tetrakis(hydroxymethyl)phosphonium] sulfate, 1,2-bis[bis(hydroxymethyl)phosphino]benzene, 1,ω-bis[bis(hydroxymethyl)-phosphino]alkylenes wherein the alkylene is a C 1-6 methylene chain, tris(hydroxymethyl)(C 1-20 alkyl)phosphonium halides, and tris(hydroxymethyl)(aryl-C 1-20 alkyl)-phosphonium halides.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The present invention effectively inhibits the generation of and decreases the levels of hydrogen sulfide and sources of hydrogen sulfide, such as sulfate reducing bacteria, and iron sulfide deposits in industrial process systems. In contrast to previously disclosed methods, such as that described in U.S. Pat. No. 6,986,358, the present invention can be performed effectively at both acidic and basic pH when the composition is contacted with the industrial process stream.
[0033] The compositions of this invention are obtained by initially generating the reaction product of an amino acid and a hydroxymethylphosphine or hydroxymethylphosphonium salt at acid pH via the direct combination of the amino acid with the hydroxymethylphosphine or hydroxymethylphosphonium salt at a molar ratio amino acid/hydroxymethyl phosphine of 1:1 to 12:1. Although such products have been previously described for biomedical motifs in the reaction with amino acids and peptides (Berning, D. E.; Katti, K. V.; Barnes, C. L.; Volkert, W. A. “Chemical and Biomedical Motifs of the Reactions of Hydroxymethylphosphines with Amines, Amino Acids, and Model Peptides”, J. Am. Chem. Soc., 1999, 121, 1658-1664), the efficiency of such reaction products in dissolving iron sulfide has not been previously reported. Surprisingly, it has been found that combinations of these reaction products with hydrogen sulfide scavengers and, optionally, quaternary ammonium compounds or amines result in more rapid iron sulfide dissolution than previously disclosed compositions (U.S. Pat. No. 6,986,358), as well as rapidly prevent the formation of residual iron sulfide scale within a system. A particularly useful aspect of the present invention is the avoidance of polymeric precipitates upon mixing the amino acid and the hydroxymethylphosphine or hydroxymethylphosphonium salt, as observed with ammonia and its salts (U.S. Pat. No. 6,986,358).
[0034] The amino acid and hydroxymethylphosphine or hydroxymethylphosphonium salt reaction product is then combined with either an aldehyde or aldehyde donor, such as a methylolhydantoin, and optionally combined with a quaternary ammonium compound or amine. The preferred pH of the composition is adjusted between about 1 and about 9, more preferably between about 2 and about 7, and most preferably between about 3 and about 6 with an appropriate acid or base, such as hydrochloric acid or sodium hydroxide, if necessary.
[0035] Quaternary ammonium compound of the general formula of (R 1 R 2 R 3 R 4 N + ) n X n− , wherein R 1 , R 2 , R 3 , and R 4 are each independently an alkyl or arylalkyl group having from 1 to 30 carbon atoms and X n− is a mono- or polyvalent anion such as a halide, a C 2-20 mono- or dicarboxylate, a borate, nitrate, bicarbonate, carbonate, sulfamate, a sulfonate, sulfate, or a phosphate are particularly efficacious. Examples include didecyldimethylammonium chloride, didecyldimethylammonium carbonate, didecyldimethylammonium phosphate, didecyldimethylammonium sulfamate, didecyldimethylammonium citrate, (C 10-18 alkyl)-dimethyl-benzylammonium chloride, or (C 10-18 alkyl)-dimethyl-benzylammonium carbonate. Commercially available products include Bardac™ 2280, Carboquat™ 250 WT, Barquat™ MB-80, and Barquat™ 50-28, all available from Lonza Inc, Allendale, N.J.
[0036] The compositions used in the method of the present invention are particularly suitable for scavenging H 2 S and preventing iron sulfide deposition. Molar ratios of the composition to the amount of H 2 S present in the system are preferably from 0.25:1 to 100:1, more preferably from 1:1 to 60:1, most preferably from 4:1 to 30:1 of the aldehyde or aldehyde donor, preferably from 0.25:1 to 50:1, more preferably from 1:1 to 30:1, most preferably from 2:1 to 10:1, for the reaction product of an amino acid with the hydroxymethyl phosphonium salt, and preferably from 0.25:1 to 100:1, more preferably from 1:1 to 60:1, most preferably from 4:1 to 30:1 of the quaternary ammonium or N-Hydrogen compound, or mixture thereof. Further, these compositions may optionally comprise additional additives such as surfactants, dispersants, demulsifiers, scale inhibitors, corrosion inhibitors, anti-foaming agents, oxygen scavengers such as ascorbic or erythorbic acid, and flocculants.
[0037] In a preferred application of the method of the present invention the industrial process system is selected from the group consisting of an oil and gas production system, a produced water storage tank, an oil storage tank, an oil or gas transmission pipeline, ballast water tank, or oil transportation tank.
[0038] In another preferred application of the method of the present invention the industrial process system is a cooling tower such as a refinery or geothermal cooling tower.
[0039] In still another preferred application of the method of the present invention the industrial process system is a fuel storage tank.
[0040] In still another preferred application of the method of the present invention the industrial process system is an oil storage tank or transport system.
[0041] In still another preferred application of the method of the present invention the industrial process fluid is a fracturing fluid or a drilling mud.
[0042] In a preferred embodiment of the method of the present invention the aldehyde or aldehyde donor, the reaction product of the hydroxymethylphosphine or hydroxymethylphosphonium compound and amino acid, and, optionally, the quaternary ammonium compound or N-hydrogen compound, are combined prior to addition to the system.
[0043] In another preferred embodiment of the method of the present invention the aldehyde or aldehyde donor and the reaction product of the hydroxymethylphosphine or hydroxymethylphosphonium compound and amino acid are combined prior to addition to the system and the quaternary ammonium compound or N-hydrogen compound is added separately to the system.
[0044] In still another preferred embodiment of the method of the present invention the aldehyde or aldehyde donor and the quaternary ammonium compound or N-hydrogen compound are combined separately from the reaction product of the hydroxymethylphosphine or hydroxymethylphosphonium compound and amino acid and each combined product is added separately to the system.
[0045] The following examples are given to illustrate the present invention. It should be understood, however, that the invention is not intended to be limited to the specified conditions or details described in the examples.
EXAMPLE 1
[0046] In order to demonstrate the H 2 S scavenging ability of products of the present invention, 400 g of a model process water system at 400 ppm alkalinity was deoxygenated with a stoichiometric amount of oxygen scavenger (ammonium bisulfite) and the pH adjusted with either HCl, NaOH, or CO 2 . Water (400.0 g) was charged with a NaSH standard in order to achieve a H 2 S concentration of about 50 ppm, followed by a solution containing 2.00 g of a 70% solution of 1,3-dimethylol-5,5-dimethylhydantoin. A solution of a composition according to the present invention was prepared by combining glycine (0.11 mol) with bis[(tetrakishydroxymethyl)phosphonium] sulfate (0.018 mol) and water (0.92 mol). 5.02 g of the resulting solution was combined with an equivalent weight of 70% (w/w) solution of methylolhydantoin and dosed such that the corresponding hydrogen sulfide solution contained the corresponding amount of methylolhydantoin scavenger. Reaction progress was monitored by measuring the residual H 2 S at specified time intervals via titration.
[0047] The % residual H 2 S levels are shown as a function of pH versus other known chemical technologies. The high performance capacity and pH-insensitive performance of the products of the present invention are readily observed.
[0000]
TABLE 1
pH
Time (min)
5
7.2
8.4
9.4
0
100%
100%
100%
100%
2.5
86%
90%
88%
91%
5
86%
89%
88%
94%
15
71%
77%
77%
81%
60
46%
50%
38%
35%
90
25%
32%
27%
34%
125
—
—
13%
—
150
19%
14%
—
—
180
—
11%
—
11%
EXAMPLE 2
[0048] In order to demonstrate the H 2 S scavenging ability of products of the present invention, 400 g of a model process water system at 400 ppm alkalinity was deoxygenated with a stoichiometric amount of oxygen scavenger and adjusted with either NaOH or CO 2 to a pH of 9.4. The water was charged with a NaSH standard to achieve ˜50 ppm H 2 S, followed by a scavenger solution containing 2.00 g of a 70% solution containing 1,3-dimethylol-5,5-dimethylhydantoin, prepared as described in Example 1 (molar ratio of scavenger to H 2 S:14:1). For comparison, triazine H 2 S scavenging was also evaluated under similar conditions at equivalent levels. Reaction progress was monitored by measuring the residual H 2 S at specified time intervals via titration. The higher performance capacity products of the present invention are readily observed.
[0000]
TABLE 2
Present
Time (min)
Invention
Triazine
0
100%
100%
2.5
91%
91%
5
94%
89%
15
81%
98%
30
61%
97%
60
35%
—
90
34%
—
125
—
83%
180
11%
—
EXAMPLE 3
[0049] In order to demonstrate the superior iron sulfide dissolution ability of the products of the present invention, the time to complete dissolution of iron sulfide was compared. To a 10 mL vial containing an iron filing in 1% NaCl, an HCl and NaSH standard solution was added to generate 480 ppm H 2 S at pH ˜5. Immediate formation of iron sulfide was observed. The precipitate was treated with the reaction product of 0.11 mol glycine with 0.018 mmol bis-[tetrakis(hydroxymethyl)phosphonium] sulfate (6:1 molar ratio) in 0.92 mol of water, prepared in a manner analogous to that described in Berning, D. E.; Katti, K. V.; Barnes, C. L.; Volkert, W. A. “Chemical and Biomedical Motifs of the Reactions of Hydroxymethylphosphines with Amines, Amino Acids, and Model Peptides”, J. Am. Chem. Soc., 1999, 121, 1658-1664. 5.02 g of this solution was combined with 5.05 g of a 70% solution containing 1,3-dimethylol-5,5-dimethylhydantoin. For comparison, the rate of iron sulfide dissolution of the reaction of ammonia with bis-[tetrakis(hydroxymethyl)phosphonium] sulfate was compared.
[0000]
TABLE 3
Time to Complete Dissolution
Present Invention
NH 3 + THPS
(10% as product)
(10% as Product)
7.0 min
17.5 min
EXAMPLE 4
[0050] In order to demonstrate the prevention of generation of iron sulfide deposits via chemical sources by compositions of the present invention, 1.0 mL multiple concentrations of the product as prepared in Example 3 were added to 9 mL of 1% salinity water in oxygen-free vials containing iron filings for iron sulfide generation upon addition of a sulfide source (target 500 ppm as H 2 S). As shown in Table 4, iron sulfide was generated immediately in the control sample upon addition of sulfide, whereas complete scavenging of H 2 S and rapid dissolution of iron sulfide was observed at multiple concentrations of formulations of the present invention.
[0000]
TABLE 4
Formulation Concentration
Observation
10%
4%
2%
1%
0.85%
0%
FeS formed
No
No
No
No
Yes
Yes
upon H 2 S
addition?
Reduced
Yes
Yes
Yes
Yes
Yes
—
FeS relative
to Control?
Solution
Clear
Clear
Clear
Clear
Gray/
Black
after 1 min
Black
Solution
Clear
Clear
Clear
Clear
Slight
Black
after 8 min
Gray
Haze
EXAMPLE 5
[0051] In order to demonstrate the ability of compositions of the present invention to prevent FeS formation, a solution was prepared via combination of 0.11 mol of glycine with 0.018 mol of bis((tetrakishydroxymethyl)phosphonium) sulfate and 0.92 mol of water. 3.77 g of this solution was combined with 3.78 g of a solution containing methylolhydantoin (mixture containing 1,3-dimethylol-5,5-dimethylhydantoin and monomethylol-5,5-dimethylhydantoins) and 2.54 g of a 70% solution of dimethyldidecylammonium chloride. 1 mL of the resulting solution was added to 9 mL of a 1% brine solution containing an iron nail. 0.15 mL of 1 N HCl was added, followed by 0.20 mL of a 39,500 ppm NaSH solution and compared to a control sample without the solution. No FeS was formed in the solution containing 1% of a mixture of the present invention, whereas FeS was formed in the control.
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The invention relates to a method for the prevention and removal of H 2 S and/or other sulfhydryl compounds and iron sulfide deposits from gas and/or liquid streams in industrial process systems. Formulations comprising aldehydes, aldehyde donors, and/or aldehyde stabilizers, excluding triazines, in combination with the reaction product of an amino acid and a hydroxymethylphosphine or hydroxymethylphos-phonium salt, and optionally a quaternary ammonium compound and/or one or more N-hydrogen compounds such as 5,5-dialkylhydantoin or amines, are rapidly and sustainedly scavenging H 2 5 originating from process and/or microbial sources. The formulations possess high capacities for H 2 5 removal and are relatively pH-insensitive.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a personal watercraft (PWC) which ejects water rearward and planes on a water surface as the resulting reaction. More particularly, the present invention relates to an engine for the personal watercraft.
[0003] 2. Description of the Related Art
[0004] In recent years, so-called jet-propulsion personal watercraft have been widely used in leisure, sport, rescue activities, and the like. The jet-propulsion watercraft is configured to have a water jet pump that pressurizes and accelerates water sucked from a water intake generally provided on a bottom of a hull and ejects it rearward from an outlet port. Thereby, the personal watercraft is propelled.
[0005] In the jet-propulsion watercraft, a steering nozzle provided behind the outlet port of the water jet pump is swung either to the right or to the left, to change the ejection direction of the water to the right or to the left, thereby turning the watercraft to the right or to the left.
[0006] Meanwhile, some jet-propulsion personal watercraft are provided with a riding seat disposed along its longitudinal direction. In such a watercraft, an engine is disposed in an engine room such that a crankshaft extends in the longitudinal direction of the watercraft. The crankshaft projects rearwardly and its rear end is coupled to a pump shaft of a water jet pump, thereby driving the water jet pump.
[0007] When such a personal watercraft is on the water and splashed with water, it sometimes becomes necessary to expose the engine by opening an engine room cover (a riding seat in some models) for inspection or repair work. In such cases, an ignition plug, mounted on the engine head, is likely to be splashed with water. Further, in some personal watercraft, the engine room is defined under the riding seat. In such a personal watercraft, heat from the engine or an exhaust pipe acts on the bottom of the seat and, as a result, the seat is heated.
SUMMARY OF THE INVENTION
[0008] The present invention addresses the above-described condition, and an object of the present invention is to provide a personal watercraft equipped with an engine designed in such a way that, even when the engine is splashed with water, its ignition plug is protected from water splashes, and heat generated from the engine or from an exhaust pipe attached thereto will not act on a riding seat.
[0009] As a solution to the aforementioned problem, a first aspect of the invention provides a jet-propulsion watercraft comprising: a water jet pump including an outlet port, the water jet pump pressurizing and accelerating water taken in from outside of the watercraft and ejecting the water from the outlet port to propel the watercraft as a reaction of the ejecting water; a multi-cylinder engine having a crankshaft extending along the longitudinal direction of the watercraft; and an air box so disposed as to overlie a cylinder head of the engine and to cover substantially at least ignition plugs attached to the cylinder head.
[0010] In the personal watercraft so constituted, the air box overlies and covers the ignition plugs. In such an arrangement, even when water splashes toward the ignition plugs, such water splashes are blocked by the air box, thereby protecting the ignition plugs from water splashes. Further, since it is possible to extend the length of an intake pipe connecting the air box and an intake port of the engine, good inertia effects for air-intake are produced.
[0011] It is preferable that the engine of the above-described personal watercraft is a fuel injection-type engine. This results in an increase in intake pipe length as described above, and therefore provides enhanced intake inertia effects and engine power.
[0012] Also, it is preferable that the air box of the personal watercraft contain a throttle valve. With this structure, the effective length, which contributes to the intake inertia effects, can be further increased and mechanism parts of the valve are covered by the air box, thereby rendering the valve portion rustproof.
[0013] Further, it is preferable that the air box of the personal watercraft is so disposed as to overlie the cylinder head and to cover substantially the entire cylinder head. This constitution is capable of effectively preventing water splashes to the cylinder head and effectively preventing engine-radiated heat from transferring to the seat.
[0014] It is preferable that, in the personal watercraft, the air box is disposed over the cylinder head so as to deviate from the cylinder head toward an exhaust pipe disposed on an opposite side of an intake port of the engine with respect to the crankshaft and so as not to overlie the intake port and its vicinity. This facilitates the inspection of the components placed on the intake port side.
[0015] It is preferable that, in the personal watercraft, the air box has a through-hole vertically defined in the air box in such a way that the through-hole coincides with a position of the ignition plug in plan view. This facilitates the replacement and inspection of the ignition plug.
[0016] It is preferable that, in the personal watercraft, the through-hole is closed by a removable cap member provided on the top end of the through-hole. This facilitates the replacement and inspection of the ignition plug and enables the ignition plug to be protected against water splashes.
[0017] A second aspect of the invention provides a personal watercraft comprising a water jet pump including an outlet port, the water jet pump pressurizing and accelerating water taken in from outside of the watercraft and ejecting the water from the outlet port to propel the watercraft as a reaction of the ejecting water; a multi-cylinder engine having a crankshaft extending along the longitudinal direction of the watercraft; and a plurality of intake pipes so disposed as to traverse over a cylinder head of the engine.
[0018] In the personal watercraft so constituted, the intake pipes of relatively low temperature are located above the engine. Therefore, heat radiated from the engine is less likely to transfer upward. Further, in contrast to the personal watercraft of the first aspect of the invention, the personal watercraft of the second aspect can have a longer intake pipe length, thereby making it possible to provide greater intake inertia effects.
[0019] It is preferable that the air box of the personal watercraft is disposed on one side of the engine and connected to tip ends of the plurality of intake pipes and an exhaust pipe of the engine is disposed below the air box. Thereby, the heat from the exhaust pipe, which is going to transfer upward, is blocked by the air box. This therefore provides a constitution which is less affected by the heat from the engine, even when the riding seat is disposed above the engine room.
[0020] It is preferable that, in the personal watercraft, each of the intake pipes is arranged so as not to overlie an ignition plug provided on the cylinder head so that the ignition plug is accessible from above. This facilitates the inspection and replacement of the ignition plug.
[0021] It is preferable that, in the personal watercraft, the one side of the engine is an opposite side of the intake port with respect to the crankshaft. This makes it possible to extend the length of the intake pipe.
[0022] The above and further objects and features of the invention will more fully be apparent from the following detailed description with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1A illustrates major components of a first embodiment of a personal watercraft of the present invention and is a partially sectional view showing a constitution in which an engine of the personal watercraft and an air filter box overlying the engine are disposed;
[0024] [0024]FIG. 1B illustrates major components of the first embodiment of the personal watercraft of the present invention, and is a plan view taken in the direction indicated by arrows Ib and Ib of FIG. 1A and showing arrangement of the engine, the air filter box, and intake pipes;
[0025] [0025]FIG. 2A illustrates major components of a second embodiment of the personal watercraft of the present invention that is different from the first embodiment (FIG. 1) and is a partially sectional view showing a constitution in which an engine of the personal watercraft and intake pipes traversing over the engine are disposed;
[0026] [0026]FIG. 2B illustrates major components of the second embodiment of the personal watercraft and is a plan view taken in the direction indicated by arrows IIb and IIb of FIG. 2A and showing arrangement of the engine, the air filter box, and the intake pipes;
[0027] [0027]FIG. 3 is an enlarged cross-sectional view showing in detail the air filter box shown in FIGS. 1A, 1B, 2 A, 2 B;
[0028] [0028]FIG. 4 is a side view showing an entire jet-propulsion personal watercraft according to the embodiments of the present invention; and
[0029] [0029]FIG. 5 is a plan view showing the entire personal watercraft of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Hereinafter, a jet-propulsion watercraft according to embodiments of the present invention will be described with reference to the accompanying drawings.
[0031] Referring now to FIGS. 4, 5, reference numeral A denotes a body of the personal watercraft. The body A comprises a hull H and a deck D covering the hull H from above. A line at which the hull H and the deck D are connected over the entire perimeter thereof is called a gunnel line G. In this embodiment, the gunnel line G is located above a waterline L of the personal watercraft.
[0032] As shown in FIG. 5, an opening 16 , which has a substantially rectangular shape seen from above, is formed at a relatively rear section of the deck D such that it extends in the longitudinal direction of the body A, and a riding seat S is provided above the opening 16 such that it covers the opening 16 from above as shown in FIGS. 4, 5.
[0033] An engine E is provided in a chamber 20 surrounded by the hull H and the deck D below the seat S. The engine E includes multiple cylinders (e.g., four-cylinders) and is of a fuel injection type. As shown in FIG. 4, a crankshaft 26 of the engine E is mounted along the longitudinal direction of the body A. An output end of the crankshaft 26 is rotatably coupled integrally with a pump shaft of a water jet pump P through a propeller shaft 27 . An impeller 21 is mounted on the pump shaft of the water jet pump P. The impeller 21 is covered with a pump casing 21 C on the outer periphery thereof. A water intake 17 is provided on the bottom of the hull H. The water is sucked from the water intake 17 and fed to the water jet pump P through a water intake passage 28 . The water jet pump P pressurizes and accelerates the water. The pressurized and accelerated water is discharged through a pump nozzle 21 R having a cross-sectional area of flow gradually reduced rearward, and from an outlet port 21 K provided on the rear end of the pump nozzle 21 R, thereby obtaining a propulsion force.
[0034] In FIG. 4, reference numeral 21 V denotes fairing vanes for fairing water flow behind the impeller 21 . As shown in FIGS. 4, 5, reference numeral 24 denotes a bar-type steering handle as a steering operation means. The handle 24 is operated through a wire cable 25 to the right or to the left in association with the steering nozzle 18 provided behind the pump nozzle 21 R such that the steering nozzle 18 is swingable to the right or to the left. The watercraft can be turned to any desired direction while the water jet pump P is generating the propulsion force. A throttle lever Lt is mounted on the right end portion of the handle 24 .
[0035] As shown in FIG. 4, a bowl-shaped reverse deflector 19 is provided above the rear side of the steering nozzle 18 such that it can swing downward around a horizontally mounted swinging shaft 19 a . The deflector 19 is swung downward toward a lower position behind the steering nozzle 18 to deflect the water ejected from the steering nozzle 18 forward and, as the resulting reaction, the personal watercraft moves rearward.
[0036] In FIGS. 4, 5, reference numeral 22 denotes a rear deck. The rear deck 22 is provided with an openable hatch cover 29 . A rear compartment (not shown) with a small capacity is provided under the hatch cover 29 . Reference numeral 23 denotes a front hatch cover. A front compartment (not shown) is provided under the front hatch cover 23 for storing equipment and the like.
[0037] In the watercraft according to the embodiments, as seen in FIGS. 1A, 1B, 2 A, 2 B, a cylinder head Ch is provided on the top end of the engine E and under the seat S. The cylinder head Ch has four intake ports Pi for introducing air into the engine and four exhaust ports Ep for discharging the exhaust gas. An exhaust pipe Pe is connected to the exhaust ports Ep. The exhaust ports Ep and the exhaust pipe Pe are arranged on an opposite side of the intake ports Pi with respect to the crankshaft 26 . Four ignition plugs Fp are vertically provided on the cylinder head Ch.
[0038] In the personal watercraft according to the first embodiment, as seen in FIGS. 1A, 1B, an air filter box (air-intake box) 1 , which is a type of air box, is so disposed as to overlie the engine E, thereby covering substantially the entire engine E including the ignition plugs Fp arranged on the cylinder head Ch of the engine E. More precisely, the air filter box 1 deviates from the cylinder head Ch toward the exhaust pipe Pe and toward the rear of the watercraft. The air box 1 does not overlie the intake ports Pi of the engine E. That is, the intake ports side end of the air box 1 deviates from the intake ports Pi toward the exhaust ports Ep.
[0039] Also, four intake pipes 3 are configured such that their tip ends are in close contact with corresponding openings 1 A of the air filter box 1 (see FIG. 3), and their base ends are respectively extended and connected to four intake ports Pi formed in the cylinder head Ch of the engine E and fixed to the cylinder head Ch. A filter 9 is provided inside of the air filter box 1 so as to be opposite to the opening 3 A (see FIG. 3). Such arrangement allows clean air to be supplied from the air filter box 1 to each intake port Pi of the cylinder head Ch.
[0040] Further, as shown in FIG. 3, a throttle valve Vs is provided in the air filter box 1 so as to be located on the opposite side of each intake pipe's 3 connecting portion or the opening 3 A with respect to the filter 9 . The throttle valve Vs serves to change air flow volume in each intake port Pi by changing the throttle position thereof. The throttle valve Vs is connected, through a control cable (wire), to a throttle lever Lt provided in the vicinity of a right grip of the handle 24 (FIG. 5).
[0041] As shown in FIGS. 1A and 1B, four through-holes 5 are vertically defined in the air filter box 1 disposed over the cylinder head Ch in such a way that these through-holes 5 coincide with the positions of the ignition plugs Fp as seen in plan view. Cap members 6 for closing the through holes 5 are removably attached to top ends of the through holes 5 . The ignition plugs Fb can be easily attached/detached by removing the cap members 6 without removing the air filter box 1 .
[0042] Further, each intake pipe 3 is provided with a fuel injection nozzle 7 , at its base end (i.e., the end on the side of the intake port Pi). The fuel injection nozzle 7 is connected to a fuel tank through a supply pipe 39 . Fuel is supplied from the fuel tank to each fuel injection nozzle 7 by using a fuel pump located in the supply pipe or in the fuel tank.
[0043] The personal watercraft of the this embodiment having the aforementioned constitution functions as follows. When removing the seat S for inspection of the engine E or the like, the opening 16 is exposed upward. During this inspection, even when, for example, water splashes toward the opening 16 from above, the ignition plugs Fp will be protected against such water splashes, because the air filter box 1 overlies the cylinder head Ch of the engine E so as to substantially cover at least the ignition plugs Fp.
[0044] As in the embodiment shown in FIGS. 1A and 1B, the tip end of the intake pipe 3 is located in the air filter box 1 located apart from the intake port Pi and above the cylinder head Ch, thereby making it possible to extend the length of the intake pipe 3 . This provides intake inertia effects.
[0045] In addition, the heat radiated from the engine E and transferred to the seat S is blocked by the air filter box 1 substantially covering the engine E.
[0046] Referring now to FIGS. 2A and 2B, a second embodiment of the present invention will be described.
[0047] In a personal watercraft according to this embodiment shown in FIGS. 2A and 2B, an air filter box 101 is so disposed as to overlie an exhaust pipe Pe of the engine E. Pour intake pipes 103 are so arranged as to traverse above the cylinder head Ch of the engine E for establishing connections between the air filter box 101 and their corresponding intake ports Pi of the engine E. Also, in this embodiment, each intake pipe 103 is arranged so as not to pass above each ignition plug Fp as seen in plan view, thereby facilitating replacement of the ignition plug Fp from above. Furthermore, in this embodiment, circular disc-like cap members 106 integrally attached to an ignition cord (not shown) are disposed above the ignition plugs Fp so that the ignition plugs Fp can be protected against water splashes coming directly toward them.
[0048] In this embodiment, components identical with or corresponding to those in FIGS. 1A and 1B are identified by the same reference numerals or reference numerals with the addition of a numeral of 100 .
[0049] According to the personal watercraft so constituted, the length of the intake pipes 103 can be extended further in comparison with the embodiment of FIGS. 1A and 1B. This makes it possible to provide a constitution suitable for the engine, because enhanced intake inertia effects are achieved.
[0050] Further, in this embodiment, since the air filter box 101 is disposed above the exhaust pipe Pe, the heat from the exhaust pipe Pe is blocked by the air filter box 101 . As a result, the seat S disposed above will not be heated. Furthermore, since the intake pipes 103 of low temperature are disposed overlying the cylinder head Ch of the engine E, the degree of heat of the seat S disposed above the cylinder head Ch is reduced.
[0051] Moreover, according to the second embodiment, the air filter box 101 is not disposed on the side of the intake ports Pi of the engine E. Accordingly, components to be inspected relatively frequently (e.g., an oil gage, a filter for cooling passage of a muffler, or the like) or components requiring replacement (e.g., an oil filter Of, or the like) may be disposed on the intake port side. This offers easy inspection and maintenance.
[0052] In the embodiments, as shown in FIG. 3, the throttle valve Vs having movable mechanism elements is accommodated in the air filter box ( 1 , 101 ) so that the movable mechanism elements of the throttle valve Vs is protected against water splashes or the like. Further, a part of the fuel containing oil is blown back toward the throttle valve Vs located in the air filter box ( 1 , 101 ) from inside of the intake pipes ( 3 , 103 ) so as to supply the oil to the movable mechanism elements of the throttle valve Vs in the closed space of the air filter box ( 1 , 101 ). For the above-described reasons, high rust-proof effects for the throttle valve are obtained. In the embodiment, as shown in FIG. 3, blowby gas containing an oil mist Me produced in a crankcase (not shown) of the engine E may be positively introduced from a breather chamber of the crankcase into the air filter box ( 1 , 101 ) through a hose 35 or the like, and a part of the oil mist Me may be led to the space in which the throttle valve Vs is accommodated, thereby achieving further enhanced rust-proof effects. In that case, it is preferred that liquefied oil separated from the blowby gas be returned toward an oil reservoir of the engine E through another hose 36 or the like.
[0053] Numerous modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, the description is to be construed as illustrative only, and is provided for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure and/or function may be varied substantially without departing from the spirit of the invention and all modifications which come within the scope of the appended claims are reserved.
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Disclosed is a personal watercraft which is equipped with an engine designed in such a way that, even when the engine is splashed with water, its ignition plugs will not get wet and the heat generated from the engine or exhaust pipe will not act on, e.g., a riding seat. The personal watercraft includes a multi-cylinder engine having a crankshaft extending along its longitudinal direction and a water jet pump driven by the engine. The water jet pump pressurizes and accelerates water, and ejects the water from an outlet port opened rearward. The watercraft is propelled as a reaction of the ejecting water. An air filter box is so disposed as to overlie a cylinder head of the engine, thereby covering substantially at least the ignition plugs attached to the cylinder head.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND
Frictionally and/or adhesively bonded joints of pipe are commonly used with many types of underground pipelines. Conventionally available joints of pipe include male and female type jointing.
It is necessary that large forces be used to cause the male end of one joint of pipe to be inserted into the female end of a second joint of pipe so that a proper seal can be made between the two joints of joined piping, along with overcoming frictional forces between the joints of pipe and the ground surface in contact with the joints of pipe.
The large forces necessary to join multiple joints of pipe together are especially difficult to create in confined spaces such as ditches or digouts where the joints of pipe are placed before being joined and which will be filled so that the pipeline will be below or underground.
Conventionally available methods for joining pipes include hammering the one joint into another.
While certain novel features of this invention shown and described below are pointed out in the annexed claims, the invention is not intended to be limited to the details specified, since a person of ordinary skill in the relevant art will understand that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation may be made without departing in any way from the spirit of the present invention. No feature of the invention is critical or essential unless it is expressly stated as being “critical” or “essential.”
BRIEF SUMMARY
The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner.
In one embodiment is provided a method and apparatus including a pulling and pulled portions detachably connectable to two pipe joints to be joined which are located in a ditch or dugout, which apparatus pulls one joint relative to the second joint causing socketing of the joints together at a joint area.
In one embodiment is provided cables or chains which detachably connect the pulling and pulled portion of the method and apparatus.
As force is applied by the gas controlled cylinders the joints of pipe are pulled together and one joint is socketed into the other at the joint between them.
In one embodiment each pipe is encircled by a clamping belt.
In one embodiment the gas controlled cylinders include a frictional enhancing material suitable for gripping each joint of pipe, such as rubber.
In one embodiment the pulling section includes a pair of gas controlled cylinders each having extension/retraction rods. In this embodiment each gas controlled cylinder will be detachably connected to a first joint of pipe with diametrically opposed positions on the first joint of pipe.
In various embodiments chains or cables or like pulling members can be connected to the extension/retraction rods of each gas controlled cylinder, and also to a pulled section which pulled section is detachably connected to a second joint of pipe.
In one embodiment the gas controlled cylinders can be actuated causing retraction of the extension/retraction rods into the gas controlled cylinders, said refraction causing the male end of the first joint of pipe to be pulled into the female end of the second joint of pipe.
In various embodiments pulling can be made at time when each joint of pipe is resting in a ditch.
In various embodiments multiple pulls of separate joints of pipe can be made without relocating pulling section when it is detachably connected to the first joint of pipe. In various embodiments at least 2, 3, 4, 5, 6, 7, 8, 9, and 10 separate joints of pipe pulled together without removing the pulling section from its detachable connection to the first joint of pipe. In various embodiments, a range of multiple pulls can be made between any two of the above referenced multiple joints of pipe being pulled without removing the pulling section from its detachable connection to the first joint of pipe.
In various embodiments pulls can be made between a plurality of joints of pipe having a minimum joint length of at least about 10, 12, 14, 15, 16, 18, 20, 22, 25, 30, 35, 40, 45, and/50 feet without removing the pulling section from its detachable connection to the first joint of pipe. In various embodiments, multiple pulls of joints of pipe having lengths falling with a range between any two of the above referenced minimum joint lengths can be made without removing the pulling section from its detachable connection to the first joint of pipe.
In various embodiments the method and apparatus includes a pulling section having a clamping belt with a plurality of pulling cylinders, with at least one of the pulling cylinders being laterally adjustable relative to the clamping belt. In various embodiments both of the pulling cylinders are laterally adjustable relative to the clamping belt. In various embodiments the apparatus includes two clamping belts with wherein at least one of the pulling cylinders has lateral adjustability, and in other embodiments two of the clamping cylinders have lateral adjustability. In various embodiments lateral adjustability can be provided by a loop connection with the at least one clamping belt. In various embodiments lateral adjustability can be provided by a sliding connection, and in other embodiments by a slot connection with the clamping belt.
In various embodiments the method and apparatus includes a pulled section having a clamping belt with a plurality of connectors, with at least one of the connectors being laterally adjustable relative to the clamping belt. In various embodiments both of the clamp connectors are laterally adjustable relative to the clamping belt. In various embodiments the apparatus includes two clamping belts with wherein at least one of the connectors has lateral adjustability, and in other embodiments two of the connectors have lateral adjustability. In various embodiments lateral adjustability can be provided by a loop connection with the at least one clamping belt. In various embodiments lateral adjustability can be provided by a sliding connection, and in other embodiments by a slot connection with the clamping belt.
In various embodiments lateral adjustability can be used to attach to joints of multiple diameters of piping with same system by adjusting length of belt clamp and relative lateral position of connectors to belt.
In various embodiments the pulling and/or pulled sections includes a belt having lateral adjustability to accommodate multiple diameter joints of pipes to be pulled. In various embodiments the pulling and/or clamping units include a belt having lateral adjustability used to attach to joints of multiple diameters of piping with same system by adjusting length of belt for pulling section and relative lateral position of cylinders to belt.
In various embodiments the diameters of pipe which can be accommodated include 6, 8, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 42, 48, 60, 72, 84, 96, 108, and/or 120 inch diameters of joints of pipe. In various embodiments, the lateral adjustability is such that it can accommodate a multiple diameters of pipe falling within a range of between any two of the above referenced diameters of joints of pipe.
In various embodiments pulling cylinders are located at 180 degrees from each other around the joint of pipe. In various embodiments pulling cylinders are spaced about 90, 100, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270 degrees from each other. In various embodiments, the pulling cylinders can be spaced within a range of between any two of the above referenced degree spacing.
In various embodiments the method and apparatus includes the steps of, after making a pull, and during the time the pipe string remains resting in a ditch, removing the pulling portion of the apparatus from the joint of pipe to which it was connected before making the pull.
In various embodiments, the pulling section is removed without having to lift resting pipe. In various embodiments, the pulling section is removed without digging out around resting pipe. In various embodiments, the pulling section is removed by sliding at least one clamping belt relative to at least one of the cylinders. In various embodiments, the clamp belt of the pulling section removed from ditch separately from both gas controlled cylinders (clamp detached from at least the separately removed cylinder/clamp detached from both cylinders). In various embodiments, the clamp belt and gas controlled cylinder can be removed from the ditch separately from other gas controlled cylinder (clamp detached from at least the separately removed cylinder/clamp detached from both cylinders)
In various embodiments, the pulled can be removed when pipe resting in ditch, clamping section removed from pipe. In various embodiments, the pulled section is removed without digging out around resting pipe. In various embodiments, the pulled section is removed by sliding at least one clamping belt relative to at least one of the connectors. In various embodiments, the clamp belt of the pulled section removed from ditch separately from both connectors. In various embodiments, the clamp belt and connector can be removed from the ditch separately from other connector for the pulled section (first connector detached from clamping belt separately removed from the clamping belt and/or second connect; and/or both connectors detached from the clamping belt and separately removed).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIG. 1 is a side view of first and second joints of pipe to be attached using the method and apparatus.
FIG. 2 is a top perspective view of the pulling and pulled section of the method and apparatus.
FIG. 3 is a perspective view of the control system for the pulling section.
FIG. 4 is a side perspective view of first and second joints of pipe to be attached shown in FIG. 1 , but now showing more clearly the ditch in which these joints rest before the pull.
FIG. 5 is a is a perspective view of the apparatus on the pulled joints shown in
FIG. 4 with the pulled section being installed around joints to be pulled.
FIG. 6 is a perspective view of a user setting up the apparatus to make a pull.
FIG. 7 is a schematic diagram of gas flow through the lines of the pulling section which will cause an extension of the pulling rods, and showing the rods in a fully extended condition.
FIG. 8 is a schematic diagram of gas flow through the lines of the pulling section which will cause a retraction of the pulling rods, and at the beginning of a pull.
FIG. 9 is a schematic diagram of gas flow through the lines of the pulling section which will cause a retraction of the pulling rods, and at the end of a pull showing complete retraction.
FIG. 10 is a perspective view of the apparatus now set up to make a pull between two joints of pipe.
FIG. 11 is a perspective view of the apparatus in the middle of a a pull between two joints of pipe.
FIG. 12 is a perspective view of the apparatus finishing a pull between two joints of pipe.
FIG. 13 is a is a perspective view of the apparatus on the pulled joints shown in FIG. 12 with the pulled section being removed from around the pulled joint so that it can be attached to a second joint of pipe to be pulled.
FIG. 14 is a perspective view of the apparatus now set up to make a second pull of a new joint of pipe onto the two joints of pipe connected in FIGS. 10 through 12 .
FIG. 15A is a sectional view of the system shown in FIG. 14 taken along the lines 15 A— 15 A in FIG. 14 .
FIG. 15B is a sectional view of the system shown in FIG. 14 taken along the lines 15 B— 15 B in FIG. 14 .
FIG. 15C is a sectional view of the system shown in FIG. 14 taken along the lines 15 C— 15 C in FIG. 14 .
FIG. 15D is a sectional view of the system shown in FIG. 14 taken along the lines 15 A— 15 A in FIG. 14 , but showing first and second cylinders laterally adjusted with respect to the centerline of the joints of pipe.
FIG. 16 is a perspective view of the system 10 .
DETAILED DESCRIPTION
Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner.
FIG. 1 is a side view of first 50 and second 60 joints of pipe to be attached using the method and apparatus 10 . Second joint 50 includes enlarged female end 68 at second end 64 within which will be pulled male end 52 of a first joint of pipe 50 . In various embodiments the pulling can occur while first 50 and second 60 joints are primarily below grade 40 level, such as inside a ditch 42 . FIG. 4 is a side perspective view of first 50 and second 60 joints of pipe to be attached, but now showing more clearly the ditch 42 in which these joints rest before the pull.
FIG. 2 is a top perspective view of the pulling 200 and pulled 100 section of the method and apparatus 10 . FIG. 3 is a perspective view of the control system 600 for the pulling section 200 . In one embodiment, pulling apparatus 10 includes pulling section 200 and pulled section 100 .
Pulled section 100 can include clamping belt 110 along with first 130 and second 140 laterally adjustable connectors. First connector 130 can include strap 131 and loop 132 , and have an extent of lateral adjustability 134 . Second connector 140 can include strap 141 and loop 142 , and have an extent of lateral adjustability 144 . Detachable connection can be achieved by the use of at least one clamping belt 110 , with first end 112 , second end 114 , and sliding lock 120 .
Pulling section 200 can include two pistons 300 , 400 which can be detachably connected to a pipe joint (e.g., joint 50 ). Detachable connection can be achieved by the use of at least one clamping belt 370 , but preferably a second clamping belt 470 is also used.
First piston 300 can have rod 320 slidably connected to its piston chamber. First piston 300 can include inlets 310 and 312 for controlling extension and retraction of rod 320 . Compressed gas entering inlet 310 causes retraction of rod 320 and compressed gas entering inlet 312 causes extension of rod 320 . Rod 320 can be connected to pulling member 350 which can be a conventionally available chain or cable. First piston 300 can include a frictional increasing member 306 , such as a rubber lining or like material.
Similar to first piston 300 , second piston 400 can have rod 420 slidably connected to its piston chamber. Second piston 400 can include inlets 410 and 12 for controlling extension and retraction of rod 420 . Compressed gas entering inlet 410 causes retraction of rod 420 and compressed gas entering inlet 412 causes extension of rod 420 . Rod 420 can be connected to pulling member 450 which can be a conventionally available chain or cable. Second piston 400 can include a frictional increasing member 406 , such as a rubber lining or like material.
First piston 300 can slidably connected to first clamping belt 370 through slot 308 , and slidably connect to second clamping belt 470 through slot 308 . First clamping belt 370 can include first end 372 , second end 374 , and sliding lock 376 . Second piston 400 can slidably connected to first clamping belt 370 through slot 408 , and slidably connect to second clamping belt 470 through slot 408 . Second clamping belt 470 can include first end 472 , second end 474 , and sliding lock 476 . First piston 300 can have an extent of lateral adjustability 360 relative to first 370 and second 470 belts. Second piston 400 can have an extent of lateral adjustability 460 relative to first 370 and second 470 belts.
FIG. 3 shows a perspective view of the control system 600 for apparatus 10 . Control system 600 generally includes switching unit 610 and portable supply of compressed gas 500 . Switching unit 610 can be controlled by handle 620 . Supply of compressed gas 500 can be connected to switching unit 610 by inlet line 650 . Switching unit 610 has two outlets which are connected to lines 710 and 810 . Handle 620 controls three states: (a) state 1 where no gas is allowed to exist to either line 710 or line 810 ; (b) state 2 where gas is allowed to exit to line 710 but not line 810 ; and (c) state 3 where gas is allowed to exit to line 810 but not line 710 . Line 710 is split into lines 720 and 730 (with lines 710 , 720 , and 730 generally being referred together as first set of lines 700 ). Line 810 is split into lines 820 and 830 (with lines 810 , 820 , and 830 generally being referred together as second set of lines 800 ). FIGS. 5 and 6 are perspective views of apparatus 10 being connected to joints 50 and 60 with pulled section 100 being installed on joint 60 and pulling section being attached to joint 50 . For purposes of clarity in FIG. 6 ditch 42 and ground 40 are not shown with all items being in empty space.
First 300 and second 400 cylinders can be positioned on the opposite sides of joint 50 . Before joint 50 is placed in ditch 42 it is preferred that straps 370 and 470 be placed in ditch 42 under where joint 50 will be lowered. Also preferably before lowering of joint 50 into ditch 42 , second cylinder 400 can be attached to straps 370 and 470 using slot 408 . Alternatively, after joint 50 has been lowered into ditch 42 and on top of straps 370 , 470 ; second ends 374 , 474 of straps 370 , 470 can be threaded through slot 408 of second cylinder 400 and attaching sliding locks 376 , 476 so said second ends 374 , 474 .
Positioning of Cylinders for Pulling Section
After joint 50 has been lowered into ditch 42 and on top of straps 370 , 470 , cylinders 300 , 400 can be positioned about joint 50 . Cylinder 300 can be slid over straps 370 , 470 (schematically indicated by arrow 301 ) to its ultimate pulling position when attached to joint 50 . Cylinder 400 can be slid with respect to straps 370 , 470 (schematically indicated by arrow 401 ) to its ultimate pulling position when attached to joint 50 . After cylinders 300 and 400 are positioned, sliding locks 376 and 476 can be used to lock in place cylinders 300 and 400 .
Preferably, as indicated in FIG. 14A , cylinders 300 , 400 are symmetrically spaced about joint 50 to provide a balanced force on each side joints 50 and 60 which balanced force is parallel to central axis 30 to avoid any tendency to skew or cock joints 50 and 60 during a pull. However, as schematically indicted in FIG. 14A , both cylinders 300 and 400 have an extend of lateral adjustment, respectively angular ranges 360 and 460 , such that cylinder 300 and/or 400 can be angularly spaced above or below the central axis 30 .
In various embodiments both cylinder 300 and 400 are angularly spaced above central axis 30 although symmetrically spaced about joint 50 .
In various embodiments both cylinder 300 and 400 are angularly spaced below central axis 30 although symmetrically spaced about joint 50 .
In various embodiments both cylinder 300 is angularly spaced above central axis 30 while cylinder 400 is angularly spaced below central axis, although both cylinders 300 and 400 are symmetrically spaced about joint 50 .
In various embodiments cylinder 300 can be non-symmetrically spaced about a joint compared to cylinder 400 .
Positioning of Connectors for Pulled Section
After joint 60 has been lowered into ditch 42 and on top of strap 110 , connectors 130 and 140 can be positioned about joint 60 . Connector 130 can be slid over strap 110 (schematically indicated by arrow 135 ) to its ultimate position for being pulled when attached to joint 60 . Connector 140 can be slid with respect to strap 110 (schematically indicated by arrow 145 ) to its ultimate position for being pulled when attached to joint 60 . After connectors 130 and 140 are positioned, sliding lock 120 can be used to lock in place connectors 130 and 140 .
Preferably, as indicated in FIG. 14C , connectors 130 , 140 are symmetrically spaced about joint 60 to provide a balanced pulled force on each side joints 50 and 60 which balanced force is parallel to central axis 30 to avoid any tendency to skew or cock joints 50 and 60 during a pull. However, as schematically indicted in FIG. 14C , both connectors 130 and 140 have an extent of lateral adjustment, respectively angular ranges 134 and 144 , such that connector 130 and/or 140 can be angularly spaced above or below the central axis 30 .
In various embodiments both connectors 130 and 140 are angularly spaced above central axis 30 although symmetrically spaced about joint 60 .
In various embodiments both connectors 130 and 140 are angularly spaced below central axis 30 although symmetrically spaced about joint 60 .
In various embodiments connector 130 is angularly spaced above central axis 30 while connector 140 is angularly spaced below central axis, although both connectors 130 and 140 are symmetrically spaced about joint 60 .
In various embodiments connectors 130 and 140 can be non-symmetrically spaced about a joint.
Operatively Connecting Cylinders to Connectors
Preferably, when positioned on joints 50 and 60 , cylinder 300 will line up with connector 130 ; and cylinder 400 will line up with connector 140 so that chains 350 and 450 will be substantially parallel with central axis 30 along with each other.
Over joint 50 , chains 350 and 450 are respectively connected to rods 320 and 420 . Over joint 60 chains 350 and 450 are respectively connected to connectors 130 and 140 . Preferably, chains 350 and 450 will have some excess length (excess 353 and 453 respectively).
As shown in FIGS. 10-14 , preferably, the length of chains 350 and 450 extend long enough to span the length of at least two normal sized joints 50 , 60 so that multiple pulls can be made without having to move pulling apparatus 200 from its attachment to joint 50 .
Making a Pull for a First Set of Pipe Joints when Below Grade
Initially, rods 320 and 420 can be placed in the initial completely extended positions. FIG. 7 is a schematic diagram of gas flow through the lines 700 of the pulling section 200 which will cause an extension of the pulling rods 320 , 420 , and showing the rods 320 , 420 in a fully extended condition (fully extended positions schematically indicated by dimensional lines 380 , 480 ). Handle 620 is moved (schematically indicated by arrow 1002 ) to allow flow from pressurized gas source 500 to flow lines 700 . This flow proceeds through line 710 (schematically indicated by arrow 1010 ), flow being split into lines 720 (schematically indicated by arrow 1014 ) and 730 (schematically indicated by arrow 1012 ), and ultimately into ports 312 and 412 of cylinders 300 and 400 . Flow into ports 312 and 412 respectively cause rods 320 and 420 to extend (schematically indicated by arrows 1030 and 1032 ). Cylinders 300 and 400 are now in a position to make a pull.
FIG. 8 is a schematic diagram of gas flow through the line set 800 of the pulling section 200 causing retraction of the pulling rods 320 , 420 at the beginning of a pull. FIG. 10 is a perspective view of apparatus 10 now set up to make a pull between two joints of pipe 50 and 60 . Handle 620 is moved (schematically indicated by arrow 1005 ) to flow from pressurized gas source 500 to flow lines 800 . This flow proceeds through line 810 (schematically indicated by arrow 1020 ), flow being split into lines 820 (schematically indicated by arrow 1022 ) and 830 (schematically indicated by arrow 1024 ), and ultimately into ports 310 and 410 of cylinders 300 and 400 . Flow into ports 310 and 410 respectively cause rods 320 and 420 to retract (schematically indicated by arrows 1040 and 1042 ). Cylinders 300 and 400 are now starting to make a pull respectively on chains 350 and 450 which are respectively connected to connectors 130 and 140 which are connected to joint 60 .
FIG. 9 is a schematic diagram of gas flow through the line set 800 of the pulling section 200 causing continued retraction of the pulling rods 320 , 420 , and in the middle of a pull. FIG. 11 is a perspective view of apparatus 10 in the middle of a pull between two joints of pipe 50 and 60 . As shown in FIGS. 9 and 11 , handle 620 is continued to be pushed in the direction of arrow 1005 allowing continued flow from source 500 to flow lines 800 . This continued flow continues to proceed through line 810 (schematically indicated by arrow 1020 ), flow being split into lines 820 (schematically indicated by arrow 1022 ) and 830 (schematically indicated by arrow 1024 ), and ultimately into ports 310 and 410 of cylinders 300 and 400 . Flow into ports 310 and 410 respectively continues to cause rods 320 and 420 to continue retract (schematically indicated by arrows 1040 ′ and 1042 ′). Assuming that the chains 350 , 450 had little to no slack in the position indicated by FIG. 9 , rods 320 and 420 have respectively pulled chains 350 and 450 an equal distance (schematically indicated by dimensional lines 384 and 484 ), which pulled distance has also moved joint 60 through connectors 130 and 140 being clamped onto belt 110 . It is noted that shoulder 67 of joint 60 will restrict relative longitudinal movement of joint 60 and belt 110 (with attached connectors 130 and 140 ). As handle 620 is continued to be place in the position indicated by arrow 1005 continued flow in the directions of arrows indicated above will cause rods 320 and 420 to continue to retract in the directions of arrows 1040 ′ and 1042 until either rods 320 and 420 bottom out in cylinders 300 and 400 or joints 50 and 60 full nest with each other.
In the situation of rods 320 and 420 bottoming out before joints 50 and 60 become fully nested a second, third, or more pulls can be made without relocated either pulling section 200 and pulled section 100 . In this situation of bottoming out, handle 620 is moved in the direction of arrow 620 to fully extend rods 320 and 420 (as described with reference to FIG. 7 ). After full extension chains 350 and 450 are detached from connectors 130 and 140 and then reattached to connectors 130 and 140 to minimize any slack in chains 350 and 450 . After reattaching chains 350 and 450 , second, third, etc. pulls can be made using the procedure described above with respect to FIGS. 8 and 9 until additional retraction of rods 320 and 420 are prevented by the full nesting/attachment/connection of joints 50 and 60 .
FIG. 12 is a perspective view of apparatus 10 finishing a pull between two joints of pipe 50 and 60 . In FIG. 12 , using the above described steps, joints 50 and 60 have full nested with each other wherein rods 320 and 420 have stopped retraction before bottoming out in cylinders 300 and 400 . Dimensional line 384 ′ schematically indicates the extent of retraction for the last pull to fully nest joints 50 and 60 .
Making a Pull for a Second Set of Pipe Joints without Relocating Pulling Section
FIG. 14 is a perspective view of apparatus 10 now set up to make a second pull of a new joint of pipe 70 onto the two joints of pipe connected together with the pull(s) described regarding FIGS. 10 through 12 .
Pulled section 100 is removed from joint 60 , which removal is schematically shown in FIG. 14 . FIG. 14 is a is a perspective view of apparatus 10 located on the pulled joints 50 and 60 with the pulled section 100 being removed from around the pulled joint 60 so that it 100 can be attached to a second joint of pipe 70 to be pulled. Sliding connector 120 is released and strap 110 removed from said connector. Belt 110 (with attached connector 140 ) can be removed from joint 60 by pulling in the direction of arrow 1100 . Preferably, before pulling out belt 110 , connector 130 is removed from belt 110 by sliding connector in the direction of arrow 1120 . At this point pulled section can be laid in ditch 42 under the location of where new joint 70 will be placed in ditch 42 and then attached to said joint 70 in a similar manner as that described with respect to attaching pulled section to joint 60 .
After attaching pulled section to joint 70 , chains 350 and 450 can be attached to connectors 130 and 140 minimizing any slack in said chains. Because pulling section 200 has not been moved, chains 350 and 450 need to have an overall length which can span the length 61 of 60 to allow attachment to relocated connectors 130 and 140 (now relocated on joint 70 ). Now the pulling of joint 70 to nest with joint 60 follows a similar procedure as describe above with the pulling of joint 60 to nest with joint 50 and will not be described in detail again. However, it should be noted that pulling on joint 70 when the pulling section 200 is attached to joint 50 has the added advantage of ensuring that joint 60 completely nests with joint 50 because when joint 70 nests with joint 60 , continued pulling forces on joint 70 will be transmitted through joint 60 causing it to want to further nest with joint 50 .
Relocating Pulling Section to New Joint of Pipe
Chains 350 and 450 will not be long enough to make an infinite numbers of pulls without the need to relocate pulling section 200 from joint 50 . Below is described a procedure for removing pulling section 200 .
Pulling section 200 can be removed from joint 50 , which removal is schematically shown in FIG. 14 . FIG. 14 is a is a perspective view of apparatus 10 located on the pulled joints 50 and 60 with the pulling section 100 being removed from around joint 50 so that it 200 can be attached to another joint in the pipe line in connection with another set of pulls. Sliding connectors 376 and 476 are released and straps 370 and 470 removed from said connectors. Belts 370 and 470 (with attached cylinder 400 ) can be removed from joint 50 by pulling in the direction of arrow 1200 . Preferably, before pulling out belts 370 and 470 , cylinder 300 is removed from belts 370 and 470 by sliding cylinder in the direction of arrow 1220 . At this point pulling section 200 can be laid in ditch 42 under the location of where new joint of pipe will be placed in ditch 42 and then attached to said joint of pipe in a similar manner as that described with respect to attaching pulling section to joint 50 .
In one embodiment the end of an already pulled pipe (e.g., first end 72 of joint 70 ) must be slightly lifted in ditch 42 to allow placement of belts 370 and 470 under such joint 70 and attachment of pulling section 200 for the next set of joints of pipe to be pulled.
In one embodiment a second set of straps 370 ′ and 470 ′ can be laid in the ditch under the same joint of pipe (e.g., joint 70 ) on which the pulled section 100 is to be attached for a pull. This is schematically shown in FIG. 14 . In this manner, belts 370 ′ and 470 ′ can be located under joint 70 for the next round of joint pulling.
Independent Adjustability of Pulling and Pulled Sections
FIG. 15A is a sectional view of the pulling apparatus 10 taken along the lines 15 A — 15 A in FIG. 14 . It is noted that pulling can be made at a time when the joints to be pulled are below grade 40 in ditch 42 . Angular indicators 360 and 460 schematically indicate lateral adjustment of cylinders 300 and 400 relative to the joints in the set of joints.
FIG. 15D is a sectional view of the pulling apparatus 10 taken along the lines 15 A — 15 A in FIG. 14 , but now showing first 300 and second 400 cylinders laterally adjusted with respect to the centerline 30 of the joint 50 . The lateral adjustment is schematically indicated by arrow 360 ′ and 460 ′. With such lateral adjustment (arrows 360 ′ and 460 ′) first 300 and second 400 cylinders are located above the height of centerline 30 of joint 50 .
Arrow 31 schematically indicates the raised position of first 300 and second 400 cylinders with respect to centerline 30 —to line 32 which is show as being horizontal as first 300 and second 400 cylinders in this figure remain symmetrically spaced about centerline 30 . In various embodiments line 32 spanning between first 300 and second cylinders will not be horizontal when first 300 and second 400 cylinders are not symmetrically spaced about centerline 30 . For example arrow 360 ′ may indicate that first cylinder 300 is laterally adjusted above centerline 30 by about 30 degrees while arrow 460 ′ may indicate that second cylinder 400 is laterally adjusted above centerline by about 15 degrees. In various embodiments one of the cylinders can be laterally adjusted above centerline 30 while the other is laterally adjusted below centerline 30 .
FIG. 15B is a sectional view of the pulling apparatus 10 taken along the lines 15 B — 15 B in FIG. 14 . Angular indicators 360 and 460 schematically indicate lateral adjustment of chains 350 and 450 relative to the joints in the set of joints.
FIG. 15C is a sectional view of the pulling apparatus 10 taken along the lines 15 C — 15 C in FIG. 14 . Angular indicators 360 and 460 schematically indicate lateral adjustment of connectors 130 and 140 relative to the joints in the set of joints. FIG. 16 is a perspective view of pulling system 10 showing lateral adjustment of first 300 and second 400 cylinders along with lateral adjustment of first 130 and second 140 connectors.
In various embodiments connectors 130 and 140 can be laterally adjusted about centerline 30 to about the same extent as their respective first 300 and second 400 cylinders. In various embodiments the extent of lateral adjustment of one or both of first 130 and second 140 connectors can differ from the extent of lateral adjustment of one or both of first 300 and second 400 cylinders.
FIG. 16 is a perspective view of the system 10 shown in FIG. 15D and showing lateral adjustment (arrows 360 ′ and 460 ′) of first 300 and second 400 cylinders along with lateral adjustment (arrows 360 ″ and 460 ″) of first 130 and second 140 connectors.
In FIG. 16 it can be noted that belt 110 of pulled section 100 is held in place by shoulder 67 of joint 60 . In this manner of connection of pulled section 100 , friction is not as important as for pulling section 200 which depends on frictional resistance between the particular joint pulling section is connected to and pulling section members (e.g., first 300 and second 400 cylinders along with belts 370 and 470 ).
The following is a list of reference numerals:
LIST FOR REFERENCE NUMERALS
(Reference No.)
(Description)
5
user
10
attachment system
30
centerline
31
arrow
32
line between first and second cylinders
40
ground
42
ditch
44
interior
45
floor or bottom
48
arrow
50
pipe joint
52
first end
54
second end
58
enlarged female end
60
pipe joint
61
overall length of joint of pipe
62
first end
64
second end
67
tapered shoulder
68
enlarged female end
70
pipe joint
72
first end
74
second end
78
enlarged female end
100
clamping section
110
clamping belt
112
first end
114
second end
120
sliding lock
130
first connector
131
strap for first connector
132
loop for first connector
134
extent of lateral adjustability of first connector
relative to clamping belt
135
arrow
140
second connector
141
strap for second connector
142
loop for second connector
144
extent of lateral adjustability of second connector
relative to clamping belt
145
arrow
200
powered section
210
first clamping belt
212
first end
214
second end
218
sliding lock
230
second clamping belt
232
first end
234
second end
238
sliding lock
300
first powered cylinder
301
arrow
302
first end
304
second end
306
frictional increasing base
308
adjustment slot
310
first inlet
312
second inlet
320
rod
322
first end
350
pull line
352
intermediate point of pull line
353
excess for pull line
354
end of pull line
360
extent of lateral adjustability of first cylinder relative
to clamping belts
370
clamping belt
372
first end
374
second end
376
sliding lock
380
extended position of rod
382
amount of extension of rod
384
amount of retraction of rod
385
retracted position of rod
400
second powered cylinder
401
arrow
402
first end
404
second end
406
frictional increasing base
408
adjustment slot
410
first inlet
412
second inlet
420
rod
422
first end
450
pull line
452
intermediate point of pull line
453
excess for pull line
454
end of pull line
460
extent of lateral adjustability of second cylinder
relative to clamping belts
470
clamping belt
472
first end
474
second end
476
sliding lock
480
extended position of rod
482
amount of extension of rod
484
amount of retraction of rod
485
retracted position of rod
500
portable supply of compressed gas
600
portable compressed gas power unit
610
switching unit
620
handle
650
inlet line
700
first set of lines
800
second set of lines
1000
arrow
1002
arrow
1005
arrow
1010
arrow
1012
arrow
1014
arrow
1020
arrow
1022
arrow
1024
arrow
1030
arrow
1030
arrow
1040
arrow
1042
arrow
1050
arrow
1060
arrow
1100
arrow
1110
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All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A method and apparatus for pulling multiple joints of pie which comprises a pulling section and a pulled section, the method and apparatus working while the joints of pipe are below grade and capable of pulling multiple joints of pipe without relocating the pulling section.
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FIELD OF THE INVENTION
This invention relates to a method and apparatus for crushing (granulating) of mineral, vegetable or embrittled materials.
BACKGROUND OF THE INVENTION
For the crushing (granulating) of mineral, vegetable or embrittled materials among others, beater mills (hammer mills) are used, the stationary crushing path of which is equipped with wear plates and striking bars, which are received between corresponding pressure plates. Wear plates and striking bars must be replaced frequently, if the desired grain size is supposed to be held within a range of variation which is as narrow as possible. This is also true, even though to a lesser extent, for the pressure plates on both sides of the striking bars.
From the chip-wood industry has become known according to German Pat. No. 33 09 517 a method and an apparatus for carrying out said method, in which the steel strip knives in use are replaced during apparatus operation continuously or periodically with sharp steel strip knives. According to experience, flakes (flat chips) of an always constant quality and form thus are produced from chips. The previously needed machine idle time for the replacement of dulled knives is hereby no longer needed.
However, for the granulating of mineral, vegetable or embrittled materials a method modified according to said German Pat. No. 33 09 517 does not present a satisfactory solution, because not only do the edges of the striking bars dull quickly, but so also do the counterlips of the wear plates which lie close adjacent the inside of the striking bars and, even though to a reduced degree, so also do the wear surfaces of the pressure plates located on both sides of each of the striking bars, which wear surfaces face the beater shoes of the rotor.
The purpose of the invention is to provide a method for the granulating of mineral, vegetable or embrittled materials and an apparatus which serves to carry out said method, with which constant grain sizes can be produced at all times during uninterrupted mill operation.
The invention attains this purpose with a method, in which the wear plates of the stationary crushing path and the striking bars then in use (and, if desired, pressure plates arranged on both sides) are replaced during mill operation continuously or periodically with new (replacement) parts of the same types. Replacement wear plates and striking bars (and their pressure plates if desired) are thus each stored in corresponding magazines on the new part input side of the beater mill, from where they are fed by cylinder-operated slide members to the crushing path. Suitable means such as simple magazines may be used on the worn part discharge side of the beater mill for receiving the worn wear plates and striking bars (and, if desired, the worn pressure plates). Corresponding with their differing wear it is possible to move the wear plates and striking bars (and, if desired, the pressure plates) at different feeding rates through the stationary crushing path. It is hereby possible to load the wear plates and striking bars on the mill's input side more heavily with granulatable material than on the mill's discharge side, in order to compensate for the fact that the mentioned wearable parts wear more the longer they are used in the crushing chamber. Such a different loading with granulatable material can be achieved by a correspondingly sloped position of the beater shoes or, in the case of a beater mill with a horizontal axis, by sloped positioning of said axis.
In a preferred embodiment of the inventive apparatus, wear plates and striking bars are manufactured of thin steel strips incorporating longitudinal grooves which are all identical in form. Each striking bar is held by at least one pressure plate, or if desired by two pressure plates between which the striking bar is tightly clamped. In order to require as little part advancing force as possible during the periodic advance, all pressure plates can be simultaneously released from their striking bars prior to a feeding (part advancing) cycle by movement of a suitable center tension ring, similar to the suggestion in German Pat. No. 24 36 316. However, a center tension ring is not needed if the striking bars are each clamped fixedly between two pressure plates and are moved therewith continuously or periodically through the stationary crushing path. The running surfaces of the pressure plates, which running surfaces face the beater shoes, can be designed in a conventional manner to be regrindable and readjustable.
In the inventive method for continuous granulating of mineral, vegetable or embrittled materials, for the first time the factors "crushed particles quality", "wear part use" and "energy consumption" are presented in a preselectable relationship and thus optimized, whereby furthermore the previously needed idle mill times ("down time") for the replacement of the worn parts, no longer exist.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be discussed in greater detail in connection with the drawings, in which:
FIG. 1 is a partially broken end view of a beater mill embodying the invention.
FIG. 2 is a fragmentary partially broken left side view of the FIG. 1 mill, the left and right end portions of FIG. 2 being broken away in central cross section substantially as taken along the line II--II of FIG. 1.
FIG. 3 is an enlarged fragment of FIG. 1, defining a cross-sectional view of a circumferential segment of the crushing ring of a beater mill, taken in a plane perpendicular to the axis of rotation of the rotor of the beater mill, and showing an embodiment in which the striking bars are movable by themselves through the stationary crushing path.
FIG. 4 is a fragmentary partially broken cross-sectional view taken approximately on the line IV--IV of FIG. 3.
FIG. 5 is an enlarged fragmentary longitudinal cross-sectional view, of a magazine which is carried on one end of the beater mill.
FIG. 6 is a cross-sectional view substantially taken on the line VI--VI with the apparatus in its dotted line position of FIG. 5.
FIG. 7 is a fragmentary end elevational view of the beater mill taken from the end thereof opposite the end shown in FIG. 1 (i.e., taken from the left in FIG. 2).
FIG. 8 is an enlarged fragmentary cross-sectional view similar to FIG. 3 but showing a modified crushing path segment, in which the striking bars are each movable together with a flanking pair of pressure plates through the stationary crushing path.
DETAILED DESCRIPTION
The beater mill 1 comprises a housing 1A (FIGS. 1 and 7) having upstanding input and output end walls 1B and 1C connected by an axially extending generally cylindrical (here multi-sided) peripheral wall 1D having an open upper end hopper 1E for receiving material to be granulated and a bottom outlet opening 1F through which granulated material exits. The beater mill 1 further comprises a cylindrical, stationary crushing path 2 and a rotor 5A carrying beater shoe arms 5 in turn carrying beater shoes 4. The crushing path 2 is formed by a plurality of circumferentially closely spaced, substantially trapezoidal cross section crossbars 2A (FIGS. 1, 3 and 4) which extend axially between the housing end walls 1B and 1C and are fixed thereto by any convenient means such as screws 2B. The crossbars are distributed coaxially around the rotor 5A which in turn is rotatable with the central shaft 5B as supported by bearings 1G in the housing end walls 1B and 1C for rotation with respect thereto, the rotor 5A being rotatably driveable by a conventional motor M1 (FIG. 2). The inside surface of the stationary crushing path 2 is formed by closely and evenly circumferentially spaced wear plates 7, in longitudinal grooves 7A in which slide exchangeable springs 11. More particularly, the crossbars 2A each have an interior surface 2C for supporting thereon a pair of the wear plates 7 and provided with a pair of axially extending grooves 2D which oppose the axial grooves 7A in the wear plates 7 and are held in circumferential registry therewith by the exchangeable springs 11, each of which extends the full depth of an opposed pair of grooves 7A and 2D for guiding the wear plates 7 axially along the corresponding crossbar 2A. A keystone-shaped guide rail 2E is centrally fixed as by screws 2F on the inner surface of each crossbar and extends axially thereon, the circumferential side edges of the guide rail 2E being undercut as seen in FIG. 3. Permanent magnets 16, each being formed by either a continuous axial strip magnet or a plurality of axially spaced magnet segments, are fixedly embedded in the interior surface 2C of each crossbar 2A near the outer circumferential edges thereof. The axial edges of the wear plates 7 are sloped as shown, so that the circumferentially outer edges thereof are coplanar with the sloped circumferential sides of the crossbar 2A and so that the circumferentially inner edges of the wear plates complement the undercut slope of the circumferential edges of the guide rail 2E. The springs 11 cooperate with the grooves 7A and 2D to fix the circumferential location of the wear plates 7 on their corresponding crossbar 2A and to hold the circumferentially inner edges of the wear plates 7 trapped under the undercut circumferential edges of the guide rail 2E, so as to maintain the circumferential inner edges of the wear plates 7 snug against the interior surface 2C of the crossbar 2A. The exchangeable springs in the present embodiment are, as generally indicated in FIG. 4, axially elongate multiple wave leaf springs (having an axial series of circumferentially extending troughs and ridges) and fitted sufficiently snugly into the grooves 2D in the crossbar 2A as to be removably fixed thereon while having sufficient clearance in the grooves 7A of the wear plates 7 as to allow the wear plates 7 to slide axially with respect to the springs 11 and crossbars 2A. The permanent magnets 16 insure a flutter-free fit of the wear plates 7 in the area of their counter-lips 10. In this way, the wear plates 7 can be slid axially along the interior surface of the crossbar 2A in their cross-sectional position shown in FIG. 3 and when centered in the housing 1A, to cover the interior surface 2C of the crossbar 2A, the wear plates 7 will, in use of the apparatus, be held firmly and immovably in place on the interior surface 2C of the crossbar 2A.
Striking bars 6 are in form completely identical to the wear plates 7. Such a striking bar 6 is located at the upstream (rightward in FIG. 3) edge of the corresponding crossbar 2A in a recess 2G of circumferential depth slightly less than the thickness of the striking bar 6. Like the wear plates 7, the striking bar 6 has parallel sloped end edges and a spring receiving axial groove 7A opposing a corresponding axial groove 2D in the recess 2G of the crossbar 2A. Accordingly, the striking bar 6 is axially insertable into its working position on the upstream edge of the crossbar 2A with its circumferential and radial position controlled by contact with the corresponding spring 11 and the walls of the recess 2G. A pressure plate 8 is actuable (as hereafter described) to clamp the striking bar 6 in the recess 2G of the crossbar 2A in its position shown in FIG. 3 and, alternately, is releasable to permit axial removal of a worn striking plate 6 in replacement thereof with a new striking plate 6, as hereafter more fully described. When clamped in place in its recess 2G, as shown in FIG. 3, the striking bar 6 has its upper edge protruding up somewhat beyond the adjacent wear plate 7 against which its back bears. The striking bar 6 is separated from the counterlip 10 of the wear plate 7 on the adjacent crossbar 2A (to the right thereof in FIG. 3) by a circumferentially narrow slot S extending axially the width of the housing 1A. It will be seen that as the beater shoe, or hammer, 4 rotates clockwise in FIG. 3, it will force material to be granulated against the sharp interior lip 10 of the striking bar 6 and tend to granulate it and drive the resulting granules radially outwardly through the slot S into the portion of the housing radially outside the crushing path 2, to fall out the bottom outward opening 1F of the housing as seen in FIG. 1.
Clamping and unclamping of the striking bars 6 by the pressure plates 8 may be accomplished as follows. A coaxial tension ring 12 is circumferentially movable as indicated by the arrow thereon in FIG. 3 to relieve the clamping force, normally applied to the striking bars 6 by pressure plates 8, during periodic axial advancement of replacement striking bars 6. In the embodiment shown in FIGS. 3 and 4, a pair of coaxial tension rings 12 are provided within the housing 1A adjacent the interior surfaces of the housing side walls 1B and 1C and are circumferentially shiftable in circumferential grooves 2H in the axial end faces of the crossbars 2A radially outward of the recesses 2G and striking bars 6. Each of the pressure plates 8 has a shaft 8A extending axially therebeyond through the tension rings 12 and thence out through circumferential slots 1K in the side walls 1B and 1C of the housing 1A. The slots 1K are of low clearance radially to accurately locate the tension rings 12 and pressure plates 8 radially of the housing and crossbars 2A. However, the slots 1K are circumferentially widened sufficient to allow enough circumferential movement of the tension rings and pressure plates 8 as to allow the pressure plates 8 to be circumferentially clamp and unclamp the striking bars 6 with respect to their crossbars 2A. Pivoting of the pressure plates 8 with respect to the tension rings 12 is prevented by keying of both against rotation on the shafts 8A, by means of keys 8B and 8C (FIG. 4). Thus, the tension rings 12 and the plurality of pressure plates 8 move circumferentially as a unit to clamp or unclamp the striking bars 6. Such circumferential clamping and unclamping movement can be accomplished, for example by actuation of pressure fluid cylinders 8D operatively interposed between the housing 1C and preferably diametrally opposed ones of the shafts 8A. The tension rings 12 and pressure plates 8 are preferably further constrained to move only circumferentially by providing the rings 12 with a radially close sliding fit within the circumferential grooves 2H. The circumferential clearance in the slot 1K is less than the depth of the groove 2D in crossbar 2A so that, even when it is released, the pressure plate 8 is close enough spaced to the opposed crossbar 2A as to keep a striking bar 6 being axially fed into, or out of, the housing, snugly in register with the recess 2G and spring 11. Accordingly, wear plates 7 and striking bars 6 when being axially fed into or out of the upper portion of the housing 1A are prevented from falling down (due to gravity) away from their proper location in the crushing path.
Stacks of replacement striking bars 6 and wear plates 7 are held stacked in the magazine 9A of a respective magazine unit 9 (of which one is shown in FIGS. 5 and 6). Each magazine unit 9 includes a slide member 13 reciprocated by a cylinder 14 periodically to successively axially feed the replacement striking bars 6 or wear plates 7, each with different feeding speeds, through the stationary crushing path 2. As soon as one striking bar 6 or wear plate 7 has been fed from the magazine to the crushing path 2, the slide member 13 returns to its initial (remote) position (shown in solid lines in FIG. 5), after which the pressure springs 15 move the next striking bar 6 or wear plate 7 into the feeding position ahead of the slide member. In the embodiment shown, the cylinder 14 is preferably a pressure fluid cylinder whose housing 14A is fixed with respect to a magazine 9B and a mounting bracket 9A and whose piston rod 14B extends leftwardly in FIG. 5 and through a coupling 14C connects to the slider member 13.
If desired, one such magazine unit 9 may be provided for each wear plate 7 and striking bar 6 location along the cylindrical crushing path 2 (i.e., three magazine units per crossbar 2A). However, this would require a substantial number of magazine units 9 which would then have to be more compactly designed than shown in FIGS. 5 and 6, in order to all fit on one end wall 1B of the housing 1A, even with relatively few (for example 7) crossbars 2A present in the mill 1. See for example the distribution of outlet slots 33 for striking bars 6 and wear plates 7 shown in FIG. 7 hereafter discussed.
Alternately, in the embodiment shown in FIGS. 1 and 2, a rotatably indexable mounting plate 31 is supported for rotation on the end of the shaft 5B close adjacent the input end wall 1B of housing 1A and carries at least three magazine units 9, namely a magazine unit 9X carrying striking bars 6, a magazine unit 9Y carrying wear plates 7 for the location 7L on each crossbar 2A and a magazine unit 9Z carrying wear plates 7 for the location 7R on each crossbar 2A (the locations 7L and 7R being shown in FIG. 2). By appropriate circumferential indexing of the mounting plate 31, either manually or by suitable motor means as schematically indicated at M2 in FIG. 2, the magazine units 9X, 9Y and 9Z are brought into registration with successive ones of corresponding inlet slots 32X, 32Y and 32Z in the input end wall 1B. In the embodiment shown, the slots 32X, 32Y and 32Z form a substantially Y-shaped composite slot with portions 32X, 32Z and 32Y respectively axially aligned with the striking bar 6 and wear plate 7R on one crossbar 2A and the wear plate 7L coacting with the striking bar 6 and located on the adjacent crossbar 2A. It will be apparent from FIG. 1 that at a given circumferential position of the mounting plate 31, the magazine units 9X, 9Y and 9Z axially oppose different crossbars 2A.
If desired, suitable detent means, not shown, may be interposed between the housing 1A and mounting plate 31 to ensure registry of the magazine units 9. If desired, the mounting plate 31 may carry additional magazine units not shown. For example, the left side of the mounting plate 31 (not shown in FIG. 1) may carry a second set of the three magazine units 9X, 9Y and 9Z, so that, for example, two striking bars 6, for example on opposite sides of the rotor 5A, could be replaced simultaneously. On the discharge side of the bear mill 1, any convenient means such as simple receiving magazines or hoppers 36 receive the worn striking bars 6 or wear plates 7. When a replacement wear plate 7 or striking bar 6 is inserted into position on its corresponding crossbar 2A, the corresponding worn wear plate 7 or striking bar 6 will be axially pushed by its replacement leftwardly in FIGS. 2 and 4 through a corresponding slot 33 in the housing end wall 1C. Slots 33X, 33Y and 33Z in the housing outlet end wall 1C correspond to and are axially aligned with the above-discussed slots 32X, 32Y and 32Z in the housing inlet end wall 1B. Although FIGS. 4, 5 and 6 show in cross section the details of one magazine unit and corresponding housing end wall slotting 32 and 33 for one kind of plate, for example the striking plates 6, the corresponding structure for the wear plates 7 will be understood to be identical and thus need not be shown in additional drawings.
In the inventive modification according to FIG. 8, the striking bars 6' are each first clamped between two adjustably and regrindably arranged pressure plates 8' by tightening screws 41 and together with these flanking pressure plates 8' are then moved, as a unitary sandwich 43, axially through the stationary crushing path 2'. In this embodiment the necessity of providing permanent magnets 16' does not exist. This is achieved in the following manner. In FIG. 8 the sandwich 43L and the adjacent (rightward in FIG. 8) sandwich 43R differ in lying respectively at a positive and a negative angle α to a radius R from the rotational axis of the mill. Accordingly, the radially inner (upper in FIG. 8) ends of the pressure plates 8' of sandwich 43L are ground at a different angle than those of the sandwich 43R.
Also, whereas the countersink for the screw 41 may be in either the rightward or leftward pressure plate 8' in the sandwich (compare sandwiches 43L and 43R for example), the groove 8K for the spring 11', since it must match the groove 7A' in the striking bar 6', must be on the upstream (rightward in FIG. 8) pressure plate 8' in both sandwiches 43L and 43R.
In the particular embodiment shown in FIG. 8, the sandwich 43R is clamped in its recess 2G' in crossbar 2A' by a secondary pressure plate 88 carried on a tension ring 12' in the manner above discussed with respect to FIG. 3 elements 8 and 12. The leftward sandwich 43L is similarly held in its recess 2G' in a further crossbar 2AL by a similar secondary pressure plate 88 similarly operated by tension ring 12'. In the embodiment shown, the sandwiches 43L and 43R are prevented from dropping radially inwardly (up in FIG. 8) from their corresponding recesses 2G' as they are being axially advanced along the crushing path 2', by means of further springs 11" disposed in grooves 46 and 47 opposed in the facing crossbar and pressure plate 8'. With the sandwiches 43L and 43R in place as shown in FIG. 8, same provide an undercut portion cooperating with the undercut edges of the guide rail 2E' circumferentially spaced therefrom, for holding the wear plates 7L' and 7R' securely against the interior face of the crossbar 2A', even when such wear plates 7L' and 7R' are being replaced by moving axially through the beater mill. Circumferentially flanking the above-discussed structure are fixed wear plates 48 secured, for example by means of screws 49, to crossbars 2AF flanking the crossbar 2A'. Unlike in the FIGS. 1-7 embodiment, the crossbars 2A' and 2AF are not identical, but rather differ in cross section depending on their location with respect to the sandwiches 43L and 43R. It will be further understood that the circumferential segment of the apparatus shown in FIG. 8 will normally be repeated several times along the circumference of the crushing path 2'.
Assuming the next circumferential repetition of the FIG. 8 structure (left and right sandwiches 43L and 43R and intervening wear plates 7L' and 7R') is spaced far enough away circumferentially, individual magazines, substantially of the kind discussed above with respect to FIG. 5, may be provided for each of the sandwiches 43L and 43R and wear plates 7L' and 7R' and may be fixedly mounted on the end wall of the housing. Indeed, some magazines may be mounted on one housing end wall and some on the other to avoid crowding. Care must be taken to avoid interference between the bracket structure of a magazine and an entry or exit slot for the adjacent one of the sandwiches or wear plates.
As one alternative, the magazines may be rotated on a rotating disc like that illustrated in FIG. 1, so that only one or two magazines need be provided for each of the replaceable members 43L, 7L', 7R' and 43R, with the disc being rotatably advanceable to new circumferential locations along the path 2', as in FIGS. 1 and 2.
As a second alternative, the sandwiches 43L and 43R each may be lengthened to several times the axial width of the housing 1A and may be gradually or periodically (a length portion at a time) advanced axially through the path 2' without the use of a magazine unit 9. Such advancement may be manual or by suitable mechanical means such as a lengthened magazine unit 9 without a magazine 9B.
Obviously the slots in the housing end wall (and in the rotating disc if provided) must be thicker for the sandwiches 43L and 43R than for the wear plates 7L' and 7R'.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
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Method and apparatus for the manufacture of chips from mineral, vegetable or embrittled materials. In the method the stationary wear plates and striking plates when worn from use are replaced during ball mill operation either continuously or periodically, either with or without pressure plates for the striking bars, and with different feeding speeds. The advance, or feeding, of these plates occurs in a time-dependent and/or energy consumption dependent manner. The apparatus includes a conventional beater mill equipped with a vertical or horizontal rotating beater wheel which has arranged on one or both sides of the stationary crushing path several magazines for storing wear plates and striking bars. The replacement of the wear plates and the striking bars is done by suitably constructed slide members.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Provisional Application No. 60/888,147 filed on Feb. 5, 2007 in the United States Patent and Trademark Office, the contents of which are herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present disclosure relates to image processing, and more particularly to a system and method for segmenting and counting cells in a microscopic image.
2. Description of Related Art
Images of cells available from 2D and 3D microscopy (and other sources) are increasingly commonplace. For many different applications it is important to analyze the images by segmenting the cells in an image from the background and each other. This segmentation is often a precursor to cell counting or classification (via cell shape, color, etc.) that may be used to answer a variety of diagnostic questions. There are a number of software packages available on the market to perform automatic cell count, however these packages are highly specialized towards a specific type of microscopic images and do now allow further analyses. Furthermore, many of them require additional hardware equipment and installation, and may be quite expensive. Examples of such software include MACE (Mammalian Cell Colony Analysis—Weiss Associates), Bio-Optics Corp., Guava Technologies, Nexcelom Bioscience, New-Brunswick Scientific, Dako Corp, QM Solutions, Partec Corp, Synoptics Inc, and others.
Therefore, a need exists for generalized method for image segmentation of microscopic images.
SUMMARY OF THE INVENTION
According to an embodiment of the present disclosure, a computer implemented method for differentiating between elements of an image and a background includes inputting an image comprising pixels forming a view of the elements and a background, providing a model for assigning a probability of belonging to a predefined class to each of the pixels, assigning a probability to each of the pixels of belonging to the predefined class, labeling each of the pixels according to a corresponding probability and a predefined threshold, determining boundaries between groups of like-labeled pixels, and outputting a visualization of the boundaries.
According to an embodiment of the present disclosure, a system for differentiating between elements of an image and a background includes a memory device storing a dataset comprising image data comprising pixels forming a view of the elements of the image and a plurality of instructions embodying the system for differentiating between the elements of the image and the background and a processor for receiving the dataset and executing the plurality of instructions to perform a method comprising, providing a model for assigning a probability of belonging to a predefined class to each of the pixels, assigning a probability to each of the pixels of belonging to the predefined class, labeling each of the pixels according to a corresponding probability and a predefined threshold, determining boundaries between groups of like-labeled pixels, and outputting a visualization of the boundaries.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will be described below in more detail, with reference to the accompanying drawings:
FIG. 1 is a flow chart of a method for cell differentiation according to an embodiment of the present disclosure;
FIGS. 2A-B are an input image and a segmentation results according to an embodiment of the present disclosure; and
FIG. 3 is a diagram of a computer system for executing computer readable code embodying instructions for cell differentiation according to an embodiment of the present disclosure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
According to an embodiment of the present disclosure, a system and method perform cell differentiation and segmentation includes. The method can be applied to both 2D and 3D microscopic cell images, and to a variety of cell types. The method can be extended to 4D where time is an additional parameter, such as in live microscopy or acquiring images in time to track the evolution of certain types of cells. The method enables different types of analyses including counting of cells, identifying structures inside the cells (e.g. existence and shape of nucleus), morphometric analysis of cells (e.g., for shape change assessment and shape analysis), cell surface, volume measurements, color change assessment (e.g. in fluorescence imaging), etc.
Referring to FIG. 1 , a method for cell differentiation and segmentation includes obtaining a color/intensity model for the cells 101 - 102 , using the model as a set of priors for the random walker segmentation algorithm, segment “cell” pixels from “background” pixels 103 , and for each connected component of “cell” pixels, an isoperimetric segmentation algorithm to divide the component into constituent cells 104 - 105 .
Referring to obtaining a color/intensity model for the cells 101 , various methods exists to produce an appearance model for the cells. An appearance model assigns a probability p i to each pixel v i that represents the likelihood that the color/intensity associated with the pixel belongs to the cell class. One exemplary method for obtaining a mapping from color/intensity to probability is via kernel estimation (Parzen windowing), given a set of pre-labeled training samples of pixels belonging to the cell.
Given a small set of training examples for the category “cell”, a model is built that assigns a probability of each pixel intensity/color to belong to class “cell” 102 . Probabilities near unity are mapped to white and probabilities near zero are mapped to black (different mappings may be implemented).
Referring to the segmentation of cell clusters 103 ; the appearance model is sufficient to roughly classify pixels into “cell” and “background”. Since the model is based purely on the intensity associated with each pixel, and not its context amongst neighbors, this model alone is susceptible to noise. To overcome this problem with noise, the learned probabilities are used as priors for a random walker to refine the label of each pixel as either “cell”, or “background” 103 . The solution is robust to noise and each pixel is labeled as “cell” or “background”. A weighting function employed for the graph in this example may be written as
w ij =exp−β(∥ I i −I j ∥) 2 (1)
where I i , represents the color at pixel v i , β is a free parameter and ∥•∥ indicates the norm of the color vector. Any measure of affinity to assign weights (e.g., color, probability difference, texture gradient, etc.) could equally be applied here.
After employing the probabilities in the building of the model 101 as the probabilities for a random walker segmentation algorithm 103 , a labeling is obtained for each pixel as either “cell” or “background”. Lines indicate the boundaries between regions labeled as “cell” or “background”. Note that, although the labelings are correct on a pixel level, the cells are still merged and therefore need additional processing in order to differentiate individual cells.
An exemplary random walker starts on an image that contains a number of seed pixels indicating the object to segment. Given a random walker starting at every other pixel, the probability that the random walker reaches one of the seeded pixels is determined. The probability that a random walker travels into a particular direction is determined by the image structure. The change in pixel intensity is a measure for the probability by which a random walker crosses over to a neighboring pixel. Therefore, there is a high likelihood for a random walker to move inside the segmented object, but a relatively low likelihood to cross the object's boundary. By multiplying probabilities determined along the paths from pixels to seed points yields a probability distribution representing a non-binary segmentation.
Referring to the differentiation of cell clusters 104 - 105 ; although the output of the labeling step 103 gives labels for each pixel to belong to “cell” or “background”, the method further differentiates each pixel labeled “cell” with a label indicating “cell 1 ”, “cell 2 ”, etc 104 . For this purpose, a isoperimetric graph partitioning technique is sequentially applied to divide clusters until the isoperimetric ratio of the proposed division is too large to accept, represented by a threshold. In this stage the same weighting function (1) from 103 was reused.
An exemplary implementation of the isoperimetric ratio is determined as the ratio between a boundary and a volume of a given set, S, denoted by h(S). The isoperimetric sets for a graph, G (a graph is a pair G=(V,E) with vertices (nodes) vεV and edges eεEεV×V), are any sets S and S for which h(S)=h G . The specification of a set satisfying the volume constraint,
Vol S = ∑ i d i ∀ v i ∈ S
together with its complement may be considered as a partition. The boundary of the set, S, is defined as ∂S={e ij |v i εS,v j ,ε S }, where S denotes the set complement, and
∂ S = ∑ c i , j ∈ ∂ S w ( e ij ) .
An edge, e, spanning two vertices, v i and v j , is denoted by e ij . The partitioning maximizes Vol s while minimizing |∂S|.
The cell segments may be further post-processed to eliminate small or otherwise undesirable (i.e., mislabeled) cells. In this example, any cells with a size below a predefined threshold were relabeled as “background”. The threshold may be set according to a type of cell being imaged, for example, a certain type of cell may have a known size range, which may be used to put upper and lower limits on a differentiation of cells from background. In a similar fashion, any segmented cells for which the percentage of cells with high probability to be cell (from 101 ) were also reassigned to the background. For particular applications, the post-processing could also re-label some cells as background if they failed other criteria for a cell of interest, such as color, shape, presence of internal structures, etc.
FIG. 2A shows an exemplary input image while FIG. 2B shows a corresponding segmentation results. The lines 200 in FIG. 2B indicate the borders between neighboring cells, e.g., 201 or between cells and the background, e.g., 202 . Given these segmentations, information about cell color, shape and number is trivial to extract.
The analysis of digital microscopy images for cell counting and many other applications includes solving the problem of segmenting the individual cells. An exemplary method employs segmentation techniques in sequential processing steps to accomplish the cell segmentation.
It is to be understood that the present invention may be implemented in various forms of hardware, software, firmware, special purpose processors, or a combination thereof. In one embodiment, the present invention may be implemented in software as an application program tangibly embodied on a program storage device. The application program may be uploaded to, and executed by, a machine comprising any suitable architecture.
Referring to FIG. 3 , according to an embodiment of the present invention, a computer system 301 for segmenting and counting cells in a microscopic image can comprise, inter alia, a central processing unit (CPU) 302 , a memory 303 and an input/output (I/O) interface 304 . The computer system 301 is generally coupled through the I/O interface 304 to a display 305 and various input devices 106 such as a mouse and keyboard. The support circuits can include circuits such as cache, power supplies, clock circuits, and a communications bus. The memory 303 can include random access memory (RAM), read only memory (ROM), disk drive, tape drive, etc., or a combination thereof. The present invention can be implemented as a routine 307 that is stored in memory 303 and executed by the CPU 302 to process the signal from the signal source 308 . As such, the computer system 101 is a general purpose computer system that becomes a specific purpose computer system when executing the routine 307 of the present invention.
The computer platform 301 also includes an operating system and micro instruction code. The various processes and functions described herein may either be part of the micro instruction code or part of the application program (or a combination thereof) which is executed via the operating system. In addition, various other peripheral devices may be connected to the computer platform such as an additional data storage device and a printing device.
It is to be further understood that, because some of the constituent system components and method steps depicted in the accompanying figures may be implemented in software, the actual connections between the system components (or the process steps) may differ depending upon the manner in which the present invention is programmed. Given the teachings of the present invention provided herein, one of ordinary skill in the related art will be able to contemplate these and similar implementations or configurations of the present invention.
Having described embodiments for segmenting and counting cells in a microscopic image, it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in embodiments of the present disclosure that are within the scope and spirit thereof.
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A computer implemented method for differentiating between elements of an image and a background includes inputting an image comprising pixels forming a view of the elements and a background, providing a model for assigning a probability of belonging to a predefined class to each of the pixels, assigning a probability to each of the pixels of belonging to the predefined class, labeling each of the pixels according to a corresponding probability and a predefined threshold, determining boundaries between groups of like-labeled pixels, and outputting a visualization of the boundaries.
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BACKGROUND OF THE INVENTION
The present invention relates to the direct inspection of castings as they emerge from a machine for continuous casting, such an inspection to be carried out under conditions of exposure of heat emanating from the barely solidifying casting.
In the past, visual inspection of a casting by experienced personnel has been the common practice. The same is true with regard to solidified casting ingots; however, other inspection methods of cold ingots involve utilization of ultrasonics, magnetic fields as they are varied by defects, chemical effects, or other metal checks. Not only does the ingot so inspected have to be cold (relatively speaking, the temperature should be lower than approximately 300° C.), but the test piece should be stationary.
German printed patent application No. 29 11 578 discloses a system for optical inspection of a casting, using a supplemental light source and detecting particular reflection features which can be attributed to surface defects.
DESCRIPTION OF THE INVENTION
It is an object of the present invention to detect surface features of a casting for purposes of early recognition of surface defects, under consideration of the surface geometry. The detection equipment should be amenable to inspection of castings of different diameters and different cross sections.
It is a feature of the present invention to directly utilize the thermal radiation that emanates from a casting, and it is a related feature that a line scan camera e.g. a linear array of radiation-sensitive diodes be used responding e.g. to radiation that emanates at temperatures of higher than 500° C.
In accordance with the preferred embodiment of the present invention, an annular or ring-shaped housing surrounds the casting; and its wall which faces the casting is provided with an annular gap; the gap is covered with suitable sheet means which revolve about the common axis. The sheet itself has a narrow gap behind which is located the line scan camera. Sheet and camera are driven in order to revolve inside the housing about their common axis to thereby inspect the surface of the casting along a, basically, helical scanning band. The housing is water-cooled, whereby for reasons of safety several independant water-cooling systems are employed. The tubing for the cooling system actually establishes the houses.
The housing is of a two-part configuration, the gap does separate the two parts. Preferably, the lower one has a U-shaped profile, the upper part is annularly flat and covers the U. Oblique lamellas should be provided in the housing, penetrating into its interior to the extent permitted by the revolving camera in order to provide a more uniform temperature in the housing.
A counterweight may be provided opposite the camera, along a diagonal line. However, one may even provide here a second camera, whereby the two scanning lines are inclined to each other at a 90° angle, each line being oblique to the central axis. In other words, the two scanning-line arrays operate along orthogonal scanning lines. This permits each scan to traverse any defect boundary from different directions so that a defect will certainly be scanned at least once, more or less transverse to its boundaries!
The revolving speed, length of the scanning strip for each line, and the speed of the casting should be selected so that adjacent "loops" of the scanning band overlap by at least 5%, possibly even as much as 50%, in order to obtain some redundancy for reason of certainty of detection. In the case of a square-shaped casting, care must be taken that the resolution of inspection does not suffer on account of the variation in a relative scanning angle. This, in effect, limits the scanning speed.
DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims, particularly pointing out and distinctly claiming the subject matter which is regarded as the invention, it is believed that the invention, the objects and features of the invention, and further objects, features and advantages thereof, will be better understood from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a schematic overview of a machine for continuous casting, improved in accordance with the preferred embodiment of the invention for practicing the best mode thereof;
FIG. 2 is a cross section through a first example of the preferred embodiment as applied for inspecting a round casting;
FIG. 3 is a schematic illustration of the inspection and evaluation process as applied to a round casting under utilization of the device shown in FIG. 2;
FIG. 4 illustrates, in an elevational view, the application of the same equipment to a casting (in cross section) with square-shaped cross section;
FIG. 5a is a similar view but for a round casting and showing certain details;
FIG. 5b is a section view along line A and B in FIG. 5a; and
FIGS. 6a, 6b, and 6c are cross sections of three different sheet profiles covering the housing gap that faces the casting.
Proceeding now to the detailed description of the drawings, FIG. 1 shows a casting ladle 16 cooperating with a tundish 17 serving as a buffer and distributor; particularly, for pouring molten steel at a regular rate into a mold 18. The mold may be of a curved configuration so that a curved casting 3 is formed directly and emerges from the open bottom of the mold. Support and withdrawal rolls 19 veer the casting into the horizontal. The frame and stand and other supporting equipment are sketched in only because they are quite conventional.
Reference numeral 20 refers to the inventive inspection equipment. It was found suitable to place it just ahead of the horizontal casting path. The station 20 is obliquely oriented as the casting is to traverse the plane of extension of station 20 at right angles. Thus, the orientation of casting 3 in the vertical, as per FIG. 2, is for purposes of illustration only, and it is understood that the true vertical in FIG. 2 would point into the 2-o'clock position.
On the other hand, it should be noted that the preferred mode of practicing the invention is to place the inspection station as close to the mold as possible because early recognition of surface defects may permit intervention in the casting process for avoiding the production of long defective castings. It is believed, at this time, that the inspection equipment can be shifted somewhat upward, but steam development of extensive external surface cooling is an impediment against optical type of inspection.
The casting 3 is surrounded by a ring-shaped housing 1, which is comprised of two parts (1' and 1") and includes a water-cooling system. Tubes 13 and 14 of rectangular cross sections run around and in the outer periphery of the housing parts to establish several cooling systems. Upper and lower housing parts do each have two cooling systems, whereby the tubes of the respective two systems are tightly interconnected and welded. In fact, these welded-together systems of tubings establish by themselves the housing parts.
The upper housing part 1' has two water inlets 9 and 9' for its two cooling systems, and there are two corresponding outlets 11 and 11' in diametrically opposed positions. The lower housing part 1" has correspondingly two inlets 12 and 12' for its two cooling systems, there being two outlets 10 and 10' accordingly. It can be seen that the two particularly identified tubes (13 and 14) pertain to different cooling systems for housing part 1".
The two housing parts are physically separated in a center joint 2 which, however, is closed, and in an inner joint which is constructed as a rather wide annular gap 4. One can also say that the inwardly directed wall of the enclosure has this annular gap facing concentrically casting 3.
This annular gap 4 is closed (except, where stated below) by an annular sheet having flange portions 5' and 5". This sheet 5 can be shifted, i.e., it may revolve about the central axis of the ring-shaped housing construction. Sheet 5 has a narrow gap 6, having its long dimension extend parallel to the direction of casting i.e., of movement of casting 3. A camera 15 is provided to observe and inspect the casting through that narrow gap.
FIG. 6 shows other versions and modifications of the sheet 5. Generally speaking, this sheet protects the interior of the housing against heat, water, and dirt. The sheet 5 is, in addition, provided with an annular ring gear 7, and a pinion on a shaft of a motor 8 engages that gear, causing sheet and camera to rotate on the central axis so that the camera is progressively oriented toward different portions of the casting 3. The motor 8 should be controlled toward a constant speed, selected as will be described more fully below. The drive is preferably an electric one, but a hydraulic drive or a pneumatic drive may be used instead. In either case, the drive should be stationary.
In FIG. 6a, the sheet has an upward flaring portion 5a and a downward extension 5b. Thus, the sheet portion 5a extends on the inside of housing part 1' and portion 5b extends generally on the inner outside of housing part 1"; the major portion of the sheet extends in approximately the middle of gap 4. Portion 5b includes a radially inward-angled and downward-flaring part from which a cylindrical portion extends to run adjacent to the inner wall of housing part 1".
The particular sheet is releasably fastened to a rotatable frame 21 which is articulated on an annular rail of the housing part 1" in a manner that permits the frame to run on this circular rail track while the camera can be swiveled up or down for proper orientation. The camera 15 is likewise affixed to frame 21 and can be turned on the center axis of the system in order to inspect casting 3 from all sides, through the gap 6 in sheet 5, as was described with reference to drive 8. Thus, the sheet 5 is, in all these instances, provided with an annular gear track.
The sheet 5 is slightly differently contoured in the example of FIG. 6b. Moreover, a shield 22 (with a narrow gap for the optical camera input) is provided in front of sheet 5, on the inside of the central space defined by the ring-shaped housing. This shield offers additional heat protection, particularly against the still rather intense thermal radiation that emanates from the casting 3.
The particular shield structure of FIGS. 6a and 6b are suitable mostly for a disposition of the inspection station along a more vertical portion of the casting;
FIG. 6c shows a configuration that is preferred for a disposition along a more horizontal portion of the casting (such as in FIG. 1). In this particular case, sheet 5c actually covers the entire outside of the radially inward-oriented wall of the housing and has additional, radial, outward flange extensions 5d. A second portion of this shielding arrangement (5e) runs in gap 4.
In all versions, a funnel-shaped element 23 in front of camera 15 is directed toward the casting and provides additional protection for the camera.
FIGS. 5a and 5b illustrate additionally lamellas 24 as being arranged along the outer inside wall of housing portion 1". The lamellas extend close to the track path of camera 15. These lamellas extend the effect of cooling much into the housing interior as possible.
After having described the equipment as to its general layout, reference is made first to the camera 15. This camera is a vertical line scan camera, having as an optical input element, for instance, a vertically oriented linear array of diodes which are sequentially electronically scanned. This way, a particular portion of casting 3 is monitored in each instance. Assuming the camera to be stationary, then an axial strip will be progressively scanned with each run, the width of the strip depending upon the area monitored by each diode in the said array. The azimuthal width of that strip being scanned as well as its axial length depend also upon the optics of the camera.
If the camera rotates, that strip being scanned in one scanning run assumes a slightly oblique position on the moving casting; and upon rotation of the camera under continuous repetition of the line scan, that strip develops into a helical scanning band. Clearly, the (axial) progression of the casting through the equipment should be such that, upon one complete revolution of the camera, the casting has progressed by not more (preferably less) than the axial length of the scanning strip. The helical band overlap should be at least 5%, possibly as much as 50%.
FIG. 3 illustrates a scanning spot 30 which is, in fact, the particular incremental area observed by the one diode in camera 15, being interrogated internally in that instant. The vertical line scan "moves" that spot 30 along a vertical line 31, and upon rotation of the camera, the scanning band 32 results.
The camera may be connected to an oscilloscope, in which one line of scanning is displayed over the horizontal, the vertical being the amplitude of the radiation received and detected. Three different, spaced-apart scanning strips "1", "2", and "3" are depicted on the casting 3 (the spot 30 is on strip "2" (=31) in this instant. The image intensity for the strips "1" and "3" will be approximately the same; but due to surface crack 33, strip "2" exhibits a different pattern of emanated radiation.
The line scan and input signals of the camera may also be fed, in digitized form, to a processor 40 which may control an alarm device 41 if a defect is detected. The processor 40 may also control a strip printer 42 on a running basis. In fact then, FIG. 3 shows three versions of monitoring the surface, two serving directly for visual inspection, and the alarm device catches any otherwise undetected surface defects.
It will be apparent that the regular inspection of the surface of a casting is facilitated when the casting is, indeed, circularly round. The situation is somewhat more complicated when the casting is of quadrilateral cross-sections, e.g., square-shaped as shown in FIG. 4. In order to ensure an adequate resolution, the angular velocity (dφ/dt) of the camera (radius of rotation=R) must be particularly related to the maximum permissable speed of surface scanning (ds/dt) max , taken in the direction of rotation. The maximum surface scanning speed is related directly to the radius r, being half the diagonal of the square. The relation is: dφ/dt≦(ds/dt) max .
Another aspect to be considered is the possibility of a second camera in diagonally opposed disposition. This establishes a redundancy, but serves an additional purpose. In the case of two cameras, their respective scanning lines should be orthogonal to each other, each at an angle of 45° to the axis. This ensures that any defect will at least once be traversed by a scan that runs, more or less, transversely across a boundary to thereby produce a noticeable drop in the radiation received. Defect recognition is easier, in comparison with a situation in which the scan runs, more or less, parallel to such a defect boundary.
The invention is not limited to the embodiments described above; but all changes and modifications thereof, not constituting departures from the spirit and scope of the invention, are intended to be included.
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A hot casting, freshly emerging from the mold, is inspected for any surface defects by a revolving line scan camera; the camera is disposed in an annular water-cooled, two-part housing having an inwardly directed annular gap covered by a sheet that revolves with the camera; the camera can look through a small gap of that sheet.
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CLAIM OF PRIORITY
[0001] This patent application claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 61/089,763, entitled CERVICAL DILATION METER, (Attorney Docket No. 2872.001PRV), filed on Aug. 18, 2008, which is hereby incorporated by reference herein in its entirety.
BACKGROUND
[0002] The cervix is the portion of the uterus connecting the uterus to the vagina. The cervix is cylindrical or conical in shape, approximately one inch in length, and having a cervical canal passing through it with an external os opening to the vaginal cavity and internal os opening to the uterine cavity. During labor and delivery, the cervical canal is the channel through which the baby passes from the uterine cavity into the vaginal cavity. During labor, the position (station) of the cervix rotates from posterior to anterior
[0003] During labor, in response to coordinated uterine contractions and pressure created by the descending fetal head, the length of the cervix shortens and the cervical walls thin in a process known as “effacement”, and the cervix opens further or dilates. Effacement can be quantified in percentage, from 0% (no change) to 100% (completely thinned). Cervical dilation can be quantified as the diameter of the cervical opening, e.g., in centimeters ranging from zero (0) to ten (10) centimeters. When the cervix dilates to ten (10) centimeters or greater, the cervical dilation can be deemed complete, and the patient can be encouraged to push the baby out. Before effacement and complete dilation, patients are encouraged not to push due to the risk of injury to both mother and baby. Effacement and dilation are critical indicators of the progress, or lack of progress, of labor. The degree and rate of effacement and dilation are monitored periodically during the first stage of labor. Slow or inadequate cervical dilation may indicate the need for administering a cervical ripening drug or applying a cervical dilating instruments or the need for surgical delivery.
[0004] A digital palpation is currently the standard procedure clinicians (physician, nurse, mid-wife, etc.) use to measure the cervical diameter. In digital examination, the clinician inserts a gloved hand into the vagina and uses the middle and index fingers to palpate or probe the cervix and external cervical os. The fingertips palpate and locate the external cervical os and are then spread until the fingertips contact opposing walls of the cervix. The distance between the spread fingertips corresponds to the cervical diameter. Using the digital palpation approach, the degree of dilation of the cervical os is estimated without any means to confirm visually the spacing between the index and middle fingers while situated within the cervical os.
[0005] During the course of labor in a patient, one or more clinicians perform, on average, ten digital examinations. However, digital examination provides only intermittent data for assessment of labor progression. Furthermore, the accuracy of digital examination is very subjective and may depend upon many factors, including the experience, judgment, and the size of the clinician's fingers, and error caused by the stretching of the cervix by the clinician's fingers. Although an individual clinician may achieve acceptable repeatability and accuracy using this method, it is normal to see a one (1) centimeter error or variation in measurement among serial measurements by the same clinician. If different clinicians examine the same patient during the course of labor, the inaccuracy of cervical dilation measurements increases due to inter-clinician variability.
[0006] Inaccurate or inconsistent measurements of cervical dilation may hinder the early detection of dysfunctional labor or delivery complications. Furthermore, despite the use of gloves, digital examination increases the risk of infection of the fetal membranes (chorioamnionitis), the lining and/or muscle of the uterus (endomyometritis), or of the infant (neonatal sepsis). This risk increases significantly after the fetal membranes have ruptured, and the risk of infection correlates to the number of digital exams. For this reason, it is preferable to minimize the number of digital exams, particularly after the fetal membranes have ruptured. Other disadvantages of digital examination measurements to determine cervical dilation include the inability to monitor dilation continuously, the procedure may dislodge fetal or uterine monitors, and the procedure is embarrassing and causes even more discomfort to the mother who is already experiencing significant pain due to labor.
[0007] Various mechanical and electrical systems have been devised to measure cervical dilation. See, e.g., Cervimetry: A Review of Methods for Measuring Cervical Dilation During Labor , Obstetrics & Gynecology Survey, Vol. 55(5): 312-320 (2000); see also, e.g., Sharf Y, Farine D. et al., Continuous Monitoring of Cervical Dilation and Fetal Head Station During Labor , Medical Engineering & Physics 29: 61-71 (2007). See also, e.g., the following U.S. patent Nos. and U.S. patent application Publication Nos.: U.S. Pat. Nos. 2,924,220; 3,768,459; 4,141,345; 4,207,902; 4,245,656; 4,476,871; 4,611,603; 4,682,609; 4,719,925; 5,222,485; 5,450,857; 5,658,295; 5,713,371; 5,935,061; 6,039,701; 6,066,104; 6,200,279; 6,270,458; 6,383,137; 6,419,646; 6,423,000; 6,423,016; 6,524,259; 6,540,977; 6,669,653; 6,802,917; 6,966,881; 6,994,678; 7,150,108; 7,207,941; US 2005/0049509; US 2006/0020230; US 2007/0156067; US 2007/0156068; US 2007/0179410; US 2007/0179410; US 2007/0213640; US 2008/0021350; and also PCT Patent Application Publications WO 1987/03189; WO 2000/051494; WO 2004/098375; WO 2004/00373.
SUMMARY/OVERVIEW
[0008] The present inventors have recognized, among other things, that, unfortunately, none of the above-mentioned methods or devices have gained commercial acceptance for many reasons, including: patient discomfort and cervical tissue trauma due to attachment, penetration or active fixation engagement of the device to the cervical tissue (e.g., by needles, barbs, hooks, clamps, grips, or sutures); lack of accuracy due to cervical tissue distortion; inability to isolate measurement of cervical os dilation from measurement of changes in the station or movement of cervix during the progression of labor; blockage of the cervical canal (thus inhibiting descent of the fetal head and monitoring of fetal status and labor progression by known monitoring devices); complexity of the device or its installation; lack of disposability (thus high cost or a need to sterilize the device for later reuse in the patient); radiation, ultrasonic and electrical shock hazards; and unsuitability for patient ambulation or home use. Consequently, the present inventors have recognized and believe that there is currently no commercially available simple, objective mechanical monitoring device or system to measure cervical diameter, and digital examination continues to be the preferred method for measuring cervical diameter and dilation.
[0009] Thus, the present inventors have recognized, among other things, the usefulness of an objective monitoring device that can accurately measure cervical dilation, that can differentiate cervical dilation from change in cervical station, that need not be invasive (need not penetrate tissue by barbs, needles, clips, sutures, or other invasive means) and need not grip, clamp or compress the cervix or otherwise distort the cervix. The present inventors have also recognized the usefulness of a device to monitor cervical dilation that can be placed and retained in the patient throughout the first stage of labor, thereby allowing continuous or ongoing monitoring of cervical dilation. The present inventors have also recognized the usefulness of a device for measuring cervical dilation that can remain in place in the patient without obstructing descent of the fetal head (which can inhibit delivery) and that can easily be displaced or expelled from the patient, such as by the natural progression of labor, without requiring manual removal by the clinician. The present inventors have also recognized the usefulness of a device that has a measurement scale that can be located outside the body and that can be simple enough to interpret that the patient or her family can directly monitor the patient's cervical dilation, without the need for clinician oversight. The present inventors have also recognized the usefulness of a cervical dilation monitoring device that can permit the patient to remain ambulatory while the device is in place. In certain examples, the present devices and methods can provide one or more of such useful characteristics in monitoring cervical dilation. To better illustrate the subject matter described herein, a non-limiting list of examples follows.
[0010] Example 1 describes an apparatus comprising first and second arms, comprising respective proximal and distal portions, the proximal portions of the first and second arms coupled together, the distal portions of the first and second arms configured to be inserted between, and to exert enough of an outward force against, opposing lateral walls of a cervix or vagina to hold the apparatus in position, while measuring cervical dilation, without requiring active fixation to the cervix or vagina. In this example, a cervical dilation gauge assembly, communicatively coupled to the first and second arms to receive information about the cervical dilation, and comprising an external cervical dilation indicator to provide an indication of the cervical dilation to a user.
[0011] In Example 2, the apparatus of Example 1 is optionally configured such that an intermediate region of the first arm comprises an outwardly bowed first cephalic curve, and wherein an intermediate region of the second arm comprises an outwardly bowed second cephalic curve, and wherein concave portions of the first and second cephalic curves are opposing each other.
[0012] In Example 3, the apparatus of any one or any combination of Examples 1-2 is optionally configured such that the concave portions of the first and second cephalic curves are sized and shaped to receive and accommodate a fetal head therebetween.
[0013] In Example 4, the apparatus of any one or any combination of Examples 1-3 is optionally configured such that the concave portions of the first and second cephalic curves are sized and shaped to receive a descending fetal head therebetween during birthing while the first and second arms continue to exert enough of an outward force against opposing lateral walls of a cervix or vagina to hold the apparatus in position while measuring cervical dilation without requiring active fixation to the cervix or vagina.
[0014] In Example 5, the apparatus of any one or any combination of Examples 1-4 is optionally configured such that the first and second arms comprise respective first and second pelvic curves at or near a location between the intermediate and proximal portions of the respective first and second arms, such that the respective intermediate portions of the respective first and second arms angle or curve upward from the respective proximal portions of the respective first and second arms at an angle that is about 15 degrees to allow placement of the apparatus if the cervix is in a mid or anterior position.
[0015] In Example 6, the apparatus of any one or any combination of Examples 1-5 optionally comprises a spring, providing a force that is coupled to the first and second arms to bias the first and second arms away from each other.
[0016] In Example 7, the apparatus of any one or any combination of Examples 1-6 is optionally configured such that the spring is configured to exert enough of an outward force of the first and second arms against opposing lateral walls of the cervix or vagina to hold the apparatus in position while measuring cervical dilation without requiring active fixation to the cervix or vagina, and without exerting so much outward force so as to substantially affect the measuring of the cervical dilation.
[0017] In Example 8, the apparatus of any one or any combination of Examples 1-7 is optionally configured such that distal portions of the respective first and second arms respectively comprise first and second feet that are respectively coupled to respective intermediate portions of the respective first and second arms by respective first and second flexible members that are respectively more flexible than the respective first and second feet and the respective intermediate portions of the respective first and second arms, and wherein the respective first and second feet flex at respective angles, with respect to the respective first and second arms, in a plane formed by intermediate portions of the first and second arms.
[0018] In Example 9, the apparatus of any one or any combination of Examples 1-8 is optionally configured such that the first and second feet are respectively angled upward from a plane formed by the respective intermediate portions of the first and second arms by an angle that is about 30 degrees.
[0019] In Example 10, the apparatus of any one or any combination of Examples 1-9 is optionally configured such that the first and second feet respectively provide a surface area of at least about 2.0 cm 2 for contacting the cervix.
[0020] In Example 11, the apparatus of any one or any combination of Examples 1-10 optionally comprises a rotational pivot joint, coupling the proximal portions of the first and second arms together; and a spring, coupled to the first and second arms to exert an outward force to drive the first and second arms apart.
[0021] In Example 12, the apparatus of any one or any combination of Examples 1-11 optionally is configured such that the spring is located at a proximal end of a member extending from a location near or distal to the rotational pivot joint to a more proximal external location.
[0022] In Example 13, the apparatus of any one or any combination of Examples 1-12 is optionally configured such that the spring is located at the external location.
[0023] In Example 14, the apparatus of any one or any combination of Examples 1-13 is optionally configured such that the member comprises a cable.
[0024] In Example 15, the apparatus of any one or any combination of Examples 1-14 is optionally configured such that the member comprises a portion of a rack-and-pinion assembly.
[0025] In Example 16, the apparatus of any one or any combination of Examples 1-15 is optionally configured such that the spring is located at the rotational pivot joint.
[0026] In Example 17, the apparatus of any one or any combination of Examples 1-16 optionally comprises a stem including: a proximal portion coupled to the external indicator of cervical dilation; and a distal portion coupled to the proximal portion of at least one of the first and second arms.
[0027] In Example 18, the apparatus of any one or any combination of Examples 1-17 optionally comprises an introducer sheath, sized and shaped to constrain the first and second arms toward each other during insertion of the apparatus, and to permit removal of the sheath over the stem.
[0028] In Example 19, the apparatus of any one or any combination of Examples 1-18 optionally comprises a cable including a proximal portion coupled to the external indicator of cervical dilation, and a distal portion coupled to at least one of the first and second arms, and wherein the cable is constrained such that a position of a proximal end of the cable is correlative to the cervical dilation.
[0029] In Example 20, the apparatus of any one or any combination of Examples 1-19 optionally comprises a spring, coupled to a proximal end of the cable, the spring configured to tend to move the proximal end of the cable in a proximal direction to exert, via the cable, a force on at least one of the first and second arms to tend to move respective portions of the first and second arms apart.
[0030] Example 21 describes a method comprising: inserting first and second arms of a cervical dilation measuring apparatus into a vagina such that respective distal portions of the first and second arms exert enough of an outward force against, opposing lateral walls of a cervix or vagina to hold the apparatus in position, while measuring cervical dilation, without requiring active fixation to the cervix or vagina; communicating information about the cervical dilation to an external location; and providing an external indicator of the cervical dilation to a user, using the information.
[0031] In Example 22, the method of Example 21 optionally comprises inserting first and second arms comprising respective outwardly bowed cephalic curves, wherein concave portions of the respective cephalic curves oppose each other.
[0032] In Example 23, the method of any one or any combination of Examples 21-22 optionally comprises comprising receiving a fetal head between portions of the first and second arms.
[0033] In Example 24, the method of any one or any combination of Examples 21-23 optionally comprises receiving a fetal head between portions of the first and second arms during birthing while the first and second arms continue to exert enough of an outward force against opposing lateral walls of a cervix or vagina to hold the apparatus in position while measuring cervical dilation without requiring active fixation to the cervix or vagina.
[0034] In Example 25, the method of any one or any combination of Examples 21-24 optionally comprises placing the apparatus when the cervix is in a mid or anterior position such that respective intermediate portions of the respective first and second arms angle or curve upward from respective proximal portions of the respective first and second arms at an angle that is about 15 degrees.
[0035] In Example 26, the method of any one or any combination of Examples 21-25 optionally comprises exerting enough of an outward force of the first and second arms against opposing lateral walls of the cervix or vagina to hold the apparatus in position while measuring cervical dilation without requiring active fixation to the cervix or vagina, and without exerting so much outward force so as to substantially affect the measuring of the cervical dilation.
[0036] In Example 27, the method of any one or any combination of Examples 21-26 optionally comprises inserting into a cervical os first and second feet at respective distal portions of the first and second arms, such that the first and second feet flex at an angle, with respect to the respective first and second arms, in a plane formed by intermediate portions of the first and second arms.
[0037] In Example 28, the method of any one or any combination of Examples 21-27 optionally comprises inserting into the cervical os the substantially flat first and second feet at respective distal portions of the first and second arms, such that the first and second feet are angled upward with respect to the plane formed by the intermediate portions of the first and second arms.
[0038] In Example 29, the method of any one or any combination of Examples 21-28 optionally is performed such that communicating information about a cervical dilation to an external location comprises receiving the information using a longitudinal position translation correlative to a degree of pivoting of intercoupled proximal portions of the first and second arms.
[0039] In Example 30, the method of any one or any combination of Examples 21-29 optionally is performed such that using a longitudinal position translation correlative to a degree of pivoting of intercoupled proximal portions of the first and second arms comprises using at least one of: a position of a rack in a rack-and-pinion; or a position of a proximal end of a member, wherein the member is constrained such that the proximal end of the member represents the degree of pivoting.
[0040] This overview is intended to provide an overview of the subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The detailed description is included to provide further information about the present patent application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
[0042] FIG. 1 illustrates an isometric drawing of an example of portions of a cervical dilation meter apparatus.
[0043] FIG. 2 illustrates a top view of an example of portions of the cervical dilation meter, the arms of which can be drawn together into a closed position for insertion.
[0044] FIG. 3 illustrates a side view of an example of portions of the cervical dilation meter.
[0045] FIG. 4 illustrates an isometric view of an example of the arms, including an example of the pivot joint.
[0046] FIG. 5 illustrates a top view of the example of the arms, including an example of the pivot joint.
[0047] FIG. 6 illustrates a side view of the example of the arms, including an example of the pivot joint.
[0048] FIG. 7 illustrates a front view of the example of the arms, including an example of the pivot joint.
[0049] FIG. 8 illustrates a front view of the example of the arms, including an example of the pivot joint.
[0050] FIG. 9 illustrates an isometric view of an example of an arm and, at its proximal portion, a pivot joint.
[0051] FIG. 10 is a schematic illustration of an example of a dilation meter, in which the stem can be hollow or otherwise configured to guide a rod that extends longitudinally along a length of the stem.
[0052] FIG. 11 is an exploded view of an example of portions of the apparatus in which a flexible string or cable can be used (e.g., instead of the rod) to communicate the cervical dilation information from the arms to an external gauge.
[0053] FIG. 12 is an exploded view of an example of portions of the apparatus in which a rack-and-pinion configuration of the pivot can be used (e.g., instead of a rod or a flexible string or cable) to communicate the cervical dilation information from the arms to an external gauge assembly.
[0054] FIG. 13 is an exploded view of an example of portions of the apparatus in which a tension cable can be used to communicate a force, such as to bias the arms away from each other.
[0055] FIG. 14 is an example of portions of the apparatus in which a dial gauge can be provided and coupled via a cable within a flexible sheath to a receptacle of a pivot joint from which the arms extend.
[0056] FIG. 15 is a schematic diagram corresponding to an example of the apparatus such as shown in the example of FIG. 14 .
DETAILED DESCRIPTION
[0057] FIG. 1 illustrates an isometric drawing of an example of portions of a cervical dilation meter 100 apparatus. In this example, the cervical dilation meter 100 can include arms 102 A-B, which can be drawn together into a closed position, such as for insertion. In an example, the arms 102 A-B can include respective proximal portions 103 A-B, intermediate portions 104 A-B, and distal portions 105 A-B, which can be configured such as shown in the example of FIG. 1 .
[0058] In an example, the proximal portions 103 A-B can be intercoupled to each other, such as at a pivot or other moving or flexing joint 110 . The joint 110 can be configured to hold the proximal portions 103 A-B close to each other while permitting the distal portions 105 A-B to be movably spread apart from each other. This can allow measuring of an amount of cervical dilation, such as when the distal portions 105 A-B are positioned within or beyond the cervical opening, for example, such that the distance between at least one of the distal portions 105 A-B, the intermediate portions 104 A-B, or the proximal portions 103 A-B represents the amount of cervical dilation. In an example, the cervical dilation meter 100 can include a cervical dilation gauge assembly 112 , which can include a stem 114 . The stem 114 can have a length (e.g., such as about 33 centimeters) that extends from its distal portion, such as at the joint 110 , to its proximal portion, which can include or be coupled to an external gauge. The external gauge can be configured to provide a user with a visual or other external indication of the amount of cervical dilation. This external indication can be based upon cervical dilation information that is communicated along the stem 114 , such as explained below.
[0059] In an example, the spreading apart of the distal portions 105 A-B of the arms 102 A-B results from providing a bias force that is communicated to the distal portions 105 A-B of the arms 102 A-B In an example, the cervical dilation meter 100 can be configured such that the bias force against the cervical or vaginal walls is enough to hold the cervical dilation meter 100 apparatus in place, with the distal portions 105 A-B in or beyond the cervical opening, such as to allow measuring of the amount of cervical dilation, but not such much as to significantly distort the dilation measurement. In an example, the cervical dilation meter 100 apparatus is held in place using the bias force and without requiring active fixation of such distal portions 105 A-B to the cervix. This means that attachment to the cervix by clipping to tissue or by penetrating tissue is not required. By not requiring active fixation, the present techniques can increase convenience and can reduce discomfort, tissue trauma, or risk of infection. Instead of using active fixation, the present techniques can provide an outward lateral force can cause the arms 102 A-B to be continuously engaged with vaginal walls or cervical walls. The lateral outward force is sufficient to overcome the inward lateral force exerted by the vaginal and cervical walls against the arms 102 A-B. Engagement of proximal portions of the arms 102 A-B with the vaginal walls, e.g., because of their shape, allows the internal portions of the cervical dilation meter 100 to be secured and retained within the body cavity, while engagement of the distal ends of the arms 102 A-B with the cervical walls allows the relative movement of the arms 102 A-B to measure cervical dilation without requiring the active fixation of invasive physical penetration, or attachment or gripping of cervical tissue (e.g., by needles, barbs, clamps, clips, grips).
[0060] In an example, the bias force can be provided at least in part by a spring 118 , such as can be located about a pin of a rotational pivot joint 110 , or located elsewhere. In an illustrative example, the spring 118 can have about six coils, an inner diameter of about 0.454 inches, an outer diameter of about 0.556 inches, a body length of about 0.39 inches, a wire diameter of about 0.051 inches, and can be wound around a mandrel having a mandrel diameter of about 0.36 inches, such available from Century Spring Corp. of Los Angeles, Calif., U.S.A. or Lee Spring Co. Other spring dimensions or configurations can be used, for example, such as can have between 5.0 and 8.0 coils, an inner diameter between about 0.2 inches and about 0.4 inches, an outer diameter between about 0.25 and 0.55 inches, a body length of about 0.18 and 0.4 inches, or other suitable dimensions or configurations.
[0061] However, neither a rotational pivot joint, or a spring is required. In an example, the bias force can be provided at least in part by a shape-memory property of the plastic or other material used for the arms 102 A-B, such as in an example in which the proximal ends of the arms 102 A-B can instead be joined together by a flexing joint 110 , such as in a manner like that of a tweezers or forceps. In another example, the bias force can be provide at least in part by a spring 122 , such as can be located along the stem 114 , such as at or near its proximal portion, or at or near its distal portion. In an illustrative example, the bias force can be communicated from a spring 122 at or near the proximal end of portion stem 114 to the arms 102 A-B, such as via an elongate member extending along the stem 114 . In an example, such an elongate member can include a cable or a rack (e.g., of a rack-and-pinion) or a shaft, such as explained below.
[0062] FIG. 2 illustrates a top view of an example of portions of the cervical dilation meter 100 , the arms 120 A-B of which can be drawn together into a closed position for insertion. As illustrated in the example of FIG. 2 , the bias force can be provided at least in part by the spring 118 , such as can be located about the pin 200 , such as with spring ends inserted into and retained by the respective arms 102 A-B. As can be observed by viewing the example of FIG. 2 , the bias force holding the apparatus in place need not be confined to the distal portions 105 A-B of the arms 102 A-B pressing against the internal walls of the cervix. In the example of FIGS. 1-2 , the intermediate portions of the arms 102 A-B can include outwardly bowed intermediate portions 104 A-B. These outward bows can be referred to as cephalic curves. In an example, the outward-facing convex sides of the outwardly bowed intermediate portions 104 A-B are shaped so that they can engage the respective opposing vaginal walls or proximal outer regions of the cervix, when inserted. This can help deliver a portion of the bias force to the respective vaginal walls or proximal outer regions of the cervix, which can help hold the cervical dilation meter 100 in place, such as while measuring the change in cervical dilation from zero (0) centimeters to ten (10) centimeters during early labor. In an example, the bowed cephalic curves of the intermediate portions 104 A-B can be sized and shaped to accommodate a descending fetal head between their opposing concave portions during birthing. In an example, the fetal head can be accommodated within the cephalic curves without dislodging the cervical dilation meter 100 , such as until the descending fetal head begins to push against the concave portions of the cephalic curves, which can then automatically dislodge the cervical dilation meter 100 without requiring any clinician or other user intervention. In another example, entry of the fetal head between the opposing concave portions of the cephalic curves during birthing automatically dislodges the cervical dilation meter 100 , without requiring any clinician or other user intervention.
[0063] In an example, the cephalic curves can respectively include a chordal length 202 (directly across) of about 3.5 cm. In an example, the cephalic curves can respectively include a curved or circumferential length of about 4.75 cm. In an example, the cephalic curves are bowed out by an amount that is between about 0.5 cm and about 1.0 cm from the chordal dimension.
[0064] FIG. 3 illustrates a side view of an example of portions of the cervical dilation meter 100 . In an example, the intermediate portions 104 A-B of the respective arms 102 A-B can respectively extend upward from a plane formed by the proximal portions 103 A-B of the respective arms 102 A-B, such as by an angle of about 15 degrees. This upward angle or curvature (which can be referred to as a pelvic curve) can help allow placement of the cervical dilation meter 100 even if the cervix is in a mid or anterior position.
[0065] In an example, the respective distal portions 105 A-B of the respective arms 102 A-B can extend upward from a plane formed by the intermediate portions 104 A-B of the respective arms 102 A-B, such as by an angle that is about 30 degrees. This upward angle can help allow the cervical dilation meter 100 to be placed such that the respective distal portions 105 A-B of the respective arms 102 A-B can be easily positioned in the cervical canal, just above the internal cervical os, below the fetal head.
[0066] FIG. 4 illustrates an isometric view, FIG. 5 illustrates a top view, FIG. 6 illustrates a side view, FIG. 7 illustrates a front view, and FIG. 8 illustrates a back view of an example of the arms 102 A-B, including an example of the pivot joint 110 , in which facing opposing-shell pivot joint housings 400 A-B can be used to carry the spring 118 and the pin 200 . In this example, one of the housings 400 A-B can be coupled to a snap-in receptacle 402 , which can extend outward from the housing 400 B, such as at an angle of about 20 degrees. A distal portion of the stem 114 can be inserted into and retained by the receptacle 402 , such as by snap-fitting the stem 114 into the angled receptacle 402 . In an example, the angled receptacle 402 can permit the inserted stem 114 to bend slightly toward the same side of the apparatus 100 as the intermediate portions 104 A-B and the distal portions 105 A-B.
[0067] In an example, the respective distal portions 105 A-B can include substantially flat or other feet 404 A-B. In an example, each foot 404 A-B can provide an outward-facing surface area that can be between about 2.4 cm 2 and about 3.84 cm 2 . The feet 404 A-B can have rounded or otherwise atraumatic distal corners and edges, or can be made of (or coated by) a softer durometer material, such as to help avoid or reduce the possibility of tissue abrasion or other injury to the mother or fetus. In an example, the feet 404 A-B can be hingedly or flexibly attached to the intermediate portions 104 A-B, such as by respective flexing couplers 406 A-B. In an example, the flexing couplers 406 A-B can include portions that are thinner than the respective feet 404 A-B and thinner than the respective intermediate portions 104 A-B, such as to provide the flexing. The flexing between the feet 404 A-B and the respective intermediate portions 104 A-B can, in an example, help resist upward movement of the cervical dilation meter 100 into a lower uterine segment. Such flexing can also help accommodate downward pressing of the fetal head against the feet 128 A-B in an example. Such flexing can also help ease removal of the cervical dilation meter 100 without damaging cervical, vaginal, or other tissue during the removal. In an example, the inward facing portions of one or both of the feet 404 A-B can optionally include a pressure sensor, such as to monitor pressure of the fetal head pressing against such inward-facing portions of the feet 128 A-B. Moreover, the orientation of the flexing feet 404 A-B, in combination with the cephalic curves of the intermediate portions 104 A-B of the arms 102 A-B can help direct pressure, delivered outward by the feet 404 A-B, more laterally against the cervical walls, rather than directing such pressure upward toward the uterus.
[0068] FIG. 9 illustrates an isometric view of an example of an arm 102 B and, at its proximal portion, a pivot joint 110 including a pivot joint housing 400 B including an opening 902 into which the pin 200 (of the opposing pivot joint housing 400 A at a proximal portion of an arm 102 A) can be inserted. This allows rotational pivoting about the pin 200 , which can be driven by the spring 118 carried within the housings 400 A-B, with ends of the spring 118 received into respective slots 904 A-B in the respective arms 102 A-B. In this way, the spring 118 can press against the outward sidewalls of the slots 904 A-B to impart the outward bias force to the arms 102 A-B, such as to hold the apparatus 100 in place for measuring cervical dilation.
[0069] In examples such as those shown in FIGS. 1-9 , portions of the apparatus 100 , such as the arms 102 A-B, the pivot joint 110 , the stem 114 , or other portions, can include or consist of molded polypropylene. This can provide an inexpensive apparatus 100 , such as to provide a single-use disposable apparatus 100 . In another example, brass or aluminum components can be used, such as to provide a more durable re-usable apparatus 100 that can be heat or chemically sterilized between uses.
[0070] FIG. 10 is a schematic illustration of an example of a dilation meter 100 , in which the stem 114 can be hollow or otherwise configured to guide a rod 1000 or other member that extends longitudinally along a length of the stem 114 . This can permit communicating of cervical dilation information from the arms 102 A-B to an external gauge 1002 . The example of FIG. 10 illustrates that a rotational pivot joint 110 can be omitted. Instead, the arms 102 A-B can be joined (e.g., in a wishbone-like fashion) to the distal portion of the stem 114 . A shape memory property of the arms 102 A-B and their respective attachments to the stem 114 can allow the distal portions of the arms 102 A-B to be drawn together, such as for insertion into the cervix, and to be self-spread apart, such as during the cervical dilation, such as to provide information about the degree of the cervical dilation.
[0071] In the example of FIG. 10 , a distal portion of the rod 1000 can be pivotably connected (e.g., via a pin) to proximal portions of respective resilient linkages 1004 A-B. The distal portion of the linkage 1004 A can be pivotably connected to the arm 102 A, such as via a pin at a proximal portion 103 A (as shown) or to a more distal portion of the arm 102 A. The distal portion of the linkage 1004 B can be similarly pivotably connected to the arm 102 B, such as via a pin at a proximal portion 103 B (as shown) or to a more distal portion of the arm 102 B. In this way, as the arms 102 A-B spread apart from each other, a proximal portion of the rod 1000 is drawn into a proximal portion of the tubular or other stem 114 and, concurrently, a distal portion of the rod 1000 is extended out from a distal portion of the tubular or other stem 114 .
[0072] In an example, the external gauge 1002 can include cervical dilation markings 1006 on the rod 1000 , which can be read against the end of the tubular or other stem 114 to provide an external indication of the degree of cervical dilation to a viewing user. For example, the rod 1000 can be manufactured such that the markings 1006 provide a scale that corresponds to the number of centimeters of cervical dilation measured using the arms 102 A-B. The scale can be linear, but need not be linear. In an example, there can be a logarithmic correlation between the scale of the markings 1006 on the rod 1000 and the degree of separation of the arms 102 A-B, which provides the indication of cervical dilation.
[0073] FIG. 11 is an exploded view of an example of portions of the apparatus 100 in which a flexible string or cable 1100 can be used (e.g., instead of the rod 1000 ) to communicate the cervical dilation information from the arms 102 A-B to an external gauge 1102 . A distal end of the cable 1100 can be anchored or otherwise affixed at one of the arms 102 A-B, such as at a proximal portion 103 A-B or an intermediate portion 104 A-B of the one of the arms 102 A-B. Measurement of the indication of cervical dilation at a location that is near the proximal portions 103 A-B of the arms can help avoid entanglement or obstruction of the cable 1100 by the fetal head or other instrumentation that may be inserted into a vagina, cervix or uterus. In an example, the cable anchoring or affixing can involve tying off or otherwise widening a distal end of the cable 1100 and inserting the cable 1100 through a hole 1101 B in the one of the arms 102 A-B, such that the widened end of the cable 1100 cannot be pulled through the hole 1101 B in the one of the arms 102 A-B. The cable 1100 can then extend across to the other one of the arms 102 A-B, such as through an opposing hole 1101 A in the other one of the arms 102 A-B. The cable 1100 can then extend within or along a tubular lumen, sheath, or other cable guide along that other one of the arms 102 A-B, into or along the pivot joint housing 400 A-B, within or along the receptacle 402 , within or along the stem 114 , and to the external gauge assembly 1102 .
[0074] At the external gauge assembly 1102 , the cable 1100 can terminate at a gauge plunger 1106 , which can travel back-and-forth within a transparent cylindrical or other elongate gauge body 1108 , as the arms 102 A-B are drawn toward each other or spread apart from each other. Scale markings on the gauge body 1108 can be read against the gauge plunger 1106 to provide an external indication of cervical dilation. Tension in the cable 1100 can be maintained by a compression spring 1110 , which can be located around the cable 1100 , such as at or near the proximal end of the cable 1100 . The compression spring 1110 can be used in addition to the spring 118 , in an example, or instead of the spring 118 , in another example. The cable-tensioning compression spring 1110 can have its proximal end seated against the plunger 1106 and its distal end seated against a stop 1112 portion of the stem 114 . In an example, a distal portion of the gauge body 1108 can also be seated against the stop 1112 . In an example (not shown in FIG. 11 ), the compression spring 1110 can instead be located near the pivot 110 , for example, its force can be communicated to the external gauge assembly by a rod or tube within the stem 114 .
[0075] The exploded view example of FIG. 11 also demonstrates an example in which the pivot 110 can include a disk-like base portion 1114 , coupled to the receptacle 402 , and including the pin 200 . The pivot 110 can also include a proximal end of the arm 102 B, which can include a housing 400 B that includes disk 1118 having a center hole 1116 through which the pin 200 can be inserted. Next, the spring 118 can then be placed about the pin 200 , such as with one end of the spring 118 inserted into or otherwise constrained by the arm 102 B, and the other end of the spring 118 then inserted into or otherwise constrained by the arm 102 A. Next, the proximal end of the arm 102 A, which can include a cylindrical housing to carry the spring 118 and a center hole 1120 , can be placed with the center hole 1120 about the pin 200 , with the end of the spring 118 constrained by the arm 102 A, such as explained above. Then, a snap-on cap 1122 can be placed about and snapped onto the pin 200 , which can help hold the various components of the pivot 110 together.
[0076] FIG. 12 is an exploded view of an example of portions of the apparatus 100 in which a rack-and-pinion configuration of the pivot 110 can be used (e.g., instead of a rod 1000 or a flexible string or cable 1100 ) to communicate the cervical dilation information from the arms 102 A-B to an external gauge assembly 1202 . In this example, the pivot 110 can include a pinion pivot base 1204 . The stem receptacle 402 can extend outward from the pivot base 1204 , in a similar manner to that described above. The base 1204 can include separate pins 200 A-B that can extend upward into respective receptacles 1206 A-B of respective arms 102 A-B. This can allow the respective arms 102 A-B to pivot about their respective pins 200 A-B. This can allow the arms 102 A-B to be drawn toward each other or spread apart from each other. The pivoting proximal ends of the arms 102 A-B can include opposing facing pinion toothed gears 1208 A-B. A toothed geared distal portion of a rack 1210 can be inserted between the opposing facing pinion toothed gears 1208 A-B. Like the rod 1000 , the rack 1210 can extend proximally through the tubular stem 114 to an external gauge assembly 1202 . In an example, a distal portion of the rack 1210 can travel into a rack receptacle 1212 . A proximal end of the rack 1210 can include a plunger 1214 that travels within an at least partially transparent barrel 1216 . The barrel can include markings 1218 forming a cervical dilation scale for user readout. In this way, as the cervix dilates, and the distal portions of the arms 102 A-B spread apart, a distal end of the rack 1210 travels toward or into the receptacle 1212 , and a proximal end of the rack 1210 travels such that the rack plunger 1214 moves more distally within the barrel 1216 of the dilation gauge assembly 1202 . The barrel 1216 can include an end-cap 1220 at its proximal end. A spring 1222 can be located near the proximal or distal portion of the rack 1210 , such as at the barrel 1216 or at the receptacle 1212 . The spring 1222 can be used to bias the rack 1210 in a distal direction such that the arms 102 A-B tend to self-spread apart, such as to allow measurement of the cervical dilation. The spring 1222 can be designed to provide a pushing or pulling force, as appropriate, to provide such a bias force to tend to spread the arms 102 A-B apart. A cap 1224 can be snap-fitted onto the pins 200 A-B, such as to hold or house the components of the rack-and-pinion pivot 110 .
[0077] In an example, the apparatus 100 can be packaged together in a kit with an introducer that can hold the arms 102 A-B together during insertion. In an example, the introducer can include a peel-away sheath that keeps the arms 102 A-B together during insertion, but which can include two separate proximal tails that can be used to concurrently pull apart and retract the sheath, leaving the arms 102 A-B in place in the opening of the cervix, and thereby permitting such arms 102 A-B to self-expand apart from each other to measure the cervical dilation. In another example, the apparatus 100 can be provided with a proximal push-rod such as to communicate a force to hold the arms 102 A-B together during insertion.
[0078] FIG. 13 is an exploded view of an example of portions of the apparatus 100 in which a tension cable 1300 can be used to communicate a force, such as to bias the arms 102 A-B away from each other. In an example, the tension cable 1300 can include a bifurcated distal portion 1302 A-B. The distal portion 1302 A can terminate at a coupling feature such as a post 1304 A, which can extend perpendicular to the distal portion 1302 A. The distal portion 1302 B can terminate at a coupling feature such as a post 1304 B, which can extend perpendicular to the distal portion 1302 B.
[0079] In the example of FIG. 13 , proximal ends of the arms 102 A-B can be coupled together, such as at a pivot joint 110 , which can include respective disks 1306 A-B at the respective proximal ends of the arms 102 A-B. The disks 1306 A-B can include respective center holes 1120 , 1118 through which a pin 200 can be inserted. A distal end of the pin 200 can be snap fitted into or otherwise engaged to a cap 1308 , thereby holding together the cap 1308 , the disks 1306 A-B, the pin 200 and the disk 1114 , such as to provide the joint 110 .
[0080] In the example of FIG. 13 , the disks 1306 A-B can include arc-shaped, semicircular, or similar guide rails 1310 A-B. The cable distal portions 1302 A-B can respectively wrap around the outsides of the respective rails 1310 A-B. The posts 1304 A-B can be respectively inserted into and engage the respective recesses 1312 A-B. The cable 1300 can pass through a tubular receptacle 402 and a flexible tubular or other sheath 1314 back to a proximal gauge 1316 , which can be located external to the patient when the distal portions of the arms 102 A-B are located within the cervix, such as to measure its diameter.
[0081] In an example, the gauge 1316 can include a proximal end of the sheath 1314 , which can include an outward flange 1315 , which can serve as a distal stop for a spring 1316 . An outward flange 1318 near a proximal end of the cable 1300 can serve as a proximal stop for the spring 1316 . In such an example, the spring 1315 can be captured between the flanges 1315 and 1318 . In an example, the spring 1315 can provide the force that is communicated by the cable 1300 to the arms 102 A-B such as to bias the arms 102 A-B away from each other during the cervical dilation measurement. In an example, a gauge pointer 1320 is optionally coupled to the flange 1318 at the proximal end of the cable 1300 , such as for reading the cervical dilation against graduations or demarcations on a transparent or translucent gauge cylinder 1322 . In another example, the flange 1318 can itself optionally be used to provide a gauge pointer for reading against the graduations or demarcations on the gauge cylinder 1322 . In another example, the apparatus 100 can be provided with a proximal push-rod (e.g., extending further proximally from the gauge pointer 1320 ) such as to communicate a force to hold the arms 102 A-B together during insertion. A dial or other gauge readout can be substituted for the linear translational gauge cylinder in this example or in one or more of the other examples described herein.
[0082] FIG. 14 is an example of portions of the apparatus 100 in which a dial gauge 1400 can be provided and coupled via a cable within a flexible sheath to a receptacle 1404 of a pivot joint 110 from which the arms 102 A-B extend. The dial gauge 1400 can include a dial gauge housing 1406 having a window 1408 through which a dilation reading on a rotating dial can be read.
[0083] FIG. 15 is a schematic diagram corresponding to an example of the apparatus 100 such as shown in the example of FIG. 14 . In this example a short cable 1500 can include ends with respective couplers, such as balls 1502 A-B, that can be coupled to respective arms 102 A-B, such as by being inserted into respective sockets in the respective arms 102 A-B at a desired proximal, intermediate, or distal location along the length of such arms 102 A-B. A middle region of the cable 1500 can be coupled to a distal end of a longer cable 1504 , which can be passed through a flexible tubular or other sheath 1506 . In an example, the sheath 1506 can extend from the receptacle 1404 on the pivot joint 110 to a spring housing 1508 . In an example, the spring housing 1508 can extend outward from the dial gauge housing 1406 . A proximal end of the cable 1504 can be coupled to a distal portion of a rack gear 1510 , which can form a rack-and-pinion arrangement with a pinion gear 1512 . The pinion gear 1512 can engage a dial gear 1514 , which drives a rotational movement of a dial 1516 . The dial 1516 can provide numerical or other indicia indicative of cervical dilation, such as can be viewable through the window 1408 on the housing 1406 of the dial gauge 1400 . In an example, the pinion gear 1512 can include a multiple stage pinion gear, such as a two-stage pinion gear, such as to translate linear movement of the rack gear 1510 into a desired degree of rotation of the dial 1516 . For example, the two-stage pinion gear 1512 can include a smaller gear 1512 A, which engages the rack gear 1510 , and which rotates together with a larger gear 1512 B, which engages the dial gear 1514 . In this example, the spring housing 1508 can include a coil spring 1518 , which can be located about the cable 1504 and confined within the spring housing 1508 between the spring housing 1508 and the distal portion of the rack gear 1510 . The spring 1518 can provide a force against the rack gear 1510 . The rack gear 1510 can communicate this force via the cables 1504 and 1502 to the arms 102 A-B such as to bias the arms 102 A-B away from each other, such as for performing the cervical dilation measurement.
[0084] Additional Notes
[0085] The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown and described. However, the present inventors also contemplate examples in which only those elements shown and described are provided. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also examples using any combination or permutation of those elements shown or described, either with respect to a particular example, or with respect to other examples shown or described herein.
[0086] All publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.
[0087] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.
[0088] Method examples described herein can be machine or computer-implemented at least in part. Some examples can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, the code may be tangibly stored on one or more volatile or non-volatile computer-readable media during execution or at other times. These computer-readable media may include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.
[0089] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
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An instrument for measuring cervical dilation can have a pair of arms connected at their proximal ends to an arm pivot or articulating member, the arms being in movable communication with a gauge assembly for measuring the relative distance between the arms at a fixed location near the proximal ends of the arms. The arms can be disposed to apply an outward lateral pressure against the walls of the cervix, thereby engaging the cervix without the need for physical penetration, gripping, or other attachment of the device to the cervical tissue. Continuous outward lateral pressure of the arms against the cervical walls can allow the arms to expand in response to and in concert with expansion and dilation of the cervix. The relative distance between the arms correlates to the diameter of the cervix, such that the correlated measurement indicated on a scale of the gauge means is the measurement of cervical dilation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of application Ser. No. 10/445,861 filed May 27, 2003, which is a continuation of application Ser. No. 10/032,853 filed Oct. 25, 2001 and now U.S. Pat. No. 6,772,064.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present methods and systems generally relate to processing and transmitting information to facilitate providing service in a telecommunications network. The methods and systems discussed herein more particularly relate to use of global satellite positioning to facilitate processing and transmission of information associated with telecommunications service locations and routing travel between more than one such service location.
[0004] 2. Description of the Related Art
[0005] Efficient and effective customer service is an essential requirement for commercial enterprises to compete successfully in today's business world. In the telecommunications industry, for example, providing customer service is an important part of sustaining market share in view of the many competitors in the industry. Customers whose telephone service, for example, is interrupted or disconnected for even a relatively short period of time may desire to seek an alternative source for service, especially if the interruption or disconnection is not addressed by a quick and effective customer service response.
[0006] One important aspect of providing customer service is maintaining accurate and complete knowledge of the customer's location. Computer systems and databases that provide customer addresses often only provide vague references, however, to the exact location of the customer. Such customer addresses typically do not include information of sufficient specificity to permit efficient identification of a service location associated with the customer. In the context of a technician transporting a vehicle to a customer's service location, for example, this lack of sufficient service location information can generate excessive driving time and slow response time. Where the response time is unacceptably high, the lack of sufficient service location information can result in delayed or missed customer commitments. It can be appreciated that such delayed or missed customer commitments can cause a commercial enterprise to lose valuable customers.
[0007] What are needed, therefore, are methods and systems for acquiring information associated with a customer's service location. Such methods and systems are needed to obtain, for example, a latitude and longitude associated with the customer's service location. In one aspect, if latitude and longitude information could be collected by a service technician when the customer's service location is visited, those coordinates could then be used to find the customer at a later date. Moreover, if latitude and longitude coordinates could be made available in a database associated with that specific customer, the coordinates could be used to assist in determining the service location of that customer. Such service location information could permit a service technician to drive directly to the customer service location with little or no time lost searching for the service location.
[0008] What are also needed are methods and systems for providing a service technician with directions, such as driving directions between two or more service locations. Such directions could be employed to route travel from a first customer service location to a second customer service location. It can be seen that such directions would further reduce the possibility of error in locating a customer service location and thereby enhance customer service response time.
SUMMARY
[0009] Methods and systems are provided for obtaining information related to a customer service location. One embodiment of the method includes requesting at least one set of coordinates associated with the customer service location; accessing a technician server to direct a global satellite positioning system to obtain the set of coordinates for the customer service location; obtaining the coordinates and updating one or more databases with the coordinates. The coordinates may include at least one of a latitude and a longitude associated with the customer service location. One embodiment of a system for obtaining information related to a customer service location includes an input device configured for use by a service technician at the customer service location. A technician server is included in the system for receiving data transmissions from the input device. The technician server is in communication with a global positioning satellite system for determining a set of coordinates associated with the input device. Computer-readable media embodiments are also presented in connection with these methods and systems.
[0010] In addition, methods and systems are discussed herein for generating directions for a service technician traveling from a first customer service location to at least a second customer service location. One embodiment of the method includes obtaining through a technician server at least one set of “from” coordinates associated with the first customer service location and at least one set of “to” coordinates associated with the second customer location; transmitting the “from” and “to” coordinates to a mapping system; and, generating directions in the mapping system based on the “to” and the “from” coordinates. One system embodiment includes an input device configured for use by a service technician at a first customer service location. A technician server is provided for receiving data transmissions from the input device. A global positioning satellite system, which is configured for determining at least one set of “from” coordinates associated with the input device is provided for use on an as needed basis. At least one database is included in the system for storing a “to” set of coordinates associated with the second customer service location and the “from” set of coordinates. The system further includes a mapping system operatively associated with the input device for generating travel directions based on the “from” and “to” coordinates. At least one of the sets of coordinates includes latitude and a longitude data. Computer-readable media embodiments of these methods and systems are also provided.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 is a schematic diagram depicting one embodiment of a system for obtaining, processing, and transmitting information related to providing customer service at a customer service location;
[0012] FIG. 2 is a schematic diagram depicting a portion of the system of FIG. 1 in more detail;
[0013] FIG. 3 is a process flow diagram showing one embodiment of a method for obtaining, transmitting and processing information related to providing service at a customer service location;
[0014] FIG. 4 is a schematic diagram depicting one embodiment of a system for obtaining, processing, and transmitting information related to providing customer service at a customer service location; and,
[0015] FIG. 5 is a progress flow diagram depicting one embodiment of a method for obtaining, processing, and transmitting information related to providing customer service at a customer service location.
DETAILED DESCRIPTION
[0016] Referring now to FIGS. 1 and 2 , a service technician visiting a customer service location is provided with a technician input device 2 for receiving and transmitting information related to a disruption or interruption of service at the service location. The input device 2 can be a wireless PC, for example, a laptop, a personal digital assistant (PDA), a wireless pager or any other device suitable for receiving and transmitting data associated with providing service at the customer service location. A transponder system 4 is operatively associated with the input device 2 for receiving and transmitting signals such as satellite transmission signals, for example.
[0017] The input device 2 is configured and programmed to permit the service technician to access a technician server 6 . As shown in FIG. 1 , access to the technician server 6 can be enabled through a wireless data network 8 through a radio connection 10 . Access to the technician server can also be enabled by a modem connection 12 through a landline server 14 . The landline server 14 can be a server configured in accordance with a server having a CSX 7000 trade designation employed by BellSouth Telecommunications (BST —Atlanta, Ga.).
[0018] A protocol server 16 receives and processes communications from both the wireless data network 8 and the landline server 14 . In operation of the input device 2 , the protocol server 16 processes information transmitted from the input device 2 including, for example, a user ID, a password, a radio serial number, an input device serial number, and other similar data associated with a service technician and service provided at a customer service location. In one aspect, the protocol server 16 can include one or more WINDOWS NT servers (Microsoft Corporation) configured to assign one or more logical ports to transmissions received from the input device 2 .
[0019] In one aspect of the present methods and systems, the technician server 6 can be a server having a TECHACCESS trade designation (Telcordia Technologies). The technician server 6 can be a conventional server configured and programmed to verify and/or process information received from the input device 2 . The technician server 6 functions as a transaction request broker between the protocol server 16 and one or more other systems operatively connected to the technician server 6 . The systems operatively associated with the technician server 6 can include, among other possible systems, a global positioning satellite system 18 (GPS system), a dispatch system 20 , an address guide system 22 , and a customer records system 24 .
[0020] In one embodiment of the present methods and systems, the GPS system 18 can be configured in accordance with the BellSouth Telecommunications Global Positioning Satellite System (GPS) as implemented by SAIC's Wireless Systems Group (WSG). The GPS system 18 is operatively associated with the transponder system 4 and can be employed to track, dispatch, and monitor service technicians and their input devices at numerous customer service locations. In one aspect, the GPS system 18 interacts with a transponder mounted on a mobile vehicle (not shown) employed by the service technician at a customer service location.
[0021] One purpose of the GPS System 18 is to provide supervisors and managers of service technicians with more comprehensive technician activity information. The GPS system 18 can include one or more servers (not shown) and one or more databases (not shown) for transmitting, receiving and storing data associated with satellite communications. In the context of the present methods and systems, the GPS system 18 serves to acquire information associated with a customer service location including, for example, the latitude and longitude coordinates of the customer service location.
[0022] The dispatch system 20 serves to receive, process and transmit information related to service required at one or more customer service locations. In one embodiment, the dispatch system 20 includes a server, a database and one or more graphical interfaces for receiving commands from a user. Such commands can include, for example, entry on a graphical user interface (GUI) of customer information and a problem description associated with a particular interruption or disruption of service. The dispatch system 20 communicates with the technician server 6 to process and transmit information related to actions to be performed at a customer service location. Examples of dispatch systems suitable for use in connection with the present methods and systems include the “LMOS,” “IDS” and “WAFA” systems of BellSouth Telecommunications.
[0023] The address guide system 22 includes a database 26 for storing universal type address information, examples of which are shown in FIG. 2 . The address guide system 22 can be considered the keeper of all addresses in the universe of telecommunications services. The address guide system 22 helps to promote valid addresses as customer service locations. For example, if a customer contacts a telecommunications service provider, the customer can be queried for the customer's address. If the customer provides an address of 123 XYZ Street and there is no 123 XYZ Street in the database 26 of the address guide system 22 , then a correct address for the customer can be confirmed and entered into the database 26 . An example of an address guide system 22 suitable for use in accordance with the present methods and systems is the “RSAG” application of BellSouth Telecommunications.
[0024] The customer record system 24 is operatively connected to the address guide system 22 and includes a database 28 for storing customer related information, examples of which are shown in FIG. 2 . In one embodiment of the present methods and systems, the customer record system 24 serves to store information related to a particular service location and customer. For example, when telephone service is initially requested by a customer, a record in the database 28 can be populated with information that will create a correspondence between the customer's address and the details of the telephone service to be installed. Records in the database 28 of the customer record system 24 typically remain effective as long as service at a particular address remains the same for that customer. The customer record system 24 interfaces with the dispatch system 20 during the operation of the dispatch system 20 to generate work orders associated with service issues at customer service locations. For example, if problems arise with a customer's service, such as the initial installation order for that service, the dispatch system 20 schedules the work order. The dispatch system 20 draws on information contained in the customer record system 24 to create the dispatch order for a service technician to perform any actions required by the work order.
[0025] Referring now to FIGS. 1 through 3 , an operative example of the present methods and systems include a service technician at a customer service location with an input device 2 . In accordance with the connections described above, in step 32 the technician server 6 can request the coordinates, in terms of latitude and longitude, from the service technician at the customer service location. The request of step 32 can be performed, for example, in step 34 by a job closeout script application of the technician server 6 that is adapted to query the service technician regarding the customer's location at the conclusion of a service call. The technician server 6 may check to determine whether a latitude and longitude are already present in the customer's information in the database 28 of the customer record system 24 .
[0026] The technician server 6 can then instruct the service technician in step 35 to verify his presence at the customer service location. In step 36 , the GPS system 18 is accessed, such as through a “Fleet Optimizer” application (BellSouth Technologies) associated with the technician server 6 , to obtain latitude and longitude coordinates derived from the location of the service technician's input device 2 . In step 38 , the GPS system 18 transmits a signal to the transponder system 4 operatively associated with the input device 2 and obtains coordinates of the customer service location in step 40 . The GPS system transmits the obtained coordinates to the technician server 6 in step 42 . In step 44 , the dispatch system 20 is updated with the newly obtained latitude and longitude information. In step 46 , the database 28 of the customer records system 24 is updated to reflect this latitude and longitude information. In step 48 , the latitude and longitude information is transmitted to and stored in the database 26 associated with the address guide system 22 .
[0027] It can be seen that just because one has a street address for a customer service location, it does not necessarily follow that locating the customer service location can be readily performed. For example, a street address in Pittsburgh, Pa. might be Three Rivers Stadium Park. If this is the only information available, however, it may be difficult to find the customer service location where work needs to be performed. Use of a GPS system to associate coordinates with a street address permits one to know the position of a customer service location, and hence the location of a service technician performing work at that customer service location.
[0028] In another example of the present methods and systems, a new customer requests service installation at ABC Street. Verification is performed to determine that ABC Street is a valid address. If it is a valid address, and if latitude and longitude information has been populated in the address guide system 22 , then the information can be used effectively by a service technician to address the customer's needs. In addition, if a service issue later arises with the customer service location, the dispatch system 20 can obtain the customer record, including the customer name, contact number, the type of facilities the customer has, and latitude and longitude information associated with the customer service location. This complete record of information provides enhanced response time for addressing the customer's service needs.
[0029] Referring now to FIGS. 4 and 5 , in another aspect of the present methods and systems, a mapping system 52 can be provided for routing travel of a service technician between more than one customer service location. The mapping system 52 is configured and programmed to provide travel or routing directions to a service technician from a first location to at least a second location where customer service is to be performed. The mapping system 52 can include conventional mapping software installed on a computer-readable medium operatively associated with the input device. The mapping system 52 can also be accessed remotely, such as through a wireless connection between the mapping system 52 and the input device 2 .
[0030] In one embodiment, the technician server 6 functions to provide latitude and longitude information to the mapping system 52 . This information includes “from” information (i.e., the origin customer service location of the service technician) and “to” information (i.e., the destination customer service location to where travel is desired for the service technician). Before dispatch to the next customer service location, the service technician requests driving instructions in step 62 . The technician server 6 queries the “Fleet Optimizer” application, or its functional equivalent, in step 64 to obtain the current customer service location in step 66 , which can be used by the mapping system 52 as the “from” location. If necessary, and in accordance with previous discussion of the present methods and systems, the GPS system 18 can be accessed to obtain “from” latitude and longitude coordinates in step 68 .
[0031] The address guide system 22 can then be accessed by the technician server 6 in step 70 to provide the “to” location to the mapping system 52 , including latitude and longitude information for the destination customer service location. In step 72 , the technician server 6 transmits the “from” and “to” coordinates to the technician input device 2 . In step 74 , the mapping system 52 processes the “from” and “to” coordinates. The mapping system 52 can then generate and output driving directions from the “from” location to the “to” location for the service technician in step 76 . It can be appreciated that the output of the mapping system 52 including the driving directions can be in any conventional format suitable for communicating the directions to the service technician. For example, the output including the driving directions can be in electronic format or hard copy format.
[0032] As discussed above, accurate latitude and longitude coordinates may have already been established for the present or origin customer service location. In the process of dispatching a service technician to a next customer service location, however, it may be necessary to engage the GPS system 18 to obtain these latitude and longitude coordinates. The GPS system 18 can therefore be employed to provide knowledge of one or more service technician locations for various customer service locations where service is required. The GPS system 18 also functions to promote providing correct customer service location information, including latitude and longitude coordinates associated with customer addresses and/or associated critical equipment. It can be seen that algorithms can be applied in the dispatch system 20 and/or the technician server 6 to use this knowledge of service technician whereabouts and customer service locations to facilitate moving the next best or available service technician to the next highest priority or most appropriate service location.
[0033] The term “computer-readable medium” is defined herein as understood by those skilled in the art. A computer-readable medium can include, for example, memory devices such as diskettes, compact discs of both read-only and writeable varieties, optical disk drives, and hard disk drives. A computer-readable medium can also include memory storage that can be physical, virtual, permanent, temporary, semi-permanent and/or semi-temporary. A computer-readable medium can further include one or more data signals transmitted on one or more carrier waves.
[0034] It can be appreciated that, in some embodiments of the present methods and systems disclosed herein, a single component can be replaced by multiple components, and multiple components replaced by a single component, to perform a given function. Except where such substitution would not be operative to practice the present methods and systems, such substitution is within the scope of the present invention.
[0035] Examples presented herein are intended to illustrate potential implementations of the present communication method and system embodiments. It can be appreciated that such examples are intended primarily for purposes of illustration. No particular aspect or aspects of the example method and system embodiments, described herein are intended to limit the scope of the present invention.
[0036] Whereas particular embodiments of the invention have been described herein for the purpose of illustrating the invention and not for the purpose of limiting the same, it can be appreciated by those of ordinary skill in the art that numerous variations of the details, materials and arrangement of parts may be made within the principle and scope of the invention without departing from the invention as described in the appended claims.
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Methods and systems are provided for obtaining information related to a customer service location and directions for routing a service technician from one customer service location to another. One embodiment includes requesting at least one set of coordinates associated with the customer service location; accessing a technician server to direct a global satellite positioning system to obtain the set of coordinates for the customer service location; obtaining the coordinates and updating one or more databases with said coordinates. The coordinates may include at least one of a latitude and a longitude associated with the customer service location. Another embodiment includes obtaining through a technician server at least one set of “from” coordinates associated with the first customer service location and at least one set of “to” coordinates associated with the second customer location; transmitting the “from” and “to” coordinates to a mapping system; and, generating directions in the mapping system based on the “to” and “from” coordinates. At least one of the sets of coordinates includes latitude and longitude data. System and computer-readable media embodiments of these methods are also provided.
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FIELD OF THE INVENTION
This invention relates generally to sculpted articles of manufacture. More specifically, this invention relates to sculpture having internal surfaces which display a variety of properties.
BACKGROUND OF THE INVENTION
Sculpture, articles of manufacture, and articles found in nature that have internal structures or colorations have long intrigued both artist and observer. For example, the semi-precious opal has been desired for centuries due to its internal "fire". This fire, which consists of colorations on thin internal faces, has been difficult to match in any artificially created object. However, in other environments, both artistic and commercial, there have been many other designs that include coloration within an internal structure. This has become more prevalent in recent years with the advent of acrylics and other transparent plastic materials that can be relatively easily formed around or on top of colored or textured materials to give the appearance that such materials are actually an integral part of the article within.
Two examples of this type of article are shown in U.S. Pat. Nos. 3,940,523 and 5,082,703 to Lecour et al. and Longobardi, respectively. Longobardi discloses a sign that includes a transparent base onto which viscus ink is deposited to form a design. The ink is thick enough that textures can be formed on the ink to create various surface appearances. A sheet can then be applied over the viscus ink and onto the substrate to give the appearance that the inked design was etched or embossed, Lecour et al. disclose a decorative object that includes an acrylic glass plate onto which various differently colored layers of polymethyl methacrylate can be deposited. The layers can be limited to various portions of the support plate and built one on top of the other to give the appearance that the colors are integral with the support plate and not merely a layer deposited onto it.
It is also known that by etching alphanumerics into a flat transparent support plate, the alphanumerics can be illuminated by supplying light to the side edges of the plate. As the light travels through the plate, which now serves as a light guide, the internal surfaces created by the etched alphanumerics, which are usually frosted, scatter the light out of the plane of the plate and thus appear illuminated.
It is known that by adhering to flat surfaces of adjacent acrylic pieces, the pieces can be made to appear continuous. With an appropriate dye, one of those surfaces could be colored. Thus, when the two surfaces were brought together and bonded, the plane of coloration, assuming it had not been altered by the adhesive, would appear to be suspended within the continuous block as though the acrylic block had been formed originally with a plane of color within it. However, this process becomes difficult and tedious as the number of desired planes of color increases. Further, the plane of color would not reflect or refract any light passing through it, but would merely tint the area, that is, it would appear that dye was added to the continuous clear solution.
SUMMARY OF THE INVENTION
It is thus an object of the invention to create an article with internal surfaces capable of reflection and refraction.
It is another object of the invention to provide an article that has colored internal surfaces.
It is yet another object of the invention to provide an article that provides internal parallel surfaces.
In accordance with the objects of the invention, an article is provided having cuts extending from an exterior surface to an internal position. The cuts are then smoothed using a solvent and simultaneously dyed with an appropriate pigment. The resulting internal faces exhibit both reflectivity and translucency depending on the illumination and viewing angles.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, advantages and embodiments will become apparent to those skilled in the art upon reading the following detailed description in conjunction with a review of the appended drawings, in which:
FIG. 1 is a perspective view of an article having a cut formed therein;
FIG. 2 is a perspective view of the article in FIG. 1 from a different viewing angle;
FIG. 3 is a cross-sectional view of a cut in an article according to the invention;
FIGS. 4A-4C are cross-sectional side views of an internal surface during manufacture of an article according to the present invention;
FIG. 5 is a perspective view of another embodiment of the invention; and
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a sculpture 10 according to the present invention is shown. In a preferred embodiment, the overall shape is a rectangular prism with planar outer surfaces 12. However, as will be discussed further below, other exterior surfaces are contemplated as well. Formed in the sculpture 10 is a cut 14 which is open to the outer surface 12 of the sculpture 10 at its mouth 16. The cut 14 extends into the sculpture 10 to a rear point 18 within the interior of the sculpture 10, but preferably does not penetrate completely through the sculpture 10. If the cut 14 extended completely through, the sculpture 10 would be severed and some of the advantages of the invention may be lost.
The cut 14 may be formed through any known methods, preferably using a saw (not shown), depending on the width of the cut 14 that is desired. Other types of cutting methods such as water jets, lasers and other mechanical cutting devices are contemplated as well. In the preferred embodiment the cut 14 is a straight cut into the sculpture 10, i.e., the two internal surfaces 20a,20b formed by the cut 14 are planar and parallel to each other. It is also contemplated that the cut 14 might be curved or might be widened by applying several passes of the blade into the sculpture 10, which would widen the cut 14 and displace the two inner surfaces 20a,20b from each other.
In the preferred embodiment, the internal surfaces 20a,20b become mirrored or reflective at particular viewing angles and illumination angles, depending on the material used. This effect is seen in FIG. 2, in which the material behind the internal surfaces 20a,20b along the line of sight of the figure cannot be seen. The same surfaces, when viewed at a different angle or illuminated from a different angle will become translucent or transparent, as seen in FIG. 1. At this angle, the rear outer edge 22 of the sculpture 10 and the interior corner 24 of the cut 14 can be seen through the upper internal surface 20a. The reflective/translucent nature of the surfaces 20a,20b and its causes will be more fully described below.
As can be seen in FIGS. 1 and 2, the preferred embodiment includes pigmentation 26 on the internal surfaces 20a,20b. The pigment 26 causes both the translucent and reflective transmission of light, depending on the angle, to be tinted.
To create the surface features of the internal surfaces 20a,20b, the cut 14 is formed as discussed above, preferably with a saw. The internal cut surfaces 20a,20b of the preferred material, clear acrylic, then have a white frosted surface that is practically opaque. To prepare the surfaces for further treatment, the internal surfaces 20a,20b of the cut 14 may be smoothed out with sand paper or other buffing materials. Preferably, standard silicon carbide sand paper is used to remove the residue from the cutting, such as grease from the blade or melted acrylic left behind from the cutting action.
It is preferred that the surface striations 28 on the internal surface caused by the saw blade (see FIG. 4A) remain. Thus, the sanding or buffing step should only reduce the striations 28, such as shown in FIG. 4B, but not eliminate them. If the striations are removed and the internal surfaces 20a,20b are polished smooth, the internal surfaces lose most of their reflective property and only become reflective at extremely shallow viewing angles.
The preferred method of achieving the pigmentation on the internal surfaces 20a,20b of the sculpture 10 is with a combined solution of solvent and pigment. The solvent partially dissolves the internal surfaces 20a,20b so they are generally clearer than they would be after only cutting and/or sanding. The solvent also primes the internal surface for the pigment 26, which pigments a thin layer of the sculpture 10 at the internal surface 20b and remains after the solvent is removed from the cut 14 (see FIG. 4C). Similar results occur with the upper internal surface 20a. To assist pigmentation of the internal surfaces 20a,20b, the surfaces are preferably rough when the solvent/pigment mixture is injected. If the striations 28 formed during cutting are removed, a rough (i.e., not polished) surface should remain to allow the pigment 26 to adhere properly.
In practice, different cuts may be dyed with different colors for various aesthetic effects. This is accomplished by sealing off the mouths 16 of the cuts 14 with tape (not shown) or other covering, except for the particular cut or cuts to be dyed. The solvent/pigment solution is injected into the one open cut and then blotted out, leaving behind a thin layer of pigmented material 26 on the internal surfaces (see FIG. 4C). The preferred solution must be quickly blotted from the cut to avoid congealing or hardening of the solvent within the cut. Filling in the cuts with a solvent or other filler, such as a molded piece, tends to eliminate the reflective properties.
Once the cuts 14 are completed, various other effects may be achieved by shaping the outer surfaces 12 of the sculpture 10 or adhering the sculpture 10 to an adjacent sculpture 10 having similar cuts 14. If the outer surfaces 12 are shaped, using grinders and the like, the resulting visual effect is that parallel internal cuts 14 have a curved appearance, due to the lensing effect of the various exterior curved surfaces 30 (see FIGS. 5 and 7). If two adjacent sculptures 10 having mating surfaces are bonded together with an acrylic type adhesive, much of the mouth 16 of many cuts 14 will be concealed at the interface between the two sculptures 10. It is preferred that the adhesive be applied in a quantity and manner such that minimal amounts of the adhesive will be pressed into the cuts 14 of the sculpture 10. For example, the cuts of the adjacent sculptures may be masked with clear tape and then mated, although some tape is then left behind between the sculptures. Alternatively, glue may be applied to the mating surface by a thin flat spacer (not shown). The mouths of the cuts on the mating surface are placed with the mouths facing down on the spacer to prevent glue from entering the cuts by gravity. Again, the spacer would remain between the adjacent sculptures.
In the preferred embodiment, the internal surfaces 20a,20b are parallel. The resulting effect approaches that of a single colored face within the sculpture, but with the added feature of reflection and translucency at different angles. Other non-parallel type cuts may be formed, although the effect is decreased as the angle between the internal surfaces increases, until eventually the two surfaces become viewed as two unrelated surfaces. The cuts 14 are preferably no wider than 1/16 inch, although wider cuts are possible.
The preferred solvent is WELD-ON #3, available from IPS Corporation of Garden, California. The preferred dye is Nitro-Dye Concentrate, available from Schwartz Chemical Company of Long Island City, N.Y. Other solvents and dyes may be used similarly. The ratio of solvent to pigment may be varied to achieve different levels of pigmentation of the internal surfaces, although if not enough solvent is used, the internal surfaces 20a,20b and the striations 28 will not become clear, but will retain their frosty appearance from the cutting and sanding.
Thus, it can be seen that the present invention provides a sculpture having internal surfaces that have both reflective and translucent properties and may be colored. Further, these surfaces may be formed without complex laminations or other layering techniques.
It is to be understood that the term sculpture is not limited to art objects, but may also refer to other types of articles or structures, which include, but are not limited to, architectural elements such as columns, walls or windows; furniture; lamps and other light sources; jewelry; and various containers.
While the embodiments shown and described are fully capable of achieving the objects and advantages of the invention, it is to be understood that these embodiments are shown and described solely for the purpose of illustration and not for the purpose of limitation.
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A sculpture is provided having cuts extending from an exterior surface to an internal position. The cuts are then smoothed using a solvent and simultaneously dyed with an appropriate pigment. The resulting internal faces exhibit both reflectivity and translucency depending on the illumination and viewing angles.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates to a display device or the like to be preferably implemented in a game machine such as a pinball machine, a slot machine, or a arcade game, and particularly to a display device for performing display, which an observer can view stereoscopically, a control method therefor, and a game machine implementing the display device.
[0003] 2. Related Art
[0004] As a display device for offering a stereoscopic vision, there is a device in which each of images or equivalent images thereto obtained by taking pictures of an object in three dimensions using four cameras into sub-pixels is divided, the sub-pixels are repeatedly displayed on a flat panel display in accordance with the positions of the four cameras, and the flat panel display is observed through a step barrier (2004, SPIE-IS&T/Vol. 5291 (p 265-272), “Step barrier system multi-view glass-less 3-D display,” hereinafter referred to as first document).
[0005] Incidentally, as a game machine, there is a machine, which variably displays numbers or the like on a display disposed on a center section of a pachinko board in response to a pachinko ball entering a start-up hole to win a prize, and pays out corresponding prize balls when the same numbers or the like stop in a line as a bell ringer. As a display device for a game machine of this kind, for example, there is a display device having a pair of light sources, a pair of polarizing filters corresponding respectively to the pair of light sources, a Fresnel lens, a fine wave plate, a first polarization plate, a liquid crystal panel, and a second polarization plate sequentially disposed along the light path (JP-A-2005-52200, hereinafter referred to as second document). In this display device, an image for a right eye and an image for a left eye are formed in combination on the liquid crystal display panel in accordance with the pattern of the fine wave plate, the pop-up amount of the image is set by the difference in the pixel positions between the image for a right eye and the image for a lift eye.
[0006] Further, as another game machine, there is a machine, which implements a stereoscopic display device provided with an image splitter having transparent sections and opaque sections alternately to allow the player to view the game pictures stereoscopically using the binocular parallax method (JP-A-9-164263, hereinafter referred to as third document). In this stereoscopic display device, there are provided a left eye image signal switching circuit and a right eye image signal switching circuit to switch between a plane image and a stereoscopic image in accordance with an instruction form a display CPU.
[0007] However, regarding the display device (in the first document) for a stereoscopic vision mentioned above, there is an only disclosure that it can display a stereoscopic vision, but there is no other disclosure about a switching display between a stereoscopic image and a plane image, nor a stereoscopic display according to the proceeding of a game.
[0008] Further, although the game machines (in the second and third documents) with the stereoscopic display can display a stereoscopic image and a plane image by switching therebetween, if it is modified to be able to display various stereoscopic images, the load of the image processing system for realizing the stereoscopic vision becomes large in particular in displaying moving images. Namely, if the three-dimensional drawing process is performed in real time, a high performance image processing circuit is required, thus increasing the cost and restricting implementation in the game machine usage in view of a heat generation problem. Further, in the case in which the moving image is displayed by frame-by-frame advance using the result of the three-dimensional drawing process performed previously in the out side and stored in an image storing memory, if a high image quality needs to be assured, in view of the restrictions in the image compression method, a need for providing unfeasible amount of image storing memory arises, as a result.
SUMMARY
[0009] Therefore, in view of the above, the invention has an advantage of providing a display device, which is low in price and can easily applied to the usage of the game machine or the like, a control method therefor, and a game machine implementing the display device.
[0010] A display device according to an aspect of the invention includes (a) a display panel having a planar image display area, (b) a barrier device having a barrier disposed opposing to the image display area, and switchable between an operative state for allowing stereoscopic viewing and an inoperative state for disabling stereoscopic viewing, wherein in the operative state, the barrier device can locally be set to a partial operative state in which a part of the image display area is covered by the barrier, and (c) a control device that outputs barrier control information to the barrier device to make the barrier device switch the state of the barrier including the partial operative state.
[0011] In the display device described above, since the barrier device is switchable between the operative state for allowing stereoscopic viewing and the inoperative state for disabling stereoscopic viewing, it becomes possible to perform display with enhanced seasoning by the stereoscopic viewing with necessary timing such as in the stage requiring warming up of the performance in view of the proceeding of the game. Further, since in the present display device, the barrier device can locally be set to a partial operative state in which a part of the image display area is covered by the barrier, the partial stereoscopic viewing becomes possible only by displaying the stereoscopic viewing image in the selective area covered by the barrier, thus the process of stereoscopic viewing, which requires relatively large amount of computation and relatively large amount of memory, can be limited to the selected area. Therefore, the load to the mage processing when displaying the stereoscopic viewing image can be reduced, thus an inexpensive display device suitable for implementation to the game machines can be provided.
[0012] According to the specific aspect or viewpoint of the invention, in the display device described above, the barrier device is divided into a plurality of partial areas, and in the partial operative state, each of the partial areas is set to either one of the operative state or the inoperative state. In this case, either of the operative state or the inoperative state is set for every partial area, thus various forms of stereoscopic viewing display can be realized by appropriately changing the display areas according to needs.
[0013] According to another aspect of the invention, the barrier device includes a drive circuit that switches each of the partial areas to one of the operative state and the inoperative state. In this case, by transmitting a predetermined control signal to the drive circuit belonging to the barrier device, each of the partial areas can be set either one of the operative state and the inoperative state.
[0014] According to still another aspect of the invention, the display panel operates in accordance with image data input to the display panel, and the control device includes the barrier control information in the image data, and the barrier device includes a barrier control device that separates the barrier control information from the image data. In this case, since the barrier control information can be included in the image data, and the barrier control information can be separated from the image data by the barrier device side, conventional data communication lines without accompanying the barrier control can be used, thus the partial stereoscopic viewing can be realized with relatively simple modification of the conventional circuit system.
[0015] According to still another aspect of the invention, the control device performs additional blending of a predetermined digit of a digital brightness signal forming the image data with a predetermined signal including the barrier control information in this case, the barrier control information can be overlapped with the image data, thus the output specification (e.g., number of bits or signal elements) of the image data can be used for the barrier control without changing the specification. It should be noted that if the image data and the predetermined signals are additionally blended, the image data is modified. However, by setting the condition not to degrade the stereoscopic viewing, no substantial problems are caused.
[0016] According to still another aspect of the invention, the control device replaces at least a part of a left vertical line of a digital brightness signal forming the image data with the barrier control information. In this case, the barrier control information can easily be overlapped with the image data, thus the output specification of the image data can be used for the barrier control without changing the specification.
[0017] According to still another aspect of the invention, the control device replaces at least a part of a left vertical line of a digital brightness signal relating to a predetermined color forming the image data with the barrier control information. In this case, the barrier control information can easily be overlapped with the image data, thus the output specification of the image data can be used for the barrier control without changing the specification. It should be noted that by selecting the predetermined color as visually indistinctive one, the modification of the stereoscopic viewing image becomes less sensible.
[0018] According to still another aspect of the invention, a communication cable for transmitting the barrier control information output from the control device to the barrier device. In this case, the state of the every partial area can be switched with a simple signal output without adding any modifications to the image data.
[0019] Further, a game machine according to another aspect of the invention includes (a) the display device according to above aspect of the invention that performs stereoscopic viewing in a display section, (b) a performance control device that makes the display device perform stereoscopic viewing display in accordance with status of the game.
[0020] According to the game machine, the display device is implemented therein, and since the game machine makes the display device perform the stereoscopic viewing display in accordance with the proceeding of the game, the game with enhanced seasoning becomes possible. In this case, in the display device, partial stereoscopic viewing becomes possible only by displaying the stereoscopic viewing image only in the selected area covered by the barrier, and the processing of the stereoscopic viewing image can be limited in the selected area. Therefore, the load of image processing in displaying the stereoscopic viewing image can be reduced, thus various forms of display become possible in the game machine having special restrictions.
[0021] Further, a method of controlling a display device according to another aspect of the invention is a method of controlling a display device switchable between an operative state for allowing stereoscopic viewing and inoperative state for disabling stereoscopic viewing including setting locally, in the operative state, the barrier device to a partial operative state in which a part of the image display area is covered by the barrier.
[0022] In the control method described above, partial stereoscopic viewing becomes possible only by displaying the stereoscopic viewing image only in the selected area covered by the barrier, and the processing of the stereoscopic viewing image can be limited in the selected area. Therefore, the load of image processing in displaying the stereoscopic viewing image can be reduced, thus an inexpensive display device suitable for implementation to the game machines can be provided.
[0023] Further, another control method of a display device controls the display device described above, thus the partial stereoscopic viewing of the display device becomes possible.
[0024] Further, a control method of a game machine according to another aspect of the invention controls the game machine described above, thus the partial stereoscopic viewing of the display device becomes possible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention will now be described with reference to the accompanying drawings, wherein like numbers refer to like elements.
[0026] FIG. 1 is a front view showing the whole of a game machine according to an embodiment of the invention.
[0027] FIG. 2 is a block diagram of a control system of the game machine shown in FIG. 1 .
[0028] FIG. 3 is a cross-sectional view for explaining the structure of an image display device.
[0029] FIGS. 4A through 4E are enlarged views for explaining an example of an arrangement of display pixels in a liquid crystal display section.
[0030] FIG. 5 is a front view showing a specific example of stereoscopic display by the image display device.
[0031] FIG. 6 is a front view for explaining the structure and a role of an LCD barrier provided to the image display device.
[0032] FIG. 7 is a diagram for explaining roles of an output interface and so on provided to a display control device.
[0033] FIGS. 8A through 8E are charts each showing an output wave form of respective one of output interface terminals.
[0034] FIGS. 9A through 9C are diagrams for explaining image data output from the output interface.
[0035] FIG. 10 is a diagram for explaining a modified example of the output interfaces and so on shown in FIG. 7 .
[0036] FIGS. 11A through 11C are diagrams for explaining image data output from the output interface.
[0037] FIG. 12 is a block diagram for explaining a display control device according to a second embodiment.
[0038] FIG. 13 is a block diagram for explaining a display control device according to a third embodiment.
[0039] FIG. 14 is a block diagram for explaining a display control device according to a fourth embodiment.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
First Embodiment
[0040] Hereinafter, a game machine and a display device implemented thereto according to a first embodiment of the invention will be explained with reference to the accompanying drawings.
[0041] FIG. 1 is a front view of the game machine according to the present embodiment. The game machine 2 is a pachinko machine, and is provided with a front face frame 3 , a main body frame 4 , and a game board 6 . The front face frame 3 is rotatably attached to the main body frame 4 outside thereof via a hinge 5 so as to be opened and closed, and the game board 6 is housed in a housing frame attached to the back side of the front face frame 3 . The front face frame 3 is provided with a cover glass 7 attached thereto for covering the front face of the game board 6 .
[0042] On the surface of the game board 6 , there is formed a game area surrounded by a guide rail, and in substantially the center of the game area, there is provided an image display device 8 as a device for displaying a special design. The image display device 8 can display an image, which can be viewed stereoscopically using the parallax effect in the left and right eyes by shifting the left-eye image and the right-eye image from each other to display them in the positions different from each other.
[0043] The image display device 8 includes a display screen formed of an LCD (liquid crystal display), namely an image display area IA. In the image display area IA, there can be provided a plurality of varying display areas, for example, each displaying images including identification information (the special design, a standard design), characters acting a game with varying display and so on. Namely, in the varying display areas respectively disposed on the left, center, and right in the center portion of the image display area IA, designs (e.g., fourteen kinds of designs composed of numbers of zero through nine and alphabetical characters off A through D) assigned as the identification information are displayed as varying images, thus the game with varying display is performed. Besides the above, in the image display area IA, in accordance with the proceeding, images corresponding to the present proceeding are displayed.
[0044] FIG. 2 is a block diagram showing the structure of the image display device 8 and a control system relating thereto in the game machine 2 shown in FIG. 1 .
[0045] A game control device 50 is a main control device for integrally controlling the game. The game control device 50 corresponds to performance control means according to the invention, and is a central section for controlling the proceeding of the game such as detection of the prizewinning ball, paying out of the prize balls, and the game with the varying display. However, the device can be configured with typical device configuration, and accordingly the explanation of the specific configuration thereof will be omitted here.
[0046] A display control device 70 is a section for appropriately operating the image display device 8 by processing and operating the image control information (e.g., design display information, background screen information, the three-dimensional display image, and so on) for the game with the varying display in accordance with instructions from the game control device 50 . The display control device 70 is provided with a CPU 71 , an input interface 72 , a video processor 73 , a work RAM 74 , a program ROM 75 , a CGROM 76 , an output interface 77 , and a barrier control section 78 as shown in the drawing. The display control device 70 is basically configured as a processing circuit for a two-dimensional image, but is capable of performing various display control of, for example, displaying or moving two-dimensional images (i.e., plane images) such as a character or a lottery design, or three-dimensional images (i.e., stereoscopic images) on the background image.
[0047] It should be noted here that, the CPU 71 and the video processor 73 treat image data for stereoscopic viewing as, for example, a group of two-dimensional display data and function as control means for controlling the operational state of the image display device 8 , and the video processor 73 , the latter one, functions as an image processing circuit for two-dimensional display for driving the Image display device 8 . Further, the CGROM 76 functions as storage means, which previously stores the image data for stereoscopic viewing and supplies the video processor 73 and so on with the data. The barrier control section 78 has a role, together with a barrier drive circuit 87 described later, of switching the state of the LCD barrier 83 of the image display device 8 to either one of operation state, non-operation state, and partial operation mode. It should be noted that the program ROM 75 stores permanent information for the operation of the display control device 70 , the work RAM 74 is used as a work area for display control based on the instruction of the game control device 50 .
[0048] The image display device 8 is a display section operating under control of the display control device 70 , and performs various display operations relating to proceeding of the game including the varying display game and so on. The image display device 8 includes a lighting device 81 , a display panel 82 , and an LCD barrier 83 . It should be noted here that the lighting device 81 evenly illuminates the display area of the display panel 82 from behind, the display panel 82 is capable of forming a desired color image by modulating the illuminated light, and the LCD barrier 83 is a mask capable of masking the display panel 82 with a fine cyclic pattern and of making the images formed on the display panel 82 as stereoscopic viewing images of four-viewpoints or two-viewpoints in cooperation with the display panel 82 . Among these elements, the lighting device 81 is driven by a backlight drive device 85 under control of the CPU 71 provided to the display control device 70 , and emits the illumination light with necessary intensity. The liquid crystal panel 82 is driven by an LCD drive device 86 under control of the video processor 73 of the display control device 70 , and forms a color transfer image by modifying the illuminated light. The LCD barrier 83 is driven by the a barrier drive device 87 as a drive circuit under control of the video processor 73 and the barrier control section 78 of the display control device 70 , and performs on/off operations, thereby switching between the two-dimensional display (i.e., the plane image display), the whole three-dimensional display (i.e., the whole stereoscopic display), and the partial three-dimensional display (i.e., the local stereoscopic display). It should be noted that in the case in which the LCD barrier 83 becomes the on state, a compositive image for stereoscopic viewing is formed on the display panel 82 for realizing the stereoscopic viewing through the LCD barrier 83 . It should be noted here that in the case in which the LCD barrier 83 becomes the on state in whole, namely it becomes the whole operation state, the compositive image for stereoscopic viewing is formed on the display panel 82 all over the area thereof for realizing the stereoscopic viewing all over the area thereof through the LCD barrier 83 in the on state in whole. Further, in the case in which the LCD barrier 83 becomes the partial on state, namely it becomes the partial operation state, the compositive image for stereoscopic viewing is formed locally on the display panel 82 for realizing the stereoscopic viewing in a partial area through the LCD barrier 83 in the partial on state
[0049] In the above cases, the image display device 8 and the display control device 70 configure a display device capable of performing stereoscopic display of moving images relating to the proceeding of the game.
[0050] Hereinafter, a typical operation of the game machine 2 shown in FIGS. 1 and 2 will be explained. In the game machine 2 , the game is started in response to a game ball struck out towards the game area by a ball launcher (not shown), and the game ball thus struck out descends the game area.
[0051] If the game ball enters the start-up hole 9 to win a prize, the game control device 50 performs a lottery, and a command for designating the display content is output to the display control device 70 . The image display device 8 , which operates under control of the display control device 70 , displays a predetermined image in response to the command. If the result of the lottery described above is the bell ringer, in the image display area IA, the display stops in the condition (the bell ringer designs) in which the three designs displayed thereon are the same.
[0052] Hereinafter the detail of the image display device 8 will be explained. The image display device 8 allows the stereoscopic viewing in the whole area or the stereoscopic viewing in a partial area by the operation of the LCD barrier 83 as described above. If the LCD barrier 83 is in the off state (in a normal display mode, namely in a plane display mode), no light blocking pattern is formed on the LCD barrier 83 not to cause the light blocking operation in accordance with the light blocking pattern, thus all of the pixels arranged in a plane can be seen. On the contrary, if the LCD barrier 83 is in the on state in whole or in the partial on state, the light blocking with spatial distribution is preformed by the light blocking pattern formed on the LCD barrier 83 , thus it becomes impossible to see all of the pixels. Specifically, when moving through the positions of the viewpoints of EY 1 through EY 4 as shown in FIG. 3 , only the pixels corresponding to each of the viewpoints of EY 1 through EY 4 as enlargedly shown in FIGS. 4A through 4D for example. By using this effect, it is possible to show different images to the left eye and the right eye of the player, thus realizing the stereoscopic viewing.
[0053] It should be noted that FIGS. 4A through 4E explanatory shows an example of a layout of the display pixels forming the display panel 82 . FIGS. 4A, 4B , 4 C and 4 D show an example of arrangement of display pixels kR, kG, and kB (k denotes the viewpoint number) corresponding to the first eye EY 1 , the second eye EY 2 , the third eye EY 3 , and the fourth eye EY 4 , respectively, shown in FIG. 3 . By composing the first through the fourth images as explained with reference to FIGS. 4A through 4D in a lump, the stereoscopic viewing image (the composite image) can be composed (see FIG. 4E ). Such a stereoscopic viewing image corresponds to an image of one frame or a part of the image displayed on the image display device 8 .
[0054] If the target stereoscopic viewing image corresponds to a whole image of one frame, the data (a group of two-dimensional display data as shown in FIG. 4E ) of the stereoscopic viewing image of the one whole frame is output from the video processor 73 to the display panel 82 via the LCD drive device 86 . Thus the player is allowed to observe the composite stereoscopic viewing image corresponding to the stereoscopic viewing image data input to the LCD drive device 86 through the LCD barrier 83 in the on state in whole, thus recognizing the stereoscopic image on or around the display panel 82 . Further, if the target stereoscopic viewing image corresponds to a partial image of one frame, the data (a group of two-dimensional display data as shown in FIG. 4E ) of the stereoscopic viewing image of that part of the one frame is output from the video processor 73 to the display panel 82 via the LCD drive device 86 . In this case, in the other part than that part, ordinary data for plane viewing image is output from the video processor 73 to the display panel 82 via the LCD drive device 86 . Thus, the player is allowed to recognize the stereoscopic image only in the partial area of the display panel 82 .
[0055] It should be noted that by storing the stereoscopic viewing image (the composite image) composed of a plurality of sequentially varying frames in the CAROM 76 provided to the display control device 70 shown in FIG. 2 for every frame, it can also be possible to display a stereoscopic moving image in the whole area of the display panel 82 . If the target stereoscopic viewing image corresponds to a partial image in the one frame, by storing data (a group of two-dimensional display data as shown in FIG. 4E ) of the sequentially varying partial image as the series of the stereoscopic viewing images in the CGROM 76 , it can also be possible to display a stereoscopic moving image in a partial area of the display panel 82 . In these cases, the CGROM 76 only stores two-dimensional images as a frame of images or the partial images, and the image data to be output to the LCD drive device 86 can be created by simply reading out the two-dimensional images or by superposing the two-dimensional images. Namely, in the present display control device 70 , the three-dimensional data processing using a polygon or the like can be eliminated, and even if the processing rate of the video processor 73 is relatively low, the moving image display can be performed with sufficient resolution and frame rate.
[0056] FIG. 5 shows a display example of a stereoscopic image by the image display device 8 . In this case, in the image display area IA of the image display device 8 , a foreground image FG with undulation in the center section thereof is displayed, and a flat background image BG is displayed in the periphery of the image display area IA of the image display device 8 .
[0057] The foreground image FG is a varying display area in the varying display game named “reach” which is a part of the game. Namely, three digits of designs assigned as identification information are respectively displayed in the varying display areas FG 1 through FG 3 provided to the left, the center, and the right of the foreground image FG. In this case, the foreground image FG is for making the display of the stereoscopic figure possible, and is stored in the CGROM 76 provided to the display control device 70 shown in FIG. 2 as a partial image. The foreground image FG is composed of a time series of stereoscopic viewing image data, and the each stereoscopic viewing image data corresponds to the composite image of the four viewpoints exemplifying in FIG. 4E , and realizes the stereoscopic viewing with four viewpoints by itself. Namely, by controlling the timing of reading out the series of stereoscopic viewing image data forming the foreground image FG from the CGROM 76 and making the video processor 73 output the data, it becomes possible to dynamically display a desired stereoscopic image with desired timing. Such stereoscopic viewing image data is calculated by, for example, performing three-dimensional image processing with an external high-speed computer. Specifically, regarding the images of the object approximated by, for example, the polygon or the texture mapping, the images corresponding to the observation from four viewpoints corresponding to the viewpoints EY 1 through EY 4 shown in FIG. 3 are individually rendered (image processing). In this case, processes necessary for performances or effects are collaterally preformed. Further, by repeating the above operation while moving or modifying the polygon or the like, images varying in time series are calculated as a moving image for every viewpoint.
[0058] On the other hand, the background image BG is typically a static or simple image, and can be an image including a character or the like. In this case, it is assumed that the background image BG is a two-dimensional image, and the image data for forming a two-dimensional image by being observed through the LCD barrier 83 in the off state is prepared. As such image data for two-dimensional display, the result of the operation conducted by an external computer can be stored in the CGROM 76 provided to the display control device 70 shown in FIG. 2 as the two-dimensional image data. It should be noted that the background image BG is not limited to a static image but can be a moving image, and in this case, the image data for every frame forming the moving image is stored, for example, in the CGROM 76 .
[0059] FIG. 6 is a diagram for explaining the role of the LCD barrier 83 provided to the image display device 8 . In this case, the LCD barrier 83 is composed of a four-by-four matrix, namely sixteen blocks of partial areas PA. Each of the partial areas PA is configured to be switched on and off independently, and any of partial areas selected as desired can be displayed with stereoscopic images. In the example shown in the drawing, the two-by-two blocks of partial areas PA in the center illustrated with hatching are partially switched on, and the stereoscopic viewing is possible in these four blocks of partial areas PA. If the four partial areas PA corresponding to the center area of the foreground image FG are switched on as shown in the drawing, the composite image (see FIG. 4E ) for stereoscopic viewing is formed only in the portion (partial image display area) existing behind the four partial areas PA in the image display area of the display panel 82 . As a result, the stereoscopic viewing can be realized in the center area of the LCD barrier 83 which has become the on state. On the other hand, other twelve blocks of the partial areas PA are in the off state, the plane viewing becomes possible in these twelve blocks of the partial areas PA surrounding the four areas in the center thereof.
[0060] It should be noted that the partial areas PA shown in FIG. 6 are exemplifications only, and it is possible to divide the LCD barrier 83 into a matrix arrangement of n-by-m (n and m are given positive integers) to define the partial areas. Further, the arrangement of the partial areas are not limited to the matrix arrangement, but the LCD barrier 83 can be divided in to one or more of areas of any shapes (e.g., polygon, ellipse, doughnut-shape, an outline of a character or other displayed materials) and the remaining. Further, it is not necessary to switch on and off every partial areas, but some partial areas can be fixed to the on state, or some of the partial areas can be fixed to the off state.
[0061] FIG. 7 is a diagram for explaining the roles of output interfaces 77 and a barrier control section 78 provided to the image display device 70 . The output interface 77 changes the image data output from the video processor 73 , namely a group of two-dimensional display data to those suitable for driving the display panel 82 . The barrier control section 78 branches the outputs of the output interface 77 and appropriately processes them to separate and extract barrier control information suitable for driving the barrier drive device 87 .
[0062] The output interface 77 is provided with dot/clock terminal, Hsync terminal, DE terminal, Vsync terminal, and pixel data terminals. It should be noted here that the dot/clock terminal outputs a waveform as exemplified in FIG. 8A , and the rising of the output of the terminal to the H state defines the output timing of the pixel data corresponding to each pixel composing the display panel 82 . Further, the Hsync terminal outputs a waveform as exemplified in FIG. 8B , and the rising of the output of the terminal to the H state represents the completion of the output of the pixel data corresponding to the horizontal scan line composing the display panel 82 . Further, the DE terminal outputs a waveform as exemplified in FIG. 8C , and is kept in the on state during the data of the pixel corresponding to the horizontal scan line composing the display panel 82 is continued to be output. Further, the Vsync terminal outputs a waveform as exemplified in FIG. 8D , and the H state of the output of the terminal represents the completion of the sub-scan operation in the vertical direction for composing the display panel 82 , namely the completion of output of the all pixel data. Further, the pixel data terminals are provided for every color, namely red (R), green (G), and blue (B), and the parallel data composed of six pins for every color, totally eighteen bits is output (in the drawing, the outputs for blue are only exemplified with solid lines as an example).
[0063] The barrier control section 78 is a section for branching a part of the pixel data to be output by the output interface 77 to the LCD drive device 86 to create a control signal output to the barrier drive device 87 . The barrier control section 78 corresponds to a barrier control means according to the invention, and configures the barrier device according to the invention together with the barrier drive device 87 and the LCD barrier 83 . Although there are various configurations of the barrier drive device 87 , the case in which the mask judgment circuit is embedded will be explained here. In this case, the barrier control section 78 , namely the mask judgment circuit creates the barrier control information regarding which of the number of the partial areas PA as exemplified in FIG. 6 should be switched to the on state as a matrix address signal, and outputs it to the barrier drive device 87 . Namely, the matrix address signal designates the partial areas PA forming the LCD barrier 83 , and is held in the H state during the time period in which the partial areas are held in the on state. Although various circuit configurations can be used as the mask judgment circuit, for example, It is assumed that the most significant bit (MSB) of the blue pixel data terminals can also be taken out as the signal for inputting to the barrier control means. In this case, the column position in the horizontal direction can be specified by counting the output of the dot/clock terminal while watching the DE terminal, and the line position in the vertical direction can be specified by counting the output of the DE terminal while watching the toggle on the Vsync terminal. Thus, it becomes possible to specify which pixel the MSB obtained as the signal comes from, and if the MSB is in condition for setting the on state of the LCD barrier 83 corresponding to one pixel (it can be switched to the on state if it has not already been set to the on state), the matrix address signal relating to the partial area PA is set to the on state. On the other hand, if the MSB is in the off state, and in the condition for setting the off state of the LCD barrier 83 in the corresponding pixel, the matrix address signal relating to the partial area PA is set to the off state. It should be noted that the mask judgment process and the variation in the matrix address signal accompanied therewith are continuously performed on the each of the drawing frames triggered by the toggle on the Vsync terminal.
[0064] FIGS. 9A through 9C are diagrams for explaining creation of image data output from the output interface 77 . FIG. 9A shows the pixel data for performance display, which is previously stored in the CGROM 76 and processed by the video processor 73 , FIG. 9B shows the pixel data for blending, which is previously stored in the CGRON 76 and processed by the video processor 73 , and FIG. 9C shows the pixel data to be output from the video processor 73 . The pixel data shown in FIG. 9A corresponds to the three primary colors of red, green, and blue with the MSB values of “0.” Namely, the pixel data shown in FIG. 9A is arranged to be able to display the image with the brightness compressed to the low brightness side. The pixel data shown in FIG. 9B corresponds to the three primary colors of red, green, and blue with the MSB values of “1” and values of other bits of all “0.” Namely, the pixel data shown in FIG. 9B is arranged to be able to display the light gray image. Further, the pixel data shown in FIG. 9C is obtained by “additional blending” the pixel data shown in FIG. 9A and the pixel data shown in FIG. 9B . Namely, the pixel data shown in FIG. 9C is for increasing the brightness of the image for performance display as much as the amount corresponding to the light gray, namely the pixel data shown in FIG. 9C realizes the display similar to the high-lighting. It should be noted that the “additional blending” of the pixel data shown in FIGS. 9A and 9B is realized easily and quickly as a function of the video processor 73 . By the “additional blending,” a light gray sprite (see FIG. 9B for the pixel data thereof) corresponding to the shape of the area (specifically, see, for example, the foreground image FG shown in FIG. 5 ) on which the stereoscopic viewing is required is previously prepared in the CGROM 76 or is calculated by the video processor 73 , and the sprite can be composed with the image (see FIG. 9A for the pixel data thereof) for performance display and displayed. Although the light gray additional blending as described above is for forcedly modifying the image for performance display brighter, since in the partial areas PA (see FIG. 6 ) where the LCD barrier 83 is switched on, the brightness is apt to decrease due to the influence of the stereoscopic viewing; namely the influence of the existence of the light blocking pattern, there is caused a secondary advantage of canceling such drop of the brightness with the light gray additional blending. Namely, by performing the light gray additional blending, it becomes difficult for the player to actually sense the variation in the brightness if the image display device 8 is switched from the ordinary display with plane viewing to the stereoscopic display with stereoscopic viewing.
[0065] It should be noted that the pixel data shown in FIGS. 9A and 9C are the pixel data output from the output interface 77 to the LCD drive device 86 and partially includes the barrier control information to be separated by the barrier control section 78 shown in FIG. 7 . Namely, in the barrier control section 785 it is sufficient to Judge whether the value of the MSB of the pixel data of either one of the colors in the pixel data exemplified in FIGS. 9A and 9C is set to “0” or “1,” and it is conceivable that each of the pixel data includes the information relating to whether or not the LCD barrier 83 should be set to the on state in the present pixel position. It should be noted that in the present embodiment, since the LCD barrier 83 is not set to the on state for every pixel, the advantage is obtained by switching on the operation of the partial areas PA covering such pixels. Since the specific process has already explained in detail as the function of the barrier control section 78 shown in FIG. 7 , the explanations therefor will be omitted here. It should be noted that, although it is also possible in principle to set the partial area of the LCD barrier 83 to the on state for every pixel, it is more practicable to switch the partial area of the LDC barrier 83 to the on or off state for every group of pixels.
[0066] By performing aforementioned process, the load of the video processor 73 required for the on/off control of the stereoscopic viewing can dramatically be reduced, and in particular, in the video processor 73 in the present embodiment, which is the drawing system for performing the two-dimensional image processing by appropriately retrieving the two-dimensional display data stored in the CGROM 76 , a large effect of load reduction can be exerted.
[0067] FIG. 10 is a diagram for explaining a modification of the barrier control section 78 and so on shown in FIG. 7 . Also in this case, the barrier control section 78 is a section for branching a part of the pixel data to be output by the output interface 77 to the LC drive device 86 to create a control signal output to the barrier drive device 87 . In this case, the mask judgment circuit configuring the barrier control section 78 creates the barrier control information regarding which of the number of the partial areas PA as exemplified in FIG. 6 should be switched to the on state as a matrix address signal, and outputs it to the barrier drive device 87 . In this case, the mask judgment circuit can be arranged to take out the least significant bit (LSB) of the blue pixel data terminals, for example. In this case, the column position and the line position can be specified by the dot/clock terminal and the DE terminal, which pixel the LSB obtained as the signal comes from can be specified, and if the LSB is the on state and is in condition for setting the LCD barrier 83 to the on state in the corresponding pixel, the matrix address signal related to the partial area PA is set to the on state. On the other hand, if the LSB is in the off state, and in the condition for setting the off state of the LCD barrier 83 in the corresponding pixel, the matrix address signal relating to the partial area PA is set to the off state.
[0068] FIGS. 11A through 11C are diagrams for explaining creation of image data output from the output interface 77 . FIG. 11A shows the pixel data for performance display, which is previously stored in the CGROM 76 or processed by the video processor 73 , FIG. 11B shows the pixel data for blending, which is previously stored in the CGROM 76 or processed by the video processor 73 , and FIG. 11C shows the pixel data to be output from the video processor 73 . The pixel data shown in FIG. 11A corresponds to the three primary colors of red, green, and blue in which the LSB value only in the blue pixel data is set to “0.” Namely, the pixel data shown in FIG. 11A corresponds to an image with the lowered blue gray scale. Further, the pixel data shown in FIG. 11B has the LSB value of “1” and values of other bits of all “0” in the blue pixel data. Namely, the pixel data shown in FIG. 11B corresponds to an image with the darkest blue color. Further, the pixel data shown in FIG. 1C is obtained by “additional blending” the pixel data shown in FIG. 11A and the pixel data shown in FIG. 11B . By the “additional blending,” a dark blue sprite (see FIG. 11B for the pixel data thereof) corresponding to the shape of the area (specifically, see, for example, the foreground image FG shown in FIG. 5 ) on which the stereoscopic viewing is required can be composed with the image (see FIG. 11A for the pixel data thereof) for performance display, and displayed. Although the additional blending as described above is for emphasizing the blue gray scale of the image for performance display for one step, since the luminosity factor of blue is originally low, no visual problem arises and no uncomfortable feeling is caused to the player.
[0069] It should be noted that the pixel data shown in FIGS. 11A and 11C are the pixel data output from the output interface 77 to the LCD drive device 86 and includes the barrier control information to be separated by the barrier control section 78 shown in FIG. 10 . Namely, in the process in the barrier control section 78 , it is nudge whether the value of the LSB of the blue pixel data of either of the pixel data exemplified in FIGS. 11A and 11C is set to “0” or “1,” and the blue pixel data includes the information relating to whether or not the LCD barrier 83 should be set to the on state in the present pixel position. It should be noted that in the present embodiment, since the LCD barrier 83 is not set to the on state for every pixel, the advantage is obtained by switching on the operation of the partial areas PA covering such pixels.
[0070] In the modified example as described above, although the barrier control information is carried on the LSB of the blue pixel data, the barrier control information can be carried ob the LSB of the red pixel data or the LSB of the green pixel data if there are no objections in display.
[0071] In the first embodiment described above, although the pixel data terminals in the output interface 77 shown in FIGS. 7 and 10 are six pins for each color and totally eighteen bits, the specification of the pixel data terminals should appropriately be changed in accordance with the usage. Therefore, these terminals can be replaced with a parallel interface handling data with appropriate number of bits in a range of, for example, a few bits through twenty-odd bits.
[0072] Further, in the above first embodiment of the invention, although the pixel position is specified, and the on/off state of the each of partial areas forming the barrier is specified using the outputs of the dot/clock terminal and the DE terminal, the Hsync terminal or other terminals can also be used, and the signal processing method can be changed accordingly.
Second Embodiment
[0073] Hereinafter, a game machine and a display device implemented thereto according to a second embodiment of the invention will be explained with reference to the accompanying drawings. It should be noted that the game machine and so on according to the second embodiment are modifications of the game machine and so on of the first embodiment, and accordingly, portions with no particular explanations are the same as those in the first embodiment, and the same sections are provided with the same reference numerals and any duplicated explanations will be omitted.
[0074] FIG. 12 is a diagram for explaining the relevant section of the display control device 70 implemented in the present embodiment. The barrier control section 178 branches a part of the image data to be output by the output interface 77 to the LCD drive device 86 to create a control signal output to the barrier drive device 87 . In this case, the mask judgment circuit configuring the barrier control section 178 creates the barrier control information regarding which of the number of the partial areas PA as exemplified in FIG. 6 should be switched to the on state as a matrix address signal, and outputs it to the barrier drive device 87 . The mask judgment circuit is assumed to take out the data from all of the pixel data terminals of all of the colors. In this case, the data reading out is started in response to the toggle on the Vsync terminal, and the data is latched in response to the toggle on the DE terminal. Thus, the eighteen bit of parallel data bundling all of the six bits for each of the three colors can be taken out. It should be noted here that since the timing of latching the data is set by the rising of the signal on the DE terminal, the pixel data for performance display output from the video processor 73 includes meaningless part corresponding to the barrier control information in the one vertical line in the left end of the display panel 82 . However, the left end vertical line is usually masked easily by existence of a masking member or the like, and accordingly, it can hardly obstruct the view of the player. It should be noted that if a mask is provided in the display panel 82 side with a filter, or the data removal is performed in the left vertical line with the control by the logic circuit elements, a process equivalent to lighting-off is performed, and accordingly, there is no chance for the control data to be observed by the player.
[0075] As described above, the barrier control information embedded in the vertical line in the left end of the display panel 82 is eighteen bits of parallel data, and can be decoded by a decoder circuit (not shown) embedded in the barrier control section 178 as the barrier control protocol signal. Such barrier control protocol information is output to the barrier drive device 87 as the matrix address signal directly or after processed by the barrier control section 178 .
[0076] Meanwhile, the video processor 73 builds the barrier control information into the image data corresponding to the image to be displayed on the display panel 82 under control of the CPU 71 . In this case, the video processor 73 embeds the barrier control information as the line data by sequentially writing the color and brightness data, which correspond to a signal to be decoded as the barrier control protocol, as a dot in one left end vertical line.
[0077] In the above process, although the barrier control information is embedded in the section corresponding to the left end vertical line in the image data to be output to the display panel 82 , the barrier control information can be embedded in the section corresponding to the right end vertical line in the image data, or the section corresponding to the upper end of the lower end horizontal line in the image data, and the barrier control information can also be sent out to the barrier control section 178 and the barrier drive device 87 .
Third Embodiment
[0078] Hereinafter, a game machine and a display device implemented thereto according to a third embodiment of the invention will be explained with reference to the accompanying drawings. It should be noted that the game machine and so on according to the third embodiment are modifications of the game machines and so on according to the second embodiment.
[0079] FIG. 13 is a diagram for explaining the relevant section of the display control device 70 implemented in the present embodiment. The barrier control section 278 branches a part of the image data to be output by the output interface 77 to the LCD drive device 86 to create a control signal output to the barrier drive device 87 . In this case, the mask judgment circuit configuring the barrier control section 278 creates the barrier control information regarding which of the number of the partial areas PA as exemplified in FIG. 6 should be switched to the on state as a matrix address signal, and outputs it to the barrier drive device 87 . The mask judgment circuit is assumed to be able to take out data from only the LSB of the blue pixel data out of the pixel data terminals. In this case, the data reading out is started in response to the toggle on the Vsync terminal, and the data is latched in response to the toggle on the DE terminal. Thus, the one bit of serial data can be taken out using a single pixel data terminal. It should be noted here that since the timing of latching the data is set by the rising of the signal on the DE terminal, the pixel data for the performance display output from the video processor 73 includes meaningless part corresponding to the barrier control information in the least significant bit of the blue pixel data terminals in the left end vertical line of the display panel 82 . However, as a result, it is nothing more than emphasizing the image for the performance display in the blue gray scale for one step, therefore, no visual problem arises and no uncomfortable feeling is caused to the player.
[0080] As described above, the barrier control information embedded in the vertical line in the left end of the display panel 82 is one bit of serial data, and can be decoded by a decoder circuit knot shown) embedded in the barrier control section 278 as the barrier control protocol signal. Such barrier control protocol information is output to the barrier drive device 87 as the matrix address signal directly or after processed by the barrier control section 278 .
[0081] Meanwhile, the video processor 73 builds the barrier control information into the image data corresponding to the image to be displayed on the display panel 82 under control of the CPU 71 . In this case, the video processor 73 embeds the barrier control information as the line data by sequentially writing the signal to be decoded as the barrier control protocol as the least significant bit of the blue brightness data as a dot in one left end vertical line.
[0082] Although in the above embodiment, the barrier control information is carried of the LSB of the blue pixel data in the left end vertical line, as a modified example, it is possible to handle the LSB of the blue pixel data in the upper horizontal line as the serial data. Further, if there are no objections in display, the barrier control information can be carried on the LSB of the red pixel data or the LSB of the green pixel data instead of the blue pixel data.
[0083] Further, in the above embodiment, although the barrier control information is embedded in the section corresponding to the left end vertical line in the image data to be output to the display panel 82 , the barrier control information can be embedded in the section corresponding to the right end vertical line in the image data, or the section corresponding to the upper end or the lower end horizontal line in the image data, and the barrier control information can also be sent out to the barrier control section 278 and the barrier drive device
Fourth Embodiment
[0084] Hereinafter, a game machine and a display device implemented thereto according to a fourth embodiment of the invention will be explained with reference to the accompanying drawings. It should be noted that the game machine and so on according to the fourth embodiment are modifications of the game machine and so on according to the first embodiment.
[0085] FIG. 14 is a diagram for explaining the relevant section of the display control device 70 implemented in the present embodiment. The output interface 377 is provided with a dedicated signal line, namely the communication cable SL, capable of independently outputting the barrier control signal to the barrier control section 378 . The barrier control section 378 receives the barrier control information via the communication cable SL, and the outputs the barrier control information to the barrier drive device 87 as the matrix address signal. Here, the barrier control information communicated through the communication cable SL is a signal of a predetermined barrier control protocol, and includes instruction information regarding which of a number of the partial areas PA exemplified in FIG. 6 should be switched on. It should be noted that the communication cable ST can be the one bit serial transmission system, but can also be the multi-bit parallel transmission system.
[0086] In the embodiment described above, since the output interface 377 is for the LCD drive device 86 by nature, it is possible to provide an output interface dedicated to the barrier control signals independently from the output interface 377 , and to intervene between the video processor 73 and the barrier control section 378 , or the video processor 73 and the barrier drive device 87 .
[0087] Although the invention is explained along the embodiments described above, the invention is not limited to the above embodiments. For example, although in the embodiments described above, the display panel 82 composed of the liquid crystal display device is built in the image display device 8 , a rear projection type of projector, a CTR, or the like can be used instead of the liquid crystal display device. Further, the method of realizing the stereoscopic viewing is not limited to the method using a kind of parallax barrier as in the embodiments, but various stereoscopic viewing methods such as a lenticular lens array (e.g., JP-A-7-16351) or an image splitter (e.g., JP-A-9-164263).
[0088] Further, although in the above embodiments, the LCD barrier 83 and the display panel 82 for four viewpoints are used, those for two viewpoints can be used for the stereoscopic viewing by changing the design of the LCD barrier 83 .
[0089] Further, although in the embodiments described above, the image display device 8 is built in the game machine 2 , the image display device 8 and the display control device 70 can be built in other devices (e.g., a vehicle navigation system, and various home electric appliances including a TV game). In this case, the display position of the stereoscopic image can be set to a desired location and a desired area in the display screen by the control of the display control device 70 .
[0090] The entire disclosure of Japanese Patent Application No. 2005-239402, filed Aug. 22, 2005 is expressly incorporated by reference herein.
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A display device includes a display panel having a planar image display area, a barrier device having a barrier disposed opposing to the image display area, and switchable between an operative state for allowing stereoscopic viewing and an inoperative state for disabling stereoscopic viewing, wherein in the operative state, the barrier device can locally be set to a partial operative state in which a part of the image display area is covered by the barrier, and a control device that outputs barrier control information to the barrier device to make the barrier device switch the state of the barrier including the partial operative state.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority of the filing date of Provisional Application Ser. No. 61/070,596 filed Feb. 21, 2008.
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
The present invention relates to compositions of matter for thermoplastic nanocomposites containing nanodiamond particulates known commonly as detonation nanodiamond.
Although detonation nanodiamond (DND) was discovered relatively early (in the 1960's) in USSR as compared to other carbon nanoparticles, viz. fullerenes, single-walled, double-walled, multi-walled carbon nanotubes (SWNT, DWNT and MWNT) and nanofiber (CNF), DND has received little or no attention until 1988 when two landmark papers appeared in open literature. Detonation nanodiamond was so-named because of its production by detonation of 2,4,6-trinitrotoluene (TNT)/1,3,5-trinitro-triazacyclohexane (hexogen) explosives in a closed steel chamber either in gaseous atmosphere, e.g. CO 2 (dry method) or in water (wet method). DND is also known by two other common names, viz. ultra-dispersed diamond (UDD) and ultrananocrystalline diamond (UNCD) particulates, because the basic constituents (primary particles) have the characteristic size in the range of 2-10 nm (ave. diameter ˜4-5 nm) and very large specific surface area (>>200 m 2 /g). With the important advantages such as availability in larger quantities (industrial production capabilities existing in Russia, Ukraine, China and Belarus) and at moderate cost, DND is very attractive as a material platform for nanotechnology. Furthermore, DND has been shown to be non-cytotoxic and biocompatible. These features give DND an additional appeal to bio-related applications in view of its rich surface chemistry that could be modified with relative ease. The surface functional groups identified by various spectroscopic techniques are mostly oxygenated moieties such as —CO 2 H (carboxylic acid), lactone, C═O (keto carbonyl), —C—O—C (ether) and —OH (hydroxyl). In addition, inter-particle hydrogen-bonding and formation of ester, ether, and anhydride bonds are believed to play important roles in assembling the DND primary particles into much larger aggregates with sizes ranging from a few hundred nanometers (“core agglutinates”) to a few ten microns (“agglomerates”). In fact, under appropriate pH conditions, these inter-particle binding forces are believed to be responsible for the large-scale self-assembly of acid-treated DND into fibers and thin films from drying the suspension. Further, the primary particles in the core agglutinates are so strongly bound together that the total binding force is even greater than that in SWNT ropes, which stems from noncovalent (van deer Waals and π-π) interactions between individual nanotubes. Indeed, it is known that even powerful ultrasonication of crude nanodiamond aggregates could only produce core agglutinates with average size of 120 nm.
Covalent surface modifications of diamond nanoparticles are generally focused on improving the DND processability and introducing suitable functional groups to impart, enhance or tailor certain properties, and eventually, to increase system compatibility and performance. The synthetic tools for such modification have entailed the conversion of the oxygenated groups (i.e. carboxylic acid, hydroxyl etc.) to suitable functionalities for subsequent manipulation. For example, DND was fluorinated using a F 2 /H 2 mixture to afford 8.6 atom % fluorine (replacing OH, CO 2 H etc.) on the surface, and the fluorinated DND was then used as a precursor for the preparation of alkyl-, amino-, and acid-functionalized DNDs that showed an increased solubility in polar solvents and much smaller size in nanoparticle agglomeration, or coated covalently onto an amine-functionalized glass surface. High temperature (400-850° C.) treatment of DND powders in the presence of H 2 , Cl 2 or NH 3 has also led to converting the surface carboxylic acid to alcohol, acid chloride, and nitrile, in that order. More recently, the reduction of the surface —CO 2 H by BH 3 .THF complex to the corresponding —CH 2 OH, followed by O-silylation with (3-aminopropyl)trimethoxysilane and coupling with biotin or a short peptide to generate promising bio-nano hybrid materials has been reported.
Besides the aforementioned reports on the covalent functionalization of DND surfaces that were likely to have occurred at the outermost layer with mixed sp 2 and sp 3 carbons, Li et al. (Li, L.; Davidson, J. L.; Lukehart, C. M. Carbon 2006, 44, 2308) reported the first example of DND-polymer nanocomposites, in which poly(methyl methacrylate) brushes were grafted from initiators, previously and covalently bonded on the DND surface, by atom transfer radical polymerization (ATRP) process. Most recently, Zhang et al. (Zhang, Q.; Natio, K.; Tanaka, Y.; Kagawa, Y. Macromolecules 2008, 41, 536) reported the grafting of aromatic polyimides from nanodiamonds. In these reports, the DND component in the polymer nanocomposites was actually aggregates (20-50 nm) of primary particles, resulting in polymer-DND particles with sizes 100-200 nm.
Conceptually, there are three general techniques for dispersing chemically unmodified DND in the linear polymer matrices: (1) melt blending (2) solution blending, and (3) reaction blending. For the reaction blending route, there are two scenarios: (a) in-situ polymerization of monomers (AB) or co-monomers (AA+BB) in the presence of dispersed DND that occurs without forming any covalent bonding between the DND and the matrix polymer, or (b) in-situ grafting of AB monomers that occurs with direct covalent bonds formed between the DND and the matrix polymer. Thus, using Friedel-Crafts acylation as a synthetic tool to exemplify reaction blending route to DND-based nanocomposites, it is shown here how to chemically attach meta-poly(ether-ketone) onto the surfaces of DND via in-situ polymerization of an appropriate AB monomer such as m-phenoxybenzoic acid in the presence of DND in poly(phosphoric acid).
Accordingly, it is an object of the present invention to provide a process for attaching a poly(ether-ketone) onto the surfaces of diamond nanoparticles.
It is another object of this invention to provide polymer-grafted nanodiamonds particles and associated nanocomposites.
Other 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 may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a poly(ether-ketone) composite of the formula:
wherein Ar represents ether-ketone repeating groups of the formula
wherein Q is —O— or —O—(CH 2 ) n —O—, wherein n has a value of 2-12; wherein R is —H, —CH 3 , or —C 2 H 5 , m has a value of 1 or 2; wherein R′ is —H or —CH 3 ; and wherein — denotes a direct C—C bond between Ar and carbon nanofibers or multi-walled carbon nanotubes. Preferably, Q is —O—, R is —H, m is 2 and R′ is —H. Nanodiamond particles include primary particles (3-5 nm) and agglutinates (10-150 nm).
Also provided is a process for preparing the above nanocomposites.
DETAILED DESCRIPTION OF THE INVENTION
The composite of this invention is prepared by reacting an aromatic acid of the formula
wherein R, R′, m and Q are as described above, with detonation nanodiamond particulates in polyphosphoric acid (PPA), as described below.
Suitable aromatic acids useful in this reaction include 3-phenoxybenzoic acid, 4-phenoxybenzoic acid, 3-(2,6-dimethylphenoxy)benzoic acid, 3-phenoxy-2-methylbenzoic acid, and the like.
Attachment of the poly(ether-ketone) onto the surfaces of nanodiamond particulates is conducted in polyphosphoric acid (PPA). Preliminarily it is helpful to describe the chemistry of phosphoric acids and strong phosphoric acids or polyphosphoric acids as follows: As used herein the term “phosphoric acid(s)” means commercial phosphoric acid(s) containing 85-86% H 3 PO 4 . The strong phosphoric acids, or polyphosphoric acids referred to as PPA (polyphosphoric acid) are members of a continuous series of amorphous condensed phosphoric acid mixtures given by the formula
H n+2 P n O 3n+1
or
HO—(PO 3 H) n —H
where the value of n depends on the molar ratio of water to phosphorus pentoxide present.
In its most general definition, polyphosphoric acid composition can range from distributions where the average value of n is less than unity, giving rise to a mobile liquid, to high values of n, where the polyphosphoric acid is a glass at normal temperatures. Because the species of polyphosphoric acid are in a mobile equilibrium, a given equilibrium composition can be prepared in many ways. For instance, the same distribution or polyphosphoric acid composition could be prepared by either starting with concentrated orthophosphoric acid (H 3 PO 4 , n=1) and driving off water or by starting with phosphorus pentoxide (P 2 O 5 ) and adding an appropriate amount of water.
All polyphosphoric acid compositions can be described as a ratio of P 2 O 5 and water by reducing the various species present (on paper) to P 2 O 5 and water. We will then use the convention that polyphosphoric acid composition will be expressed in terms of a P 2 O 5 content (as a percentage) defined as P 2 O 5 content
=(weight of P 2 O 5 )/(weight of P 2 O 5 +weight of water)×100.
Thus, the P 2 O 5 content of pure orthophosphoric acid could be derived by reducing one mole of H 3 Pa 4 to 0.5 moles P 2 O 5 +1.5 moles H 2 O. Converting to weights gives the P 2 O 5 content as
(0.5*142)/((0.5*142)+(1.5*18.01))*100%=72.4%
Similarly, the P 2 O 5 content of commercial polyphosphoric acid can be derived in the following way. Polyphosphoric acid is available commercially in two grades, 105% and 115%. These percentages refer to H 3 PO 4 content, which means that 100 g of the two grades contain 105 and 115 grams of H 3 PO 4 . The P 2 O 5 content of 115% polyphosphoric acid can then be calculated knowing the P 2 O 5 content of 100% H 3 PO 4 :
(115 g/100g)*72.4%=83.3%
The polymerization is conducted in polyphosphoric acid (PPA) at a polymer concentration of about 5 weight percent at a temperature of about 130° C. The acid, detonation nanodiamond particulates, and PPA (83% assay) are combined and stirred with dried nitrogen purging at about 130° C. for about 3 hours. Additional P 2 O 5 is then added in one portion; and heating is continued, with stirring for about 24-60 hours. The reaction product is then precipitated from the PPA reaction solution with water or other polymer nonsolvent. The amount of P 2 O 5 added is optimized at 25 wt % of the PPA used at the beginning of the reaction, leading to a total P 2 O 5 content of about 86.7%.
The following examples illustrate the invention:
Example 1
Functionalization of DND with 4-(2,4,6-trimethylphenoxy)benzoic acid (TMPB-g-DND)
Into a 100 mL resin flask equipped with a high torque mechanical stirrer, and adaptors for nitrogen inlet and outlet, 4-(2,4,6-trimethylphenoxy)benzoic acid or TMPBA (0.20 g, 0.78 mmol), DND (0.20 g), PPA (83% P 2 O 5 assay, 10 g) and phosphorus pentoxide (P 2 O 5 , 2.5 g) were charged, and the reaction mixture was stirred under dried nitrogen purging at 130° C. for 72 h. After cooling down to room temperature, water was added to the reaction mixture. The resulting precipitate was collected, washed with diluted ammonium hydroxide and Soxhlet extracted with water for three days and methanol for three days. It was then dried over P 2 O 5 under reduced pressure at 100° C. for 72 h to afford 0.31 g (80% yield) of gray solid. Anal. Calcd. for C 7-89 H 3 N 1.75 O 0.56 (based on the assumption that for every 100 carbon, there are 2.35 4-(2,4,6-trimethylphenoxy)benzoyl groups attached): C, 87.58%; H, 2.10%; N, 1.75%; O, 7.01%. Found: C, 86.73%; H, 1.58%; N, 1.90%; O, 7.51%. 1 H-NMR (DMSO-d 6 , δ in ppm): 2.03 (s, 6H), 2.27 (s, 3H), 6.88 (d, 2H), 7.001 (s, 2H), 7.69 (d, 2H). FT-IR (KBr, cm −1 ): 3418 (OH), 2922 (CH 3 ), 1712 (O—C═O), 1658 (C—C═O), 1595, 1234, 1157, 1079.
Example 2
PPA-Treated DND
In order to investigate the effect of PPA/P 2 O 5 on DND, a control experiment was conducted, in which DND (0.20 g), alone was heated in PPA/P 2 O 5 [ 83% P 2 O 5 assay, 20 g) and phosphorus pentoxide (P 2 O 5 , 5.0 g] at 130° C. for three days to afford a sample (0.18 g), designated as PT-DND, in 90% recovery yield. The work-up procedure was same as that for Example 1.
The IR spectrum of PT-DND is essentially identical with that of the pristine DND except that most of the absorption peaks of PT-DND are sharper. The TGA results indicate that the thermo-oxidative stability of PT-DND has been significantly improved over the pristine DND. The powder samples PT-DND shows a 5% weight loss at 577° C., 50° C. higher than the pristine DND, in air. PT-DND was also observed to generate a higher char yield (94.5%) than the pristine DND (92.4%) in nitrogen (Table 2). The higher stability of PT-DND is probably due to the removal of some inorganic impurities from the pristine DND during PPA treatment. Scanning electronic microscopy (SEM) results indicated that the sizes and shapes of PT-DND are similar to the ground pristine DND, albeit the surface of PT-DND has become slightly smoother. All above results indicate that apart from being an efficient Friedel-Crafts catalyst, PPA is also chemically benign to the DND structure, and improves the thermal stability of DND by effectively removing the residual contaminants.
Example 3
Representative Procedure for Preparation of In-Situ Nanocomposites (mPEK with 20 wt % DND Load)
Into a 250 mL resin flask equipped with a high-torque mechanical stirrer, adaptors for nitrogen inlet/outlet, and a solid-addition port, 3-phenoxybenzoic acid (PBA; 4.00 g, 18.7 mmol), DND (1.00 g), and PPA (83% P 2 O 5 assay; 100 g) were added, and the reaction mixture was stirred under dry nitrogen purge at 130° C. for 3 h. P 2 O 5 (25.0 g) was then added in one portion via the solid-addition port. The initially dark mixture (due to dispersion of DND) became lighter and more viscous as the polymerization of PBA and the growth of mPEK grafts on progressed. The temperature was maintained at 130° C. for 48 h. At the end of the reaction, the color of mixture was dark brown, and water was added to the reaction vessel. The resulting purple nanocomposite clusters were put into a Waring blender, and the solid chunks were chopped, collected by suction filtration, and washed with diluted ammonium hydroxide. Then, the nanocomposite product was then Soxhlet-extracted with water for 3 days and then with methanol for 3 more days and was finally dried over phosphorus pentoxide under reduced pressure at 100° C. for 72 h to give a purple powder in quantitative yield. Anal. Calcd for C 6.84 H 3.44 N 0.03 O 0.44 : C, 82.20%; H, 3.44%; N, 0.44%; O, 13.92%. Found: C, 81.44%; H, 3.57%; N, 0.21%; O, 12.74%. FT-IR (KBr; cm −1 ): 3431, 3063, 1657 (carbonyl), 1576, 1433, 1237, 1161, 877, 757.
Example 4
Extraction of Free mPEK from 20 wt % mPEK-g-DND
Although the AB-monomer (3-phenoxybenzoic acid) is soluble in hot methanol, mPEK is insoluble in hot methanol, but it is very soluble in methylene chloride (CH 2 Cl 2 ). Therefore, 20 wt % mPEK-g-DND (purple powder sample, 1.00 g) was dispersed in CH 2 Cl 2 in a closed vial at room temperature for 48 h. During this period, the suspension was sonicated, and then filtered through 0.2 μm PTFE membrane. The purple solid was collected. It was dispersed in fresh CH 2 Cl 2 , sonicated and filtered again. The filtrate was spotted on a thin-layer chromatography (TLC) plate, which was checked for fluorescence due to mPEK with a hand-held UV lamp. The above extraction routine was repeated 3 times until TLC showed no sign (fluorescent spot) of free mPEK in the CH 2 Cl 2 filtrate. After the removal of CH 2 Cl 2 from the sample, the residue was dried in vacuum to afford 0.92 g of purple powder. This test indicates that most of mPEK was grafted onto DND.
Example 5
Various polymerizations were carried out with different ratios of the AB-monomer, 3-phenoxybenzoic acid (PBA) and DND using the procedure given in Example 1. The elemental analysis results of these nanocomposites as well as those for pristine DND TMPB-g-DND and PT-DND (for reference and comparison purposes) are given in Table 1:
TABLE 1
Element analysis data for pristine, TMPB-g-DND,
and PT-g-DND and mPEK-g-DND.
Sample
Elemental Analysis
C (%)
H (%)
N (%)
O (%)
Pristine DND
Calcd
100
0
0
0
Found a
90.35
1.06
2.06
4.87
TMPB-g-DND
Calcd b
87.58
2.10
1.75
7.01
Found
86.73
1.58
1.90
7.51
PT-DND
Calcd
100
0
0
0
Found
90.87
1.10
1.92
4.98
mPEK-g-DND,
Calcd c
79.74
4.05
0.02
16.19
1 wt %
Found
79.43
4.33
<0.1
15.87
mPEK-g-DND,
Calcd c
79.82
4.01
0.04
16.06
2 wt %
Found
79.18
4.21
<0.1
15.67
mPEK-g-DND,
Calcd c
80.25
3.92
0.11
15.71
5 wt %
Found
80.07
3.92
0.08
15.67
mPEK-g-DND,
Calcd c
80.41
4.26
0.21
15.12
10 wt %
Found
80.69
3.84
0.16
14.93
mPEK-g-DND,
Calcd c
82.20
3.44
0.44
13.92
20 wt %
Found
81.44
3.57
0.21
12.74
mPEK-g-DND,
Calcd c
83.47
3.14
0.66
12.73
30 wt %
Found
83.53
3.14
0.61
12.48
a Based on the elemental analysis result, the empirical formula of pristine DND is C 7.52 H 1.06 N 0.15 O 0.30 , which was used in the subsequent calculation of mPEK-g-DND. nanocomposites compositions.
b Its molecular formula of C 7.89 H 3 N 1.75 O 0.56 is based on the assumption that for every 100 carbon, there are 2.35 2,4,6-trimethylphenoxybenzoyl groups attached. The molecular formula of 4-(2,4,6-trimethylphenoxy)benzoyl group is C 16 H 15 O 2 .
c Calculated composition based on the assumption that the molar mass of the repeat unit of mPEK (C 13 H 8 O 2 ) is 196.20. Empirical formulas derived from the molar ratios of DND:mPEK, i.e., C: C 13 H 8 O 2 , are as follows: (1/99) C 6.64 H 4.05 N 0.0016 O 1.01 ; (2/98) C 6.65 H 4.01 N 0.003 O 1.00 ; (5/95) C 6.67 H 3.92 N 0.008 O 0.98 ; (10/90) C 6.70 H 4.22 N 0.015 O 0.95 ; (20/80) C 6.84 H 3.44 N 0.03 O 0.44 ; (30/70) C 6.91 H 3.12 N 0.05 O 0.79-
Example 6
The glass-transition temperatures (T g 's) and exotherms of mPEK-g-DND samples were determined by DSC. The powder samples were heated to 300° C. in the DSC chamber in the first run and cooled to ambient temperature at 10° C./min under nitrogen purge. Then, the samples were heated to 300° C. at 10° C./min in the second run. As shown in data summarized in Table 2, pure mPEK displays a T g at 136° C. during both first and second heating runs. However, the mPEK-g-DND samples show exotherms with peak values varying between 131 and 147° C., and no T g 's were detected during the first heating runs. The exothermic peak value increases somewhat proportionately with DND contents. The exotherms of as-produced samples (i.e. without prior heat treatment to 300° C.) were attributed to the storage strain energy induced by the shear field (i.e. generated by mechanically stirring) during the polymerization process at 130° C. in viscous PPA. After polymerization, the samples were cooled down and the storage strain energy of mPEK was retained kinetically by the increase in PPA bulk viscosity. When they were heated close to T g 's, the frozen polymer chains started to move, with the strain energy being released. For neat mPEK, no exotherm was observed during the first heating run. Since its T g at 136° C. is very close to polymerization temperature (130° C.), either the storage strain energy did not build up or it was released just before cooling down due to its lower viscosity than mPEK-g-DND after polymerization. The T g 's of nanocomposites appear in the second heating scan. As the amount of DND increased, the T g 's of the nanocomposites gradually increased to 155° C. for 30 wt %. This is consistent with the rationale that the attachment of flexible mPEK chains to the rigid DND surface imposes constraints over their mobility, resulting in as much as a 19° C. increase in the glass-transition temperature. Most importantly, the presence of a single T g for all the mPEK-g-DND samples provide a strong support to the assertion that the polymer-grafted diamond nanoparticles were indeed homogeneously dispersed throughout the nanocomposites, and the effectiveness of our in-situ polymerization method.
TABLE 2
Physical properties of mPEK-g-DND composites.
DSC
2 nd
TGA
1 st Heating
Heating
in nitrogen
in air
DND
[η] a
T exo b
ΔH
T g c
T d5% d
Char e
T d5% d
Char e
(wt %)
(dL/g)
(° C.)
(J/g)
(° C.)
(° C.)
(%)
(° C.)
(%)
0
0.46
136 (T g )
—
136
402
47.1
414
0.80
1.0
0.67
131
2.64
138
461
46.8
448
1.18
2.0
0.88
132
3.78
138
478
49.0
452
1.56
5.0
1.03
134
6.3
139
467
50.3
463
1.56
10
1.42
137
7.8
143
501
54.1
489
1.78
20
1.37
143
6.5
151
488
58.6
498
1.14
30
0.95
147
5.9
154
510
62.5
502
0.42
a Intrinsic viscosity measured in MSA at 30.0 ± 0.1° C.
b Exothermic peak on DSC thermogram obtained in N 2 with a heating rate of 10° C./min.
c Inflection in baseline on DSC thermogram obtained in N 2 with a heating rate of 10° C./min.
d Temperature at which 5% weight loss recorded on TGA thermogram obtained with a heating rate of 10° C./min.
e Char yield at 850° C.
Example 7
Degree of Polymerization (DP) for the mPEK Grafts
On the basis of the experimental results in our model compound study (Example 1), it is proposed that with an appropriate ether-activated, aromatic carboxylic acid, functionalization of DND via Friedel-Crafts acylation in PPA:P 2 O 5 (w/w 4:1) medium could result in arylcarbonylation of 2.35 carbons in every 100 carbon sites. Furthermore, the arylcarbonylation reaction is most likely to occur at the sp 2 C—H defect sites. On this assumption, it is determined the upper-limit values for the DP and molecular weight of each DND-bound mPEK, ranging from a DP of 5.6 with the corresponding MW of 1,099 Da to a DP of 233 and MW of 45,715 Da. Our computation algorithm and results are shown in Table 3.
TABLE 3
Calculation of Total Number of Grafting Sites and
Degree of Polymerization (DP) for mPEK-g-DND Samples
wt %
wt %
mol grafting
mPEK
mPEK
Sample
(DND/PBA)
(DND/mPEK) a
mol DND b
mol mPEK b
site c
DP/chain d
MW/chain e
mPEK-g-DND,
1/99
1.1/98.9
0.092
0.504
0.00216
233
45715
1 wt %
mPEK-g-DND,
2/98
2.2/97.8
0.183
0.498
0.00430
116
22759
2 wt %
mPEK-g-DND,
5/95
5.4/94.6
0.450
0.482
0.01058
45.6
8947
5 wt %
mPEK-g-DND,
10/90
10.8/89.2
0.899
0.455
0.02112
21.5
4218
10 wt %
mPEK-g-DND,
20/80
21.5/78.5
1.79
0.400
0.04206
9.5
1864
20 wt %
mPEK-g-DND,
30/70
31.9/68.1
2.66
0.347
.06251
5.6
1099
30 wt %
a Theoretical calculation as followed:
wt % PBA/214.20 (FW C 13 H 10 O 3 ) × 196.20 (FW C 13 H 8 O 2 )
wt % mPEK = —————————————————————————————————————————
wt % PBA/214.20 (FW C 13 H 10 O 3 ) × 196.20 (FW C 13 H 8 O 2 ) + wt % DND
wt % DND = 1 − wt % mPEK
b For a 100 g sample, mol (DND) = wt (DND)/12.01 and mol(mPEK) = wt (mPEK)/196.20 (FW C 13 H 8 O 2 ).
c Total number of grafting sites (mol): mol(DND) × 0.0235 based on the assumption that there are 2.35 arylcarbonylation sites for every 100 carbons of the DND.
d Degree of polymerization (DP)/chain = mol(mPEK)/mol(grafting sites).
e MW (mPEK) = DP × 196.20 (FW C 13 H 8 O 2 ).
Having thus described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the disclosures herein are exemplary only and that alternatives, adaptations and modifications may be made within the scope of the present invention.
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A poly(ether-ketone) composite of the formula:
wherein DND is detonation nanodiamond particle; wherein Ar represents ether-ketone repeating groups of the formula
wherein Q is —O— or —O—(CH 2 ) n —O—, wherein n has a value of 2-12; wherein R is —H, —CH 3 , or —C 2 H 5 , m has a value of 1 or 2; wherein R′ is —H or —CH 3 ; and wherein — denotes the presence of a direct C—C bond between Ar and DND. Also provided is a process for preparing the nanocomposites.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority, pursuant to 35 U.S.C. § 119(e), to U.S. Patent Application Ser. No. 60/785,045, filed on Mar. 23, 2006, which is herein incorporated by reference in its entirety.
BACKGROUND OF INVENTION
1. Field of the Invention
The invention relates generally to a method for removing metal or mineral deposits from surfaces, in particular, from surfaces of drilling machinery in the oil industry.
2. Background Art
Subterranean oil recovery operations may involve the injection of an aqueous solution into the oil formation to help move the oil through the formation and to maintain the pressure in the reservoir as fluids are being removed. The injected water, either surface water (lake or river) or seawater (for operations offshore) generally contains soluble salts such as sulfates and carbonates. These salts may be incompatible with the ions already contained in the oil-containing reservoir. The reservoir fluids may contain high concentrations of certain ions that are encountered at much lower levels in normal surface water, such as strontium, barium, zinc and calcium. Partially soluble inorganic salts, such as barium sulfate (or barite) and calcium carbonate, often precipitate from the production water as conditions affecting solubility, such as temperature and pressure, change within the producing well bores and topsides. This is especially prevalent when incompatible waters are encountered such as formation water, seawater, or produced water.
Some mineral scales have the potential to contain naturally occurring radioactive material (NORM). The primary radionuclides contaminating oilfield equipment include Radium-226 ( 226 Ra) and Radium-228 ( 228 Ra), which are formed from the radioactive decay of Uranium-238 ( 238 U) and Thorium-232 ( 232 Th). While 238 U and 232 Th are found in many underground formations, they are not very soluble in the reservoir fluid. However, the daughter products, 226 Ra and 228 Ra, are soluble and can migrate as ions into the reservoir fluids to eventually contact the injected water. While these radionuclides do not precipitate directly, they are generally co-precipitated in barium sulfate scale, causing the scale to be mildly radioactive.
Because barium and strontium sulfates are often co-precipitated with radium sulfate to make the scale mildly radioactive, handling difficulties are also encountered in any attempts to remove the scale from the equipment. Unlike common calcium salts, which have inverse solubility, barium sulfate solubility, as well as strontium sulfate solubility, is lowest at low temperatures, and this is particularly problematic in processing in which the temperature of the fluids decreases. Modern extraction techniques often result in drops in the temperature of the produced fluids (water, oil and gas mixtures/emulsions) (as low as by 5° C.) and fluids being contained in production tubing for long periods of time (24 hrs or longer), leading to increased levels of scale formation. Because barium sulfate and strontium sulfate form very hard, very insoluble scales that are difficult to prevent, dissolution of sulfate scales is difficult (requiring high pH, long contact times, heat and circulation) and can only be performed topside.
When pipes and equipment used in oilfield operations become layered with scale, the encrustation must be removed in a time- and cost-efficient manner. Occasionally, contaminated tubing and equipment is simply removed and replaced with new equipment. When the old equipment is contaminated with NORM, this scale encrusted equipment cannot be disposed of easily because of the radioactive nature of the waste. The dissolution of NORM scale and its disposal can be a costly and hazardous affair. At present, a considerable amount of oilfield tubular goods and other equipment awaiting decontamination is sitting in storage facilities. Some equipment, once cleaned, can be reused, while other equipment must be disposed of as scrap. Once removed from the equipment, several options for the disposal of NORM exist, including canister disposal during well abandonment, deep well injection, landfill disposal, and salt cavern injection.
Typical equipment decontamination processes have included both chemical and mechanical efforts, such as milling, high pressure water jetting, sand blasting, cryogenic immersion, and chemical chelants and solvents. Water jetting using pressures in excess of 140 MPa (with and without abrasives) has been the predominant technique used for NORM removal. However, use of high pressure water jetting generally requires that each pipe or piece of equipment be treated individually with significant levels of manual intervention, which is both time consuming and expensive, but sometimes also fails to thoroughly treat the contaminated area. When scale includes NORM, this technique also poses increased exposure risks to workers and the environment.
While chemical chelants, such as EDTA (ethylenediaminetetraacetic acid) or DTPA (diethylenetriaminepentaacetic acid), have long been used to remove scale from oil field equipment, once EDTA becomes saturated with scale metal cations, the spent solvent is generally disposed of, such as by re-injection into the subsurface formation. However, because the process requires that disposal of the solvents once saturated, the large amounts of a fairly expensive solvent necessary for decontamination renders the process economically prohibitive.
U.S. Pat. No. 5,234,602 discusses a process whereby the chelating agent is regenerated in solution throughout the decontamination cycle. The '602 patent teaches that by lowering the pH of the solution to a pH of 4-9, preferably 5-7, following the sequestration of barium by DTPA, the chelated barium ions may be displaced from the chelating agent and precipitated as an insoluble barium salt, such as barium sulfate. Once the precipitant has formed and has been removed from the DTPA solution, the DTPA solution may be reused to dissolve additional scale. FIGS. 1-2 of the '602 patent show that while the cumulative amount of barium sulfate removed from a tubular can be increased using the regenerated DTPA, the amount removed per cycle actually decreases. The observed decrease in productivity of the DTPA solution may result from increased levels of impurities, i.e., insoluble salts formed from the other mineral deposits on the equipment or the successive addition of the acid and base, in the solution with each successive cycle and/or a reduction in the concentration of the chelating agent as more water is formed during the regeneration cycle.
Accordingly, there exists a need for an economically efficient means for removing scale from oilfield equipment with a low risk of exposure to radioactive materials.
SUMMARY OF INVENTION
In one aspect, embodiments disclosed herein relate to a method of removing metal scale from surfaces that includes contacting the surfaces with a first aqueous solution of a chelating agent, allowing the chelating agent to dissolve the metal scale, acidifying the solution to form a precipitant of the chelating agent and a precipitant of the metal from the metal scale, isolating the precipitant of the chelating agent and the precipitant of the metal from the first solution, selectively dissolving the precipitated chelating agent in a second aqueous solution, and removing the precipitated metal from the second solution.
In another aspect, embodiments disclosed herein relate to a method of removing scale from surfaces, that includes contacting the surfaces with a first aqueous solution of EDTA and potassium carbonate, allowing the EDTA to dissolve the scale, where the scale comprise at least one of barium sulfate, strontium sulfate, and radium sulfate, acidifying the first solution to form a precipitant of EDTA and precipitant of an insoluble salt of at least one of barium, strontium, and radium, isolating the precipitated EDTA and the precipitated insoluble salt of the at least one of barium, strontium, and radium from the first solution, selectively dissolving the precipitated EDTA in a second aqueous solution, and removing the precipitated insoluble salt of at least one of barium, strontium, and radium from the second solution.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a flowchart of one embodiment disclosed herein for dissolving mineral scale.
DETAILED DESCRIPTION
In one aspect, embodiments disclosed herein relate to a method of dissolving mineral scale from oilfield equipment. In particular, embodiments disclosed herein relate to a method of dissolving scale in which the active chelating agent may be reclaimed for further use.
Mineral scale that may be effectively removed from oilfield equipment in embodiments disclosed herein includes oilfield scales, such as, for example, salts of alkaline earth metals or other divalent metals, including sulfates of barium, strontium, radium, and calcium, carbonates of calcium, magnesium, and iron, metal sulfides, iron oxide, and magnesium hydroxide.
A method of dissolving a mineral scale according to an embodiment disclosed herein is described in FIG. 1 . As shown in FIG. 1 , the scale may be initially removed from the oilfield equipment by exposing the scale to an aqueous solution that includes a chelating agent and a converting agent (step 100 ). As used herein, “chelating agent” is a chemical whose molecular structure can envelop and/or sequester a certain type of ion in a stable and soluble complex. Divalent cations form stable and soluble complex structures with several types of chelating chemicals. When held inside the complex, the cations have a limited ability to react with other ions, clays or polymers, for example. As used herein, “converting agent” is a chemical that may assist in the dissolution of the scale by converting an extremely insoluble salt to a more soluble salt. GB 2314865, which is herein incorporated by reference in its entirety, discloses the incorporation of a converting agent in a dissolving solution to increase the rate of dissolution of the scale.
By exposing the scale to the chelating agent, the chelating agent may cause the scale to dissolve by complexing with the alkaline earth metal of the scale salt (step 110 ). Once the chelating agent becomes saturated with the metal cations from the scale, the solution may be acidified to a pH of about 0-1 (step 120 ). As the pH is reduced, the availability of anions with which the sequestered cations may react may allow the cations to be released from the chelated complex to form an insoluble salt that will precipitate out of solution. The reduction of the pH to about 0-1 may also cause the chelating agent to precipitate out of solution in its acid form.
The precipitated chelating agent and alkaline earth metal salt may then be isolated from the remainder of the solution (step 130 ). Isolation of the precipitants may be performed by filtering the solids or decanting the solution off the solids, for example. Once isolated from the remainder of the first solution, the solids may be introduced into a fresh solution containing water and converting agent to selectively dissolve the precipitated chelating agent (step 140 ). Once the chelating agent has become selectively redissolved, the still-precipitated alkaline earth metal salt may be separated from the solution for disposal (step 150 ).
The pH of the solution may be raised to about 9-14, and the solution may be optionally reused to remove scale from another piece of equipment or additional scale from the same piece of equipment (step 160 ). By isolating the two precipitants and selectively dissolving the chelating agent in solution of fresh water and the converting agent, the recycled solution may consist essentially of water, the converting agent, and the chelating agent.
In one embodiment, the chelating agent that may be used in the solution to dissolve the metal scale may be a polydentate chelator so that multiple bonds with the metal ions may be formed in complexing with the metal. Polydentate chelators suitable for use in embodiments disclosed herein include, for example, ethylenediaminetetraacetic acid (EDTA), diethylenetriaminepentaacetic acid (DTPA), nitrilotriacetic acid (NTA), ethyleneglycoltetraacetic acid (EGTA), 1,2-bis(o-aminophenoxy)ethane-N,N,N′,N′-tetraacetic acid (BAPTA), cyclohexanediaminetetraacetic acid (CDTA), triethylenetetraaminehexaacetic acid (TTHA), salts thereof, and mixtures thereof. However, this list is not intended to have any limitation on the chelating agents suitable for use in the embodiments disclosed herein. One of ordinary skill in the art would recognize that selection of the chelating agent may depend on the metal scale to be dissolved. In particular, the selection of the chelating agent may be related to the specificity of the chelating agent to the particular scaling cation, the logK value, the optimum pH for sequestering and the commercial availability of the chelating agent.
In a particular embodiment, the chelating agent used to dissolve metal scale is EDTA or salts thereof. Salts of EDTA may include, for example, alkali metal salts such as a tetrapotassium salt or tetrasodium salt. However, as the pH of the dissolving solution is altered in the processes disclosed herein, a dipotassium or disodium salt or the acid may be present in the solution.
In one embodiment, the converting agent may include any suitable chemical that can assist in the dissolution of the metal scale and formation of the chelating agent-metal complex. In a particular embodiment, the converting agent may include potassium carbonate. In other embodiments, the converting agent may include at least one of alkali metal carbonates, alkali metal bicarbonates, and ammonium chloride.
The acidification of the solution in precipitating the chelating agent out of solution may be achieved by the addition of a mineral or strong acid. In a particular embodiment, the acid may include at least one of hydrochloric acid, nitric acid, hydrobromic acid, hydroiodic acid, formic acid, hydrofluoric acid, sulfuric acid, and chloric acid. In another particular embodiment, hydrochloric acid is used to acidify the dissolving solution. In yet another particular embodiment, sulfuric acid may be used alone or in combination with at least hydrochloric acid to acidify the dissolving solution.
As the chelating agent is precipitated out of solution, the sequestered metal ions are released and may react with anions in the solution to form an insoluble salt which will also precipitate out of the dissolving solution. In one embodiment, a source of additional anions which will form an insoluble salt may be optionally added to the solution to ensure a sufficient quantity of available anions that will react with the released metal cations. In another embodiment, a source of sulfate ions may be optionally added to the solution.
In one embodiment, the precipitated insoluble salt may include at least one of barium sulfate, strontium sulfate, and radium sulfate. In another embodiment, an alkali metal sulfate is added to the solution to ensure adequate formation of the at least one of barium sulfate, strontium sulfate, and radium sulfate. The precipitants may be separated from the solution using techniques known by one ordinary skill in the art, such as, by filtration, decantation, and/or siphoning.
To selectively dissolve the precipitated chelating agent without dissolving the precipitated metal salt, the isolated precipitants are introduced to an aqueous solution in which the pH of the solution may be such that the chelating agent may dissolve yet have limited ability to re-chelate the barium sulfate. In one embodiment, the pH of the solution may be brought to a pH ranging from about 5 to about 7. In another embodiment, the pH of the solution may be brought to about 6. In a particular embodiment, the aqueous solution in which the chelating agent is selectively dissolved includes a converting agent. In another particular embodiment, the pH of the solution may be reached by the addition of an alkali metal hydroxide, carbonate, or bicarbonate.
In one embodiment, the fresh solution including the redissolved chelating agent may be reused for dissolving scale off of the same or another piece of equipment. The still-precipitated insoluble metal salt may be removed from the solution, such as by filtration, decantation, and/or siphoning. Prior to reuse of the solution and following removal of the insoluble metal salt, in one embodiment, the pH of the solution is raised to a pH in the range of 9-14. In another embodiment, the pH of the solution is raised to a pH in the range of 10-10.5. In yet another embodiment, the pH of the solution is raised by adding an additional amount of converting agent to the solution. In yet another embodiment, the pH of the solution is raised by adding an alkali hydroxide to the solution. One of ordinary skill in the art will recognize that the amount of converting agent to be added will depend upon the particular converting agent used and the desired pH of the solution.
In some embodiments disclosed herein, the dissolving solution may possess a dissolution capacity of at least 70 grams of scale per liter of dissolving solution. In other embodiments, the dissolving solution may possess a dissolution capacity of at least 80 grams of scale per liter of dissolving solution.
In one embodiment, high power ultrasound, low frequency sonic energy, or a low power ultrasound may be used in conjunction with the embodiments disclosed herein to increase the rate of dissolution of the scale by the solutions disclosed herein.
Exemplary Embodiment
In one embodiment, an aqueous solution that includes 10% by weight EDTA, 15% by weight potassium carbonate, and 75% by weight water is introduced to a piece of equipment having at least a portion of its surface covered by a barium sulfate mineral scale. After the aqueous solution has substantially dissolved the barium sulfate scale, the solution may be acidified with hydrochloric acid to a pH between 0 and 1. Upon isolation of the precipitated solids, a fresh solution of potassium carbonate may be added to the solids to achieve a final pH of about 6, whereby the dipotassium salt of EDTA will be formed and will be soluble at a level of about 10% by weight. After filtering the still-precipitated barium sulfate out of the solution, additional potassium carbonate may be added to the filtrate to bring the amount of potassium carbonate in the solution to about 15% by weight. The following equations illustrate the dissolution and subsequent isolation of a barium sulfate scale and regeneration of EDTA according to an embodiment disclosed herein:
EDTA-K 4 +K 2 CO 3 +BaSO 4 (1)
↓
EDTA-K 4 +BaCO 3 +K 2 SO 4 (2)
↓
EDTA-K 2 Ba+K 2 CO 3 +K 2 SO 4 (3)
↓+2HCl
EDTA-K 2 Ba+2KCl+H 2 O+CO 2 +K 2 SO 4 (4)
↓+4HCl
EDTA-H 4 (s)+BaSO 4 (s)+6KCl+H 2 O (6)
↓Filter→6KCl+H 2 O
EDTA-H 4 (s)+BaSO 4 (s) (7)
↓+K 2 CO 3
EDTA-K 2 H 2 (aq)+BaSO 4 (s)+H 2 O+CO 2 (8)
↓Filter→BaSO 4
EDTA-K 2 H 2 +H 2 O (9)
↓+K 2 CO 3
EDTA-K 4 +2H 2 O+CO 2 (10)
↓+K 2 CO 3
EDTA-K 4 +2H 2 O+K 2 CO 3 (11)
Equations (1)-(3) show the conversion of barium sulfate by potassium carbonate to barium carbonate and the subsequent chelation of barium by the tetrapotassium EDTA to form potassium sulfate as a by-product. In the acidification of the solution, shown in Eq. (4)-(6), hydrochloric acid initially reacts with the potassium carbonate to produce potassium chloride, water, and carbon dioxide gas. Once potassium carbonate has all reacted, further hydrochloric acid displaces the sequestered barium from the chelate and then replaces the two potassium ions associated with EDTA to form EDTA in its insoluble acid form which will precipitate out of solution in the pH range of 0-1. The displaced barium ions may form insoluble barium sulfate and precipitate out of solution. The precipitants may be isolated from the potassium chloride solution, as shown in Eq. (7). A solution of potassium carbonate may be added to the precipitants to selectively redissolve the EDTA as the dipotassium salt at a pH of about 6 and not dissolve the barium sulfate so that it may be removed from the solution, as shown in Eq. (8)-(9). As shown in Eq. (10)-(11), additional potassium carbonate may be added to convert the dipotassium salt of EDTA to the tetrapotassium salt and also to act as a converting agent so that the reaction cycle may be repeated upon introduction of additional barium sulfate scale.
Advantageously, embodiments disclosed herein may provide for a process by which mineral scale can be removed from oilfield equipment and the dissolving solution may be reclaimed without loss of performance. By precipitating the metal scale and the chelating agent as an insoluble acid, the inactive salts remaining in the dissolving solution may be removed from the system to avoid buildup of impurities in the dissolving solution which could otherwise lead to a reduction in the rate and/or efficiency of scale dissolution performance. If small quantities of chelating agent are lost in the process, small amounts may be added for subsequent reaction cycles so that recycling of the chelating agent and dissolving solution may be achieved without performance losses in dissolution rate or sequestering capacity in successive cycles. Contaminated equipment may be easily treated by soaking the item or a number of items in a volume of solution to dissolve scale encrusted thereon. Risk of exposure to decontamination operators may be minimal due to the chemical dissolution of the contaminated material without requiring operator contact.
While the invention 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 can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
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A method of removing metal scale from surfaces that includes contacting the surfaces with a first aqueous solution of a chelating agent, allowing the chelating agent to dissolve the metal scale, acidifying the solution to form a precipitant of the chelating agent and a precipitant of the metal from the metal scale, isolating the precipitant of the chelating agent and the precipitant of the metal from the first solution, selectively dissolving the precipitated chelating agent in a second aqueous solution, and removing the precipitated metal from the second solution is disclosed.
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FIELD OF THE INVENTION
[0001] The present invention relates to a LED street lamp. More particularly, the exemplary embodiments herein provide a method of installing a secondary optical lens on a LED street lamp.
BACKGROUND OF THE INVENTION
[0002] LED street lamp instead of traditional street lamp is a revolution in the field of public utilities because the LED street lamp is well known as saving energy, desirable color, free maintenance, and long service life compared with traditional street lamp. At present, high-power LED street lamp is in the stage of test or trial production, but hardly formally used, although many magnates in illumination industry in the global market have set foot in the field of high-power LED street lamp.
[0003] The basic research in high-power LED street lamp has made a breakthrough, for example, Chinese Patent (CN1928624A) applied by Tsinghua University discloses a method of designing a 3D optical lens, which provides a kind of immersion lens with low loss and strong phototactic reaction on P.13 of Description and P.8 of Drawings. However, the actual effects of the lens is not perfect, because of the high costs of encapsulation as a primary lens, and the fault of the chips which will lead to scrap with lens and cause the waste accordingly. Moreover, as a secondary lens, when install a secondary lens in front of a LED bulb rigidly usually, the positional error of secondary lens is not avoided as the installing positional error of LED bulb which includes scraping tin, surface mounting, and welding. These will lead to a problem which is the big positional accumulated error of secondary lens relative to LED bulb, thus cause the clearance between LED bulb and secondary lens. Therefore, the problems will increase the optical loss and decrease the performance of lens itself, and the popularization and application of the secondary lens is limited.
SUMMARY OF THE INVENTION
[0004] The object of the present invention is to provide a method of installing a secondary optical lens on a LED street lamp, which overcome the defects of existing technology mentioned above, and make LED bulb and secondary optical lens contact directly and locate precisely.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a cubic chart showing a lens floor installing a secondary optical lens in an embodiment of the present invention.
[0006] FIG. 2 is a front view showing a lens floor installing a secondary optical lens in an embodiment of the present invention.
[0007] FIG. 3 is a bottom view showing a lens floor installing a secondary optical lens in an embodiment of the present invention.
[0008] FIG. 4 is a cut-out plan view of A-A in FIG. 2 of the present invention.
[0009] FIG. 5 is a cut-out plan view of B-B in FIG. 2 of the present invention.
[0010] FIG. 6 is a cut-out enlarged view of C-C in FIG. 2 of the present invention.
[0011] FIG. 7 is an enlarged view of D in FIG. 5 of the present invention.
[0012] FIG. 8 is a cut-out plan view showing a body of LED street lamp installing a lens floor with secondary optical lens and LED arrayed board in an embodiment of the present invention.
[0013] FIG. 9 is a flow chart in an embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0014] The present invention provides a method of installing a secondary optical lens on a LED street lamp comprising,
[0015] a. installing said secondary optical lens on a lens floor;
[0016] said lens floor has a plurality of lens mounting hole which has two elastic tongue pieces symmetrically on the edge;
[0017] said secondary optical lens has a dent in flat bottom which has two hooks symmetrically outside the bottom face, and said dent has the same shape with the convex top of a LED bulb;
[0018] said bottom of said secondary optical lens is in close contact with the front of said lens floor, said dent of said secondary optical lens falls into the area of said lens mounting hole, said two hooks buckle said two tongue pieces on the edge of lens mounting hole;
[0019] said two hooks of said secondary optical lens have clearance along the x axis and y axis of said lens floor in the area of lens mounting hole, when give a force to said secondary optical lens along the z axis, that is, vertical to said lens floor, which make said secondary optical lens have the trend of leaving said lens floor, said secondary optical lens will move along the z axis, meanwhile, overcome the elastic force of said two tongue pieces on the edge of lens mounting hole;
[0020] each of said lens mounting hole corresponds to one of said secondary optical lens;
[0021] b. install said lens floor placed said secondary optical lens and a LED arrayed board on the body of said LED street lamp;
[0022] combine the back of said lens floor placed said secondary optical lens with the front of said LED arrayed board which has a plurality of LED bulb, that is, the position of said LED bulb corresponds to the position of said secondary optical lens;
[0023] said body of LED street lamp has a capacity space, where the back of said LED arrayed board is in close contact with the bottom of said capacity space, the back of said lens floor placed said secondary optical lens is in close contact with the front of said LED arrayed board, and said LED arrayed board and said lens floor make the fixd connection to said body of LED street lamp with a fastener.
[0024] A method of installing a secondary optical lens on a LED street lamp, wherein said lens floor of step a is one block, said LED arrayed board of step b is also one block, and said capacity space in the body of LED street lamp of step b is one cavity.
[0025] A method of installing a secondary optical lens on a LED street lamp, wherein said lens floor of step a is more than one block, said LED arrayed board of step b is also more than one block, however, said capacity space in the body of LED street lamp of step b is one cavity.
[0026] A method of installing a secondary optical lens on a LED street lamp, wherein said lens floor of step a is more than one block, said LED arrayed board of step b is also more than one block, and said capacity space in the body of LED street lamp of step b is more than one cavity.
[0027] A method of installing a secondary optical lens on a LED street lamp, wherein said lens floor of step a is flat, said LED arrayed board of step b is also flat, and said bottom of capacity space in the body of LED street lamp of step b is plane.
[0028] A method of installing a secondary optical lens on a LED street lamp, wherein said lens floor has two blocks, said LED arrayed board also has two blocks, and said capacity space in the body of LED street lamp has two cavities, the shape of said body of LED street lamp is figure, where said two cavities placed in shape respectively.
[0029] A method of installing a secondary optical lens on a LED street lamp, wherein said lens floor of step a is arc, said LED arrayed board of step b is also arc, and said bottom of capacity space in the body of LED street lamp of step b is arc surface.
[0030] A method of installing a secondary optical lens on a LED street lamp, wherein the front of said arc lens floor is concave, the front of said LED arrayed board is concave, and said arc bottom of capacity space in the body of LED street lamp is concave surface.
[0031] A method of installing a secondary optical lens on a LED street lamp, wherein said lens floor of step a is spherical, said LED arrayed board of step b is also spherical, and said bottom of capacity space in the body of LED street lamp of step b is spherical surface.
[0032] A method of installing a secondary optical lens on a LED street lamp, wherein the front of said spherical lens floor is concave, the front of said LED arrayed board is concave, and said spherical bottom of capacity space in the body of LED street lamp is concave surface.
[0033] A method of installing a secondary optical lens on a LED street lamp, wherein said LED arrayed board and said lens floor make the fixd connection to said bottom of capacity space in the body of LED street lamp with a screw, the back of said lens floor has a plurality of outshoot which limits the distance between said lens floor and said LED arrayed board.
[0034] The present invention also provides a method of installing a secondary optical lens on a LED street lamp comprising,
[0035] a. install said secondary optical lens on a lens floor;
[0036] said lens floor has a plurality of lens mounting hole which is circular, said lens mounting hole has three elastic tongue pieces evenly distributed on the edge;
[0037] said secondary optical lens has a dent in flat bottom, said dent has the same shape with the convex top of a LED bulb, and three hooks which are outside the bottom face evenly distributed around said dent;
[0038] said bottom of said secondary optical lens is in close contact with the front of said lens floor, said dent of said secondary optical lens falls into the area of said lens mounting hole, said three hooks buckle said three tongue pieces on the edge of lens mounting hole;
[0039] said two hooks of said secondary optical lens have clearance along the x axis and y axis of said lens floor in the area of lens mounting hole, when give a force to said secondary optical lens along the z axis, that is, vertical to said lens floor, which make said secondary optical lens have the trend of leaving said lens floor, said secondary optical lens will move along the z axis, meanwhile, overcome the elastic force of said two tongue pieces on the edge of lens mounting hole;
[0040] each of said lens mounting hole corresponds to one of said secondary optical lens;
[0041] b. install said lens floor placed said secondary optical lens and a LED arrayed board on the body of said LED street lamp;
[0042] combine the back of said lens floor placed said secondary optical lens with the front of said LED arrayed board which has a plurality of LED bulb, that is, the position of said LED bulb corresponds to the position of said secondary optical lens;
[0043] said body of LED street lamp has a capacity space, where the back of said LED arrayed board is in close contact with the bottom of said capacity space, the back of said lens floor placed said secondary optical lens is in close contact with the front of said LED arrayed board, and said LED arrayed board and said lens floor make the fixd connection to said body of LED street lamp with a fastener.
[0044] The present invention has two independent technical schemes which subordinate to one invention conception and has the common technical feature, that is, installing secondary optical lens on lens floor with elastic tongue pieces, and then installing lens floor placed secondary optical lens and LED arrayed board on the body of LED street lamp, thus as one application.
[0045] The method of installing a secondary optical lens on a LED street lamp provided in present invention overcome the defects of existing technology which is the installing positional error and the clearance between LED bulb and secondary lens, because the elastic tongue pieces can make up the installing positional error, thus make secondary optical lens in close contact with LED bulb. Moreover, the installing positional error of secondary lens along the x axis and y axis of said lens floor relative to LED bulb can be corrected by the auto alignment of the convex top of a LED bulb and the dent in secondary optical lens, because the secondary optical lens have clearance with lens floor along the x axis and y axis of the lens floor, and the secondary optical lens has a dent in the bottom which has the same shape with the convex top of a LED bulb, which realize the precise positioning.
EXAMPLES
[0046] In the following paragraphs, description will be made with reference to the drawings.
[0047] A preferred embodiment of the present invention provides a method of installing a secondary optical lens on a LED street lamp as shown by FIG. 9 comprising the first step of installing a secondary optical lens on a lens floor and the second step of installing said lens floor with said secondary optical lens and a LED arrayed board on the body of said LED street lamp. The following detailed description of said secondary optical lens, said lens floor, and said LED arrayed board, and said body of LED street lamp in the embodiment will be taken in conjunction with FIGS. 1-9 .
[0048] Said lens floor 102 has a plurality of lens mounting hole which has two elastic tongue pieces symmetrically on the edge; said secondary optical lens 101 has a dent in flat bottom which has two hooks symmetrically outside the bottom face, and said dent has the same shape with the convex top of a LED bulb 104 ; said bottom of said secondary optical lens 101 is in close contact with the front of said lens floor 102 , said dent of said secondary optical lens 101 falls into the area of said lens mounting hole, said two hooks buckle said two tongue pieces on the edge of lens mounting hole; said two hooks of said secondary optical lens 101 have clearance along the x axis and y axis of said lens floor 102 in the area of lens mounting hole, when give a force to said secondary optical lens 101 along the z axis, that is, vertical to said lens floor 102 , which make said secondary optical lens 101 have the trend of leaving said lens floor 102 , said secondary optical lens 101 will move along the z axis, meanwhile, overcome the elastic force of said two tongue pieces on the edge of lens mounting hole; each of said lens mounting hole corresponds to one of said secondary optical lens 101 ; combine the back of said lens floor 102 placed said secondary optical lens 101 with the front of said LED arrayed board 103 which has a plurality of LED bulb 104 , that is, the position of said LED bulb 104 corresponds to the position of said secondary optical lens 101 ; said body of LED street lamp 105 has a capacity space, where the back of said LED arrayed board 103 is in close contact with the bottom of said capacity space, the back of said lens floor 102 placed said secondary optical lens 101 is in close contact with the front of said LED arrayed board 103 , and said LED arrayed board 103 and said lens floor 102 make the fixd connection to said body of LED street lamp 105 with a screw.
[0049] Said lens floor 102 in the embodiment has six blocks, said LED arrayed board 103 also has six blocks correspondingly, however, said capacity space in the body of LED street lamp 105 is one cavity. Combine all said lens floor 102 with all said LED arrayed board 103 , and placed in one said capacity space. Apparently, said body of LED street lamp can have more than one cavity, and the combination of said lens floor and said LED arrayed board in each of capacity space can be one group of combination or more than one group of combination. Said lens floor 102 in the embodiment is flat, said LED arrayed board 103 is also flat, and the bottom of said capacity space in the body of LED street lamp 105 is plane. Apparently, said lens floor, said LED arrayed board, and the bottom of said capacity space in the body of LED street lamp can be arc surface or spherical surface, moreover, can be concave surface or convex surface for different results of different launching light. The back of said lens floor has a plurality of outshoot 1021 which limits the distance between said lens floor and said LED arrayed board. Said elastic tongue pieces in the embodiment are on the edge of said lens mounting hole in said lens floor 102 , both sides of said tongue pieces have open slot, and only the root of said tongue pieces connects with said lens floor 102 .
[0050] A second embodiment of the present invention provides a method of installing a secondary optical lens on a LED street lamp comprising, and the steps are the same as the first embodiment of the present invention. The difference in second embodiment is that said secondary optical lens has three books evenly distributed around said dent, said lens floor has three elastic tongue pieces correspondingly, the second embodiment is suitable to a secondary optical lens with circular horizontal section.
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The present invention relates to a LED street lamp, and especially provides a method of installing a secondary optical lens on a LED street lamp. A method of installing a secondary optical lens on a LED street lamp comprising the first step of installing a secondary optical lens on a lens floor and the second step of installing said lens floor with said secondary optical lens and a LED arrayed board on the body of said LED street lamp. The object of the present invention is to provide a method of installing a secondary optical lens on a LED street lamp, which make LED bulb and secondary optical lens contact directly and locate precisely.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to garments made of flexible material such as nonwoven fabrics, and particularly to garments of such type which are adjustable to fit variously sized wearers, such as disposable diapers, panties, swimwear, rainwear, laboratory coats, paint smocks, and the like.
2. Description of the Prior Art
In the art of disposable clothing, such as for example garments of the general type referred to hereinabove, the fact that such garments are intended only for one or a limited number of uses prior to disposal requires that they be formed of low cost materials, such as paper, nonwoven synthetic fabrics, etc. Similarly, such articles are desirably manufactured in as inexpensive a manner as is feasible, consistent with their disposable character. However, the fact that such articles are intended to have but a limited useful life and typically are made of inexpensive materials by high speed manufacturing techniques, leads to problems of obtaining good fit for the wearer. For disposable articles such as paper laboratory overcoats, paint smocks and the like, this may not be a severe problem where such articles can be made somewhat oversized relative to the wearer's size and can readily be rolled up or cut for use as desired, even though expedients may be inconvenient. However, disposable garments such as short pants, diapers, training panties and the like have more demanding fit requirements in that they must be reasonably comfortable and conformable to the wearer without necessity of undue modification of the garment by the user/wearer. One approach that has been employed with such garments is the use of elastic waist and leg gathers which, within a given range of sizes, provide a conformable fit to wearers of different waist, leg, etc., sizes. Nonetheless, for the purpose of high speed, low cost production, the use of elastic strips, e.g., spandex bands, tensioned elastomeric tapes and the like, have the disadvantages that such means introduce an additional oomplexity into the manufacturing process and increase the manufacturing cost of the garment. Accordingly, it would be an advance in the art to provide a garment having an opening through which an extremity or other part of the wearer's body is insertable, wherein the garment opening is able to accommodate a variety of sizes and which is easily manufactured at low cost.
U.S. Pat. No. 1,716,065 to N. A. Kiami discloses a diaper adapted for adjustment of the sizes of the waist opening as well as the leg openings. The diaper has on its transverse and end margins a series of spaced-apart buttonholes accommodating button fasteners which may be inserted into various buttonholes along the respective edges to adjust the size of the waist and leg openings.
U.S. Pat. No. 3,150,665 to W. L. May, Jr., et al discloses a waterproof panty of heat sealable plastic material which is cut or stamped from a single sheet to form front and rear portions connected by a narrower crotch portion and adapted to define leg openings of the panty when side edges of the front and rear sheet portions are secured together along side seams. A binding, or trim, is provided around the waist opening of the panty and similar bindings are secured around the leg openings. In this disclosed article, the front and rear portions each are folded inwardly along their edges at the side seams in the form of inwardly extending flanges. The flanges are superimposed on each other at the seams and held together by plural heat seals spaced apart from one another along the length of the flanges. The flanges contact one another along the heat sealed portions and separate slightly from one another between the heat seals to form ventilation openings for the panty.
U.S. Pat. No. 3,945,051 to E. R. Burkard discloses short pants in which left and right seat panels are independent of left and right front panels, with the seat panels being attached to the waistband at their upper edges and extending over substantially greater than one-half of the circumferential direction of the waistband. The forward edges of the seat panels slant downwardly and rearwardly from the waistband so that the front panels overlap the left and right seat panels at the waistband. The garment disclosed in this patent involves the use of overlapping front and rear panels which are not bonded to one another in any way, so that the garment accommodates movement of the wearer, with the front overlapped panel moving with the leg of the wearer in the forward or lateral direction relative to the rear panel.
U.S. Pat. No. 4,145,763 to J. L. Abrams, et al discloses a surgical/medical undergarment comprising at least two completely separable cloth panels which are removably fastened to one another by the use of Velcro® fasteners or similar adhering materials. The disclosed undergarment may also contain a slit positioned near the urinary tract for catheterization or drainage, and/or adhering means for keeping a folded-back upper or lower side or crotch portion of the undergarment open and secured in place during examination, treatment or surgery. Both the slit and the adhering means are also separably sealed by Velcro® fasteners or similar adhering material.
British Patent Specification No. 543,369 to H. Perry discloses knickers composed of two pieces of fabric each substantially rectangular and each having at one side edge a substantially triangular extension. The lower edge of the triangular extension extends down to the bottom corners of the piece and the upper edge thereof merges upwardly with a concave curve into the side edge of the piece. Each of the pieces is folded to bring the aforementioned lower edge into register with the lower part of the other side edge of the piece. The meeting edges are seamed together to provide the leg portion with a seam at the inside thereof, the two pieces also being seamed together with a central rear seam joining the upper edges of the extensions and the side edges into which they merge. The rear seam extends forward beneath the crotch to the leg seams. A central front seam joins the other side edges of the two pieces above the part of the edges that is seamed by the leg seam to the lower edge of the extension.
None of the foregoing approaches taught by prior art is wholly satisfactory for providing adjustably sizable extremity openings, particularly in disposable garments in a readily manufactured manner at low cost, particularly with reference to undergarments such as disposable panty-type garments, as is provided by the present invention.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a garment including at least one opening for encircling a portion of the wearer's body and having at the periphery of the opening a gusset fold comprised of disengagably bonded together gusset faces, which optionally may be intermittently bonded together, whereby the opening can be increased in size by manual disengagement of at least a portion of the bonded together gusset faces.
In another aspect of the invention, the bonded together faces of the gusset fold are inwardly-folded sections of an outer-facing surface of the garment and define a lateral gusset seam in said outer-facing surface.
Another aspect of the invention provides that the gusset faces are disengagably bonded together along the lateral gusset seam, and optionally are intermittently disengagably bonded together along the lateral seam.
Yet another aspect of the invention provides that the bonded together faces of the gusset fold are sections of an inner-facing surface of the garment, whereby the gusset fold is disposed exteriorly of the opening.
Other aspects of the invention provide one or more of the following features: the gusset fold may be folded along a central fold line and may comprise two disengagably bonded together faces; the central fold line may coincide with a seam of the garment; the central fold line may be reinforced against tearing; at least the gusset fold of the garment may comprise a thermally bondable material and the gusset faces are thermally disengagably bonded together, e.g., ultrasonically bonded together; and the garment may comprise gusset folds at the leg openings, each converging in a direction away from an associated leg opening and with outer lateral edges thereof being manually disengagably bonded to one another, whereby the leg openings may be adjusted in use to larger sized legs, by manual disengagement of the bonded outer lateral edges of the gussets.
In another aspect of the invention, the thermally bondable material is weakened in the area immediately adjacent the disengagably bonded areas to facilitate disengagement of the bonded together gusset faces by mechanical failure of the material in the weakened area.
In accordance with the method aspects of the present invention, there is provided a method for making a garment having adjustable openings therein for encircling a portion of a wearer's body, the method comprising the steps of: providing a garment having one or more of said openings therein; folding, e.g., inwardly angularly folding, material at said openings to form therein gusset faces providing one or more gusset folds at the edge of said leg openings; and manually disengagably bonding, e.g., intermittently disengagably bonding, gusset faces of the gusset folds to one another.
Other method aspects include forming gusset seams and folding material in a manner to provide the structures described above, including providing a panty-type garment by the steps of: providing a longitudinally-extending sheet of flexible material having arcuate cut-outs at its ends; longitudinally folding said sheet so that at each of said ends, transverse edges on either side of said arcuate cut-outs are superposed to form closed leg openings from said arcuate cut-outs; bonding said superposed transverse edges to form side seams, and bonding by thermally, e.g., ultrasonically, bonding the material.
Other aspects of the invention may be discerned from the following description of preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a panty-type garment having bonded side seams and configured to have gusset folds formed therein in the area shown in dotted line representation.
FIG. 2 is a perspective view of a portion of the FIG. 1 garment viewed at the side seam portion thereof, and showing an intermediate step in the forming of an inwardly folded gusset fold.
FIG. 3 is a perspective view of a portion of the side seam of the garment of FIG. 1, showing an inwardly-folded gusset fold in accordance with one embodiment of the invention formed therein.
FIG. 3A is a view taken along line 3A--3A of FIG. 3.
FIG. 3B is a perspective view similar to the end view of FIG. 3A but showing an outwardly-folded gusset fold in accordance with another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The garment of the present invention embodies a construction for manually adjusting the size of one or more openings therein which encircle the wearer's body, and which is simple in construction whereby the manufacture of such garment may readily be effected at low cost by high speed construction from continuous traveling webs of material.
As used herein, the term "opening" in the garment refers to any opening in the garment which accommodates any part of the wearer's body by encircling it, e.g., it refers to and includes arm, leg, waist and neck openings. Thus, although the invention will be hereinafter described in detail with specific reference to panty-type garments wherein the manually adjustable openings are leg openings, it will be appreciated that the present invention embraces manually adjustable collar openings, sleeves, waistbands, and the like. Thus, the invention encompasses openings for parts of the wearer's body in various garments including pants, panties shirts, smocks, trunks, socks, shoes, shoe covers, etc. The opening of the garment may be one which is not openable and closeable or otherwise adjustable in size, except for the gusset folds provided by the present invention. That is, the opening may be a fixed size opening except for the gusset folds.
Referring now to FIG. 1, there is shown a perspective view of a panty-type garment 10 having a front panel 11 and a rear panel 12 integrally joined to one another at crotch section 13. On either side of the crotch section are leg openings 14, 15 bounded by respective leg opening edges 26 and 27. Front panel 11 is superposed on rear panel 12 in a manner more fully described below, such that respective front panel side margins 16, 17 are in register with the corresponding back panel side margins 18, 19, with the registered side margins 16, 18 bonded to one another by a continuous side seam 20, and the registered side margins 17, 19 bonded to one another by a continuous side seam 21.
The front and rear panels 11 and 12 of the garment with the integrally joining crotch section 13 constitute an assembly which may be cut from a unitary web or a plurality of overlaid unitary webs, in a manner which is well known, for example, in the manufacture of disposable diapers and the like. In such manufacturing techniques, pads of an absorbent material cut from a continuous moving web of the same, are sandwiched between a continuous moving web of a liquid-impervious backing sheet and a liquid-permeable front or liner sheet, and discrete, garments are cut from the joined webs. The garment may be formed of any suitable material or combinations of materials, such as, for example, nonwoven fabrics, thermoplastic sheets, etc. Typically, a training panty or incontinence control garment may be made from an outer, liquid-impervious material such as a polyolefin sheet, an inner liquid-pervious material such as a nonwoven web of polyolefin fibers and an intermediate, liquid absorbing sheet or pad sandwiched between the inner and outer liners. A particularly preferred material of construction for the garment of the type shown in FIG. 1 is a nonwoven sheet of polyolefin fiber material, such as a sheet of spunbonded or meltblown polyolefin fibers, which may be coated with a thermoplastic film to provide a liquid-impervious outer sheet as a composite material. In such construction, the thermoplastic film-coated side is used on the inside of the garment, and a second nonwoven sheet of material is used as the liquid-pervious liner. Such nonwoven and thermoplastic film materials are readily manufactured at low unit cost in high speed assembly operations. Thus, although not specifically shown in FIG. 1, the garment 10 may have disposed in the interior thereof a suitable absorbent pad or sheet or a multilayer absorbent material, e.g., a cellulosic nonwoven liner overlying a layer of air-felt or cotton batt material, covered by a liquid-pervious inner liner. Such construction provides a garment which may be used as a disposable training panty for infants or toddlers being toilet trained, or a disposable garment for incontinent persons of any age.
The side seams 20, 21 of the garment shown in FIG. 1 may be formed by any suitable manufacturing method conventionally employed for the specific material of construction. For materials such as spunbonded polypropylene fiber nonwoven webs or other thermoplastic films or nonwoven fabrics, the side seams may be formed by thermal bonding such as with a hot knife applied to the superposed margins or by a heated embossing roll, or by ultrasonic bonding techniques using an ultrasonic horn and a suitably shaped anvil to form the seam. In any event, the side seams preferably are continuous in character to provide uninterrupted joinder and reinforcement at the seams 20, 21 of the garment.
Subsequent to the forming of side seams 20 and 21, any side margins of material protruding outwardly from the seams may be severed from the formed garment. Alternatively, the seams may be formed with protruding side margins turned inwardly prior to forming the side seams 20 and 21. It is possible in some instances to bond side seams like seams 20 or 21 at the edge of the material without side margins of material protruding beyond the seams, thereby requiring no trimming or inward folding of protruding margins. However, the practice of high volume manufacture of garments from continuous webs of material travelling at high speeds, e.g., 300 to 500 feet per minute, generally requires a protruding side margin at the seams in order to give some latitude in the bonding area to insure good structural integrity of the seams in the mass-produced items.
The leg openings 14 and 15 on either side of the crotch section 13 are bounded by leg opening edges 26 and 27, which may, if desired, be provided with flexible gathers or other resilient tensioned material which enhance the fit of the garment. However, it is a specific feature of the present invention that adequate fit may be usefully provided without the use of such elasticity means, thereby simplifying the manufacturing process and reducing the cost of the garments. The dotted-lines 22 and 23 in FIG. 1 denote fold lines which will define, respectively, one of the outer lateral edges of gusset folds to be formed in the article, as described more fully hereinafter.
FIG. 2 shows a perspective view of a portion of the garment of FIG. 1 along side seam 20 in the vicinity of leg opening edge 26 which is partially inwardly folded at an intermediate stage of forming a gusset fold. The dotted-line 22, also shown in FIG. 1, denotes a fold line which provides an outer lateral edge of the gusset fold to be formed from both front panel 11 and back panel 12. A corresponding fold line is indicated by dotted line 24 in the rear panel. Fold line 24 correspondingly provides the other outer lateral edge of the gusset fold to be formed. Thus, the gusset is formed by inwardly folding the garment along fold lines 22, 24 and side seam 20, at its leg opening 26 at point A to point B along side seam 20. A gusset fold, e.g., a gathered and folded generally wedge- or triangular-shaped portion of the material of the garment is thus formed within the polygon defined by lines joining points AB (center fold line, along seam 20) and BD and BC (respective outer lateral edges 24, 22 of the gusset fold). As shown, the resulting gusset fold converges in a direction away from the leg edge 26 with the outer lateral edges 22, 24 of the gusset being drawn together as more fully shown in FIGS. 3 and 3A. Thus, the outer lateral edges 22, 24 of the gusset fold intersect one another at an angle subtending a portion 26a of the leg opening edge 26, with the subtended portion (the edge portion DAC in FIG. 2) being bisected by a center fold line AB of the gusset, along a section of seam 20. The router lateral edges 22, 24 and the fold line AB together with the subtended edge portion DAC define opposed congruent triangular faces of material, viz, the triangular faces ABC and ABD.
The center fold line AB in the FIGS. 1-3A embodiment, is reinforced against tearing by the side seam 20. However, it is within the purview of the present invention to utilize the gusset fold in the side portion of a panty-type garment or otherwise in a garment at an opening thereof, wherein the gusset center fold line is not reinforced. That is, the center fold line need not coincide with a seam or other reinforcement. Preferably however, the center fold line of the gusset is reinforced conveniently by seam 20 as shown in FIGS. 1-3A, particularly when the garment is constructed of low basis weight material, such as the low basis weight materials used in disposable garments. The reinforcement along center fold line need not of course be a seam of the garment but may be provided by any suitable means such as by reinforcing strips, or the like.
FIG. 3 is a perspective view corresponding to FIG. 2, but, together with FIG. 3A, showing the completed gusset fold wherein the outer lateral edges 22, 24 of the gusset have been brought together and disengagably bonded to one another, such as by a series of intermittent ultrasonic weld bonds 25a, 25b, 25c, 25d and 25e. Each of the weld bonds is at regularly spaced intervals along the length of the opposed outer lateral edges 22, 24 of the gusset fold. Intermittent bonding of outer lateral edges 22, 24 may be suitably carried out as by means of a slotted hot knife, pattern-applied adhesive or the like, or may be patterned ultrasonic bonding. In any case, the intermittent bonding will permit the resulting bonded outer lateral edges 22, 24 to be manually disengaged from one another, simply by pulling apart the intermittent bonded edges to expose a part at least of the interior of the gusset fold to a predetermined extent. Thus, the leg opening of the panty-type garment shown in FIGS. 1-3A may be manually adjusted to larger sizes simply by grasping between thumb and forefinger the material on either side of the intermittently bonded seam 22/24 and pulling the material apart to break one or more of bonds 25a, 25b, 25c, 25d and 25e, to open the gusset fold to a desired extent. It will be appreciated that due to the angled configuration of the lateral outer edges of the gusset (as shown best in FIG. 2), the intermittently bonded seam 22/24 may be pulled open a selected distance therealong to increase the leg opening dimension by a desired amount, with proportionally larger portions of the opened gusset seam 22/24 corresponding to proportionally larger leg openings for the garment. Thus, the construction shown is extremely simple and manually openable to provide a range of sizes and thereby a proper fit for the garment opening. In panty-type garments used for toilet training and control of incontinence, leg opening size is important because both comfort of the wearer and control of leakage through the leg opening must be accommodated. If all of the intermittent bonds are disengaged, the gusset fold can be opened completely and will revert generally to the condition illustrated in FIG. 2, but with segments 26a opened outwardly to be aligned as a straight-line or smooth curve segment of leg opening 26.
While not shown or specifically described in connection with FIGS. 1-3A above, it will be appreciated that a similar gusset type construction may be utilized with the waist opening 36 of the garment to provide a range of varying waist sizes therefor.
Although the manually disengagable bonding of the outer lateral edges of the gusset has been shown as being effected by intermittent bonds 25a-25e, it will be appreciated that other methods of bonding or joining the outer seam of the gusset may be utilized to the same effect. For instance, it may be possible to provide a continuous bond of sufficiently low bond strength between the opposed faces of the gusset so as to be manually disengagable; a low tack, high shear strength adhesive may be useful for such bonding of the opposed gusset surfaces. Further, spot welding of the entire surface of the opposed gusset faces, i.e., the triangular faces ABC and ABD, may be usefully employed in some instances. It will therefore be appreciated that various approaches may be usefully employed to secure the gusset fold and its outer lateral edges in manually disengagable bonded character, and all such suitable means and methods are to be regarded as being within the scope of the present invention.
The completed gusset fold illustrated by FIGS. 3 and 3A is an inwardly folded gusset fold which extends inwardly of the leg opening. FIG. 3B illustrates an alternate embodiment of the invention wherein the gusset fold 37 is obtained by folding together the inner-facing surfaces of the garment to provide a gusset fold 37 disposed exteriorly of the garment having an outer fold 40 with disengagable intermittent bonds 42a, 42b, 42c, 42d and 42e shown in dotted outline in FIG. 3B as sandwiched between and joining an inner lateral seam (unnumbered) of gusset fold 38. The intermittent bonds 42a-42e may comprise intermittent ultrasonic weld bonds spaced apart one from the other at intervals along the length of the inner lateral seam of the gusset fold. The garment in which the gusset fold 38 is formed may have a side seam corresponding to side seam 20 of the garment of FIG. 3A, which side seam may, but need not, coincide with outer fold 40 illustrated in FIG. 3B. The garment of FIG. 3B may thus be comprised of a front panel 11' joined to a rear panel 12', along a side seam (not illustrated in FIG. 3B) which would coincide with outer fold 40. Gusset fold 38 subtends a portion 26a' of the leg opening edge 26'. As with the FIG. 3A embodiment, if it is desired to enlarge the size of the leg openings, it is necessary only to grip the material adjacent the leg opening on either side of the gusset fold between respective thumbs and forefingers and pull apart the material to successively break or disengage one or more of intermittent bonds 42a, 42b, etc. In this manner, the size of the leg opening may be increased a selected amount.
While, as noted above, the intermittent bonds may be provided by any suitable means such as adhesive, or ultrasonic or thermal welding a preferred form of construction is the utilization of "thermal bonding" which term, as used herein and in the claims, is intended to include ultrasonic welding or bonding as well as the use of high temperature knives or dies. Thermal bonding is a preferred mode of applying the intermittent bond because the thermal bonding will weaken the fusible, i.e., thermally bondable, material immediately adjacent the bond point. This facilitates disengaging the intermittent bonds by avoiding the need to separate the two bonded surfaces while leaving the material intact. Instead, a portion of the weakened material adjacent the bond area on one of the faces of the gusset will tear away so that as the gusset fold is opened the bond itself remains intact but is separated from one of the gusset faces by the tearing of the immediately adjacent material. For example, with reference to FIGS. 2 and 3, when a disengagable ultrasonic weld bond, say 25a, is disengaged the bond will usually stay intact and remain at one of lateral edges 22 or 24 and separate from the other with a small tear resulting in the fabric along the edge from which the bond is removed. As more of the intermittent bonds 25b, etc., are disengaged, the bonds themselves will remain either along lateral edges 22 or 24 with a small tear resulting along the fold from which they are removed. Given the disposable nature of the garment, which may have a somewhat fuzzy or soft nap on its outer surface, the small tears do not present a significant problem of appearance or unduly adversely effect structural integrity. This tear-away aspect is advantageous because it avoids the necessity for utilizing a material of construction with a tear strength greater than the separation strength of the bond, and avoids the necessity of having to accurately control the bond strength to a level below the tear strength of the material. Such low bond strength may be insufficient to keep the gusset fold intact. The tear-away feature thus makes advantageous use of the inherent weakening of a material, such as a nonwoven fabric or thermoplastic film material in the area immediately adjacent a thermal bond, e.g., an ultrasonic bond. From the foregoing, it will be clear that as used herein and in the claims, the term "disengagably bonded" or the like, with reference to the bonds of the invention, does not necessarily require that the two bonded together layers of material be separated at the bond site itself, but includes tearing away of a portion of the material of one of the bonded layers adjacent the bond site, so as to permit unfolding of the gusset fold.
Accordingly, preferred materials of construction are those which are thermally bondable, preferably by ultrasonic bonding, and which are weakened in the area immediately adjacent the thermal bond so that at least one of the bonded together layers will tear or fail, but only in the weakened area immediately adjacent the bond site, in order to permit unfolding of the gusset fold. Accordingly, preferred thermoplastic films include by way of example and not limitation, polymers of polypropylene, ethylene ethylene-methyl-acrylate, ethylene-vinyl-acetate, ethylene-ethyl-acrylate, and blends, copolymers or co-extrusions of two or more of the foregoing. Preferred nonwoven materials include, by way of example and not limitation, thermally bonded polypropylene staple fiber or spunbonded polypropylene, or other nonwovens such as thermally bonded polyester, or blends of polypropylene, polyester, or blends of polypropylene, polyester, cotton, rayon, chisso, and the like. Composite layers of thermoplastic film and nonwoven materials are preferably selected from film-coated nonwovens wherein the nonwoven material is extrusion- or otherwise coated with any suitable thermoplastic film, e.g., polypropylene, ethylene-methyl-acrylate, poly-ethylene-vinyl-acetate, ethyleneacrylic-acid, or a blend of two or more of the aforementioned polymers.
While specific preferred embodiments of the present invention have been shown and described in detail, it will be appreciated that numerous modifications and variations thereof are possible, together with other embodiments, and accordingly, all such apparent modifications, variants, and embodiments are to be regarded as being within the spirit and the scope of the present invention.
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A garment, such as an incontinence control garment, having an opening to accommodate a part of the wearer's body, such as a leg opening, includes one or more gusset folds at the opening and having at least a portion of the faces of the gusset fold, e.g., the lateral edges thereof, manually disengagably bonded to one another, whereby the opening may be increased in size by manual disengagement of the bonded outer lateral edges. For example, a disposable panty-type garment having leg openings which are manually adjustable in size is provided, each featuring the disengagably bonded gusset fold structure described above. Also disclosed is a method for making garments such as panty-type garments, by the steps which may include cutting articles from a web of material, longitudinally folding the sheet to form a garment having closed leg openings, and folding the material at the opening to form gusset folds thereat which may be selectively opened to provide larger sized openings.
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CROSS REFERENCE
[0001] This Nonprovisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No. 2007-031780 filed in Japan on Feb. 13, 2007, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a continuous carburizing furnace which performs a plurality of processes, including a carburizing process, successively upon a workpiece, the subject for processing, which is being conveyed in an ambient atmosphere which includes a carburizing gas.
[0003] With a continuous carburizing furnace, a heating zone, a carburizing zone, a diffusion zone, a cooling zone, and so on are provided within the furnace. A workpiece which has been loaded upon a tray is subjected to processing in each of these zones, while the tray is conveyed from a transport entrance of the furnace towards a removal aperture thereof.
[0004] As methods for conveying the workpiece within the furnace, both the tray pusher method and the roller hearth method are available. With a continuous carburizing furnace which utilizes the tray pusher method, as for example disclosed in Japanese Laid-Open Patent Publication 2004-10945, a tray most to the upstream side is pushed by a pusher from the transport entrance towards the removal aperture, and thereby a plurality of trays are conveyed while being kept in mutual contact. On the other hand, with a continuous carburizing furnace which utilizes the roller hearth method, a large number of hearth rollers which are arranged across the floor of the furnace are rotationally driven, so that the trays are shifted over these hearth rollers.
[0005] It is necessary to apply mutually different levels of heating energy to the heating zone and to the carburizing zone within the furnace. Furthermore, the carburizing zone receives an input of a carburizing gas. In order to enhance the product quality of the workpiece after carburizing processing, it is necessary to keep the temperature and the ambient atmosphere in each zone constant; and, to this end, it has been contemplated to selectively isolate the heating zone, in which the temperature differences with the previous and successive zones are most conspicuous, with intermediate doors which are opened and closed as required.
[0006] With the roller hearth method, it is possible to adjust the gaps between the various trays in a simple and easy manner by controlling the rotation of the hearth rollers. Due to this, continuous carburizing furnaces which utilize the roller hearth method, and in which intermediate doors are installed between the heating zone and the carburizing zone, are nowadays widespread.
[0007] However, with a continuous carburizing furnace which utilizes the roller hearth method, it is necessary to drive the large number of hearth rollers from the exterior, and a considerable amount of thermal energy is wasted by thermal diffusion from the side walls of the furnace in which the shafts of the hearth rollers are supported. Furthermore, it becomes necessary to oscillate the hearth rollers by rotating them forwards and backwards periodically in order to prevent deflection of the hearth rollers due to the loadings imposed upon them from the trays, so that the drive control of the rollers becomes troublesome. Moreover, the maintenance of this large number of hearth rollers also becomes complicated and troublesome. Yet further, the size of the furnace is increased due to the provision of the gaps between the plurality of trays.
[0008] On the other hand, with a continuous carburizing furnace which utilizes the tray pusher method, it is possible to eliminate the above described shortcomings of the roller hearth method; and, by changing the stroke of the pusher, it is possible to provide a gap between the tray which is most towards the upstream side and the tray in front of it. However, a purge chamber which is provided with an intermediate door between itself and the heating zone is present at the transport entrance side of the furnace, and it is not possible to bring in the next tray to this purge chamber until the previous tray has been conveyed from the heating zone to the carburizing zone, so that the time period between bringing in trays becomes long.
[0009] Moreover, by providing a plurality of pushers whose pushing angles in plan view are mutually orthogonal, and by changing the direction of conveyance of the trays within the furnace in a zigzag manner, it is possible to create a gap between a pair of trays, during their passage through the furnace. However, in this case, the shape of the furnace in plan view cannot be made to be linear, so that the area which the device occupies is increased in size.
[0010] The objective of the present invention is to supply a continuous carburizing furnace which operates according to the tray pusher method, with which, while maintaining the shape in plan view of the conveyance path as being a straight line, the conveyance path for trays with workplaces loaded upon them is made to include a plurality of stages at the upstream side of the carburizing zone, and with which, by providing a plurality of pushers which push the trays at each stage, it is made possible to establish gaps between each of the trays being successively conveyed and the next one, in order to allow the operation of intermediate doors which are installed.
SUMMARY OF THE INVENTION
[0011] The continuous carburizing furnace of this invention provides a furnace, a lift mechanism and a plurality of pushers. A furnace has a carburizing zone and a plurality of regions including a first region and a second region at the upstream side of said carburizing zone. The second region and the first region being disposed successively along a direction of conveyance of workpieces loaded upon a tray in this order. The lift mechanism lowers a tray in some region, among the plurality of regions, other than the region most to the upstream side in the direction of conveyance. A plurality of pushers includes a first pusher and a second pusher. The first pusher pushes a tray in said first region to said carburizing zone. The second pusher pushes a tray in said second region to said first region. A plurality of pushers are arranged the lower, the further towards the downstream side in said direction of conveyance is the position at which they push said trays.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a plan sectional view of a continuous carburizing furnace according to an embodiment of the present invention;
[0013] FIG. 2 is a side sectional view of this continuous carburizing furnace; and
[0014] FIGS. 3A through 3E are schematic side cross sectional views for explanation of the operation of the principal portions of this continuous carburizing furnace.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In the following, an embodiment of the present invention will be described in concrete terms with reference to the drawing. FIG. 1 is a plane sectional view showing an example of a continuous carburizing furnace according to an embodiment of the present invention. And FIG. 2 is a side sectional view of this continuous carburizing furnace.
[0016] This continuous carburizing furnace 100 continuously performs, as one example, pre-processing, heating processing, carburizing processing, diffusion processing, cooling processing, and quenching processing upon workpieces which are loaded upon trays to during conveyance along a conveyance path which is shaped as a straight line in plan view. This continuous carburizing furnace 100 is a continuous carburizing furnace employing a hybrid method, and conveys trays which are loaded with a large number of workpieces through pre-processing, heating processing, carburizing processing, and diffusion processing by a tray pusher method, and then conveys them through cooling processing and quenching processing by a roller hearth method. And this continuous carburizing furnace 100 comprises a furnace main body 1 , a lift mechanism 2 , pushers 3 and 4 , intermediate doors 5 through 8 , an introduction door 9 , a roller hearth 10 , a quenching device 11 , and a removal device 12 .
[0017] The furnace main body 1 is the “furnace” of the Claims, and, in plan view, is made as a rectangle of approximately constant width, extending along the direction of conveyance of trays 200 , as shown by an arrow sign X. A purge chamber 21 , a heating chamber 22 , a carburizing zone 23 , a diffusion zone 24 , and a cooling zone 25 are arranged in that order in the furnace main body 1 , along the direction of the arrow sign X. The purge chamber 21 and the heating chamber 22 correspond to the “plurality of regions” of the Claims.
[0018] In this example, in the purge chamber 21 , heat at approximately 400° C. is applied to a workpiece which is loaded upon a tray 200 in an ambient atmosphere which has been isolated from the external air, and pre-processing such as degreasing processing and so on is performed thereupon. The purge chamber 21 is not to be considered as being limited by the above; any configuration will be acceptable, provided that it is one with which it is possible to replace the ambient atmosphere therein.
[0019] In the heating chamber 22 , the workpiece is subjected to preliminary heat application at approximately 900° C. in an ambient atmosphere of a carrier gas such as RX gas or the like.
[0020] In the carburizing zone 23 , a carrier gas such as RX gas or the like and an enrichment gas such as a hydrocarbon gas or the like are supplied, and carburizing processing is performed by applying heat to the workpiece at approximately 930° C. to 950° C. in an ambient atmosphere of carburizing gas.
[0021] In the diffusion zone 24 diffusion processing is performed, in order to diffuse the carbon which has been loaded by the carburizing processing onto the surface of the workpiece, into the interior of the workpiece.
[0022] In the cooling zone 25 , the workpiece is cooled and soaked to a temperature of approximately 850° C., which is the temperature before the start of quenching processing.
[0023] The lift mechanism 2 is disposed in the heating chamber 22 , and comprises a lift stage 31 , which constitutes a portion of the floor surface of the heating chamber 22 , and a raising and lowering cylinder 32 .
[0024] By raising and lowering the lift stage 31 with the raising and lowering cylinder 32 (which is hydraulically driven), this lift mechanism 2 displaces the conveyance path of the trays 200 downwards. The lift mechanism 2 could also raise and lower the lift stage 31 with a pneumatic drive system or a motor drive system.
[0025] The floor surface of the purge chamber 21 is higher than the floor surfaces of the carburizing zone 23 and of subsequent zones. As compared with the conveyance path from an introduction stage 13 to the interior of the purge chamber 21 , the conveyance path for the trays 200 from the carburizing zone 23 onwards is lower, so that the conveyance path in the furnace main body 1 is structured in two stages, an upper stage and a lower stage.
[0026] In the heating chamber 22 , the lift mechanism 2 lowers the trays 200 , which are to be displaced from the upper stage conveyance path for the trays 200 to the lower stage conveyance path.
[0027] The pushers 3 and 4 are the “plurality of pushers” of the Claims. The pusher 3 is the “first pusher” of the Claims, and pushes the trays 200 in the direction of the arrow sign X from the introduction stage 13 to the purge chamber 21 , and from the purge chamber 21 to the heating chamber 22 . And the pusher 4 is the “second pusher” of the Claims, and pushes the trays 22 in the direction of the arrow sign X from the heating chamber 22 to the carburizing zone 23 .
[0028] The intermediate doors 5 ˜ 8 are the “plurality of intermediate doors” of the Claims. The intermediate door 5 opens and closes between the purge chamber 21 and the heating chamber 22 . The intermediate door 6 opens and closes between the heating chamber 22 and the carburizing zone 23 . The intermediate door 7 opens and closes between the diffusion zone 24 and the cooling zone 25 . The intermediate door 8 opens and closes between the cooling zone 25 and the quenching device 11 . And the introduction door 9 opens and closes a transport entrance 21 A of the purge chamber 21 .
[0029] Due to these intermediate doors 5 and 6 , it is possible selectively to mutually isolate the purge chamber 21 and the heating chamber 22 , and the heating chamber 22 and the carburizing zone 23 . It is accordingly made possible to maintain mutually different ambient atmospheres and temperatures in the purge chamber 21 , the heating chamber 22 , and the carburizing zone 23 .
[0030] The roller hearth 10 comprises a plurality of hearth rollers 10 A, and a motor not shown in the figures which supplies rotatory power to this plurality of hearth rollers 10 A. The plurality of hearth rollers 10 A are arranged at approximately equal intervals so as to constitute a floor surface from a portion of the diffusion zone 24 on its downstream side via the cooling zone 25 to a portion of the quenching device 11 on its upstream side. Both end portions of each of these hearth rollers 10 A are passed through the side walls of the furnace main body 1 so as to be exposed to the exterior of the furnace main body 1 , and are supported rotatably by bearings not shown in the figures. And the rotation of the motor is transmitted to the one end portions of each of these hearth rollers 10 A.
[0031] The quenching device 11 comprises an outlet door 41 , a lift mechanism 42 and an oil tank 43 . The outlet door 41 opens and closes between the quenching device 11 and the removal device 12 . The lift mechanism 42 comprises a lift stage 42 B which can be raised and lowered freely, and which comprises a plurality of rollers 42 A. A tray 200 which has been brought into the cooling zone 25 is mounted upon this lift stage 42 B. The oil tank 43 is disposed below the conveyance path of the tray 200 , and stores quenching oil. The lift mechanism 42 lowers the lift stage 42 B with a tray 200 mounted upon it, and dips the tray 200 into the oil tank 43 . Thereby a workpiece which is loaded upon the tray 200 is abruptly cooled by the quenching oil.
[0032] The removal device 12 comprises a plurality of rollers 51 and a removal door 52 . This plurality of rollers 51 constitutes a conveyance surface within the removal device 12 for a tray 200 . And the removal door 52 controls the opening and closing of a removal outlet 12 A of this removal device 12 .
[0033] FIGS. 3A through 3E are schematic side cross sectional views for explanation of the operation of the principal portions of this continuous carburizing furnace according to an embodiment of the present invention. In the following, the explanation will only focus attention upon the operations related to the intermediate doors 5 and 6 and the introduction door 9 during the processing for bringing in the trays 200 to the purge chamber 21 , the heating chamber 22 , and the carburizing zone 23 ; and explanation of the operation of the other doors will be omitted.
[0034] Before a tray 200 is brought in, the intermediate doors 5 through 8 and the introduction door 9 are in their closed positions, so that the conveyance path is interrupted at the positions where these doors are disposed. Furthermore, due to considerations of safety, the lift mechanism 2 is waiting in its position with the lift stage 31 lowered.
[0035] After a first tray 200 A with a large number of workpieces loaded upon it has been mounted upon the introduction stage 13 , as shown in FIG. 3A , the introduction door 9 is shifted to its open position so that the transport entrance 21 A is opened, and the tray 200 A is pushed in the direction of the arrow sign X by the pusher 3 . Thereby the tray 200 A is brought in from the introduction stage 13 to the purge chamber 21 . After the tray 200 A has been brought into the purge chamber 21 , the introduction door 9 is shifted to its closed position, so that the purge chamber 21 is closed. And degreasing processing is performed, in which the workpieces which are loaded upon the tray 200 A are heated up to a predetermined temperature within an ambient atmosphere which is isolated from the external atmosphere, so that oil and grease and so on adhering to their surfaces are burnt away.
[0036] After this degreasing processing has been completed, as shown in FIG. 3B , along with the lift mechanism 2 shifting the lift stage 31 to its upper position and stopping it there, the intermediate door 5 is shifted to its opened position so that the purge chamber 21 and the heating chamber 22 are communicated together, and then the tray 200 A is pushed by the pusher 3 in the direction of the arrow sign X. Thus the tray 200 A is brought in from the purge chamber 21 to the heating chamber 22 , and is mounted upon the lift stage 31 . After the tray 200 A has thus been brought within the heating chamber 22 , the intermediate door 5 is shifted to its closed position, and thereby the communication between the purge chamber 21 and the heating chamber 22 is interrupted. The workpieces which are loaded upon the tray 200 A are then subjected to pre-heating processing by the application of heat, so as to heat them up to a predetermined temperature within an ambient atmosphere of carrier gas.
[0037] While this pre-heating processing is being performed upon the workpieces which are loaded upon the first tray 200 A, a second tray 200 B is mounted upon the introduction stage 13 , the introduction door 9 is shifted to its opened position so as to open up the transport entrance 21 A, and the tray 200 B is pushed by the pusher 3 in the direction of the arrow sign X. Thus, the tray 200 B is brought into the purge chamber 21 from the introduction stage 13 . After the tray 200 B has been brought into the purge chamber 21 , the introduction door 9 is shifted to its closed position, so that the purge chamber 21 is closed. And the workpieces which are loaded upon the tray 200 A are then subjected to degreasing processing by the application of heat at a predetermined temperature within an ambient atmosphere which is isolated from the external atmosphere.
[0038] Until the pre-heating processing has been completed upon the workpieces which are loaded upon the tray 200 A, the lift stage 31 is kept lowered to its downward position, along with the tray 200 A, as shown in FIG. 3C .
[0039] When the pre-heating processing upon the workpieces which are loaded upon the tray 200 A has been completed, as shown in FIG. 3D , the intermediate door 6 is shifted to its opened position so that the heating chamber 22 and the carburizing zone 23 are communicated together, and then the tray 200 A is pushed by the pusher 4 in the direction of the arrow sign X. Thus the tray 200 A is brought into the carburizing zone 23 from the heating chamber 22 . After the tray 200 A has been brought into the carburizing zone 23 , the intermediate door 6 is shifted to its closed position so that the heating chamber 22 and the carburizing zone 23 are isolated from one another. And then carburizing processing is performed upon the workpieces which are loaded upon the tray 200 , by application of heat so as to raise them to a predetermined temperature within an ambient atmosphere of carburizing gas.
[0040] After having brought the tray 200 A into the carburizing zone 23 , the intermediate door 6 is shifted to its closed position (refer to FIG. 3E ). By the above, one cycle of processing to bring a tray 200 into the carburizing zone 23 is completed.
[0041] Subsequently, when the operations shown in FIGS. 3B through 3D are performed, and when the tray 200 B is brought into the carburizing zone 23 from the heating chamber 22 , then the tray 200 A is pushed by the tray 200 B and is shifted within the carburizing zone 23 in the direction of the arrow sign X. And, as the operations shown in FIGS. 3B through 3E are repeated, the plurality of trays 200 in the carburizing zone 23 and the diffusion zone 24 are shifted in the direction of the arrow sign X due to their state of being in mutual contact.
[0042] By providing the lift mechanism 2 in the heating chamber 22 , the conveyance path for the trays 200 is structured in two stages, an upper stage and a lower stage, so that, on the upper stage conveyance path from the introduction stage 13 through the purge chamber 21 to the heating chamber 22 , the trays 200 are pushed by the upper stage pusher 3 , while, on the lower stage conveyance path from the heating chamber 22 to the carburizing zone 23 , the trays 200 are pushed by the lower stage pusher 4 . According to this structure, on the upstream side of the carburizing zone 23 in the conveyance path, between each pair of trays 200 which are being conveyed, it is possible to establish a suitable gap for installation of the intermediate door 6 .
[0043] It is also possible to convey the plurality of trays 200 within the carburizing zone 23 in mutual contact, if the purge chamber 21 and the heating chamber 22 on the upstream side of the carburizing zone 23 in the conveyance path are arranged in a state in which it is possible to mutually isolate them by the intermediate doors 5 and 6 . And it is possible, while shortening the overall length of the furnace, and while keeping the area which it occupies compact, to perform pre-processing in the purge chamber, pre-heating processing in the heating chamber 22 , and carburizing processing upon a large number of workpieces in the carburizing zone, in a uniform manner.
[0044] While, in the embodiment described above, the purge chamber 21 and the heating chamber 22 were disposed on the upstream side of the carburizing zone 23 in the conveyance path, the present invention is not limited to the case in which such processing is performed in the two regions; it would also be acceptable for these to be regions in which other types of processing are performed. Moreover, it would also be possible to implement the present invention in a similar manner, with three or more regions being provided. In this case, the same number of pushers as the number of regions would be arranged in upper and lower stages, lift mechanisms would be provided to each of the regions with the exception of the region most towards the upstream side, and the same number of stages of conveyance path as the number of regions would be provided as upper and lower stages.
[0045] It should be understood that, in the above described explanation of an embodiment of the present invention, all of the features are shown by way of example, and should not be considered as being limitative of the present invention. The scope of the present invention is not to be defined by any of the features of the embodiment described above, but only by the scope of the appended Claims. Moreover, equivalents to elements in the Claims, and variations within their legitimate and proper scope, are also to be considered as being included within the range of the present invention.
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The continuous carburizing furnace of this invention provides a furnace, a lift mechanism and a plurality of pushers. A furnace has a carburizing zone and a plurality of regions including a first region and a second region at the upstream side of said carburizing zone. The second region and the first region being disposed successively along a direction of conveyance of workpieces loaded upon a tray in this order. The lift mechanism lowers a tray in some region, among the plurality of regions, other than the region most to the upstream side in the direction of conveyance. A plurality of pushers includes a first pusher and a second pusher. The first pusher pushes a tray in said first region to said carburizing zone. The second pusher pushes a tray in said second region to said first region. A plurality of pushers are arranged the lower, the further towards the downstream side in said direction of conveyance is the position at which they push said trays.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 794,198 filed Nov. 1, 1985, now abandoned.
BACKGROUND
This invention relates to the field of art pertaining to board test fixtures and other mechanical interfaces for electrically interconnecting electronic circuit cards and the like to electrical switching systems.
A board test system consists of numerous electronic sources and detectors which are connected through an electric switch, or scanner, to a plurality of contact points referred to as scanner pins. A board test fixture then provides an interface between these scanner pins and the electronic components located on an electronic circuit card. Since the electronic signals which are used to determine whether the electronic component is operating properly must pass through the board test fixture both on their way to and from the electronic component, the board test fixture must maintain the signal quality of these signals to ensure that the electronic component is not incorrectly diagnosed as operating properly or improperly.
In order to insure maximum signal quality, the length of the signal path between the scanner and the electronic circuit card should be kept as short as possible. This normally dictates a vertical configuration with the board test fixture sitting directly on top of the scanner and the electronic card directly on the fixture. However, any board test fixture must be easy to assemble and maintain in order to be cost effective and many prior art vertical configuration test fixtures have sacrificed assembly and maintainability to obtain short lead length The ability to automate assembly of the fixture is also an important feature.
Various prior art solutions have attempted to address these requirements. A first prior art solution uses a stiff probe pin to conduct the electronic signal directly from a spring loaded scanner pin to the electronic component under test. The probe pin passes through a first plate having a hole for each scanner pin and through a second plate have holes drilled according to the location of the electronic components on the card. This probe pin may be vertical if the component is located directly over the scanner pin, or the probe pin may be at an angle. At an angle, the probe pin may miss the component which it is trying to contact, or may make a high resistance contact, both being undesirable.
A second prior art solution replaces the stiff probe pin with a flexible probe pin. This permits the holes in both the first and second plate to be at right angles to the scanner pins and electronic components assuring a low resistance contact with the electronic component.
Both the first and second prior art solutions are impractical because they require a large number of scanner pins in order for a scanner pin to be located sufficiently close to the component to be able to use a straight or slightly bent pin. More scanner pins mean additional expensive pin electronics. In order to reduce the number of scanner pins, the fixturing method should permit signals from the scanner pins to be routed, or translated, to probe pins located at a different x and y axis positions from the scanner pins with respect to the plane of the probe plate. For incircuit and functional testing, the fixturing method must permit translation between the component location and the scanner pin location.
A third prior art solution permits translation at the expense of long connecting wires. The fixture again has two plates, the first plate drilled according to the locations of the electronic components on the card and the second plate with holes positioned above the scanner pins. A spring loaded probe with a wire wrap post is mounted in the first plate making electrical contact with the electronic components on the card. An interconnect pin with a wire wrap post is mounted in the second plate making electrical contact with the scanner pin. A wire is then wire wrapped between the probe pin and the interconnect pin to complete the electrical connection. This wire is typically quite long to enable the fixture to be opened for easy building and maintenance. Because the wire is long, the electrical performance of the third solution is inferior. A fourth prior art solution is similar to the third prior art solution but uses short wires between the probe pin and the interconnect pin. However, in order to use short wires, the second plate of the fourth solution is divided into interconnect strips. The interconnect strips are arranged in rows below the probe plate. Electrical connections are made one row at a time between the probe pins and the interconnect pins located in these strips. Starting at one end and after each row of connections is made, each strip is sequentially mounted across the bottom of the fixture. The fourth prior art solution, although offering good electrical performance, is difficult to wire, especially if there is a large number of x and y axis translations. This solution is impossible to automate and service is very difficult.
The fifth and final prior art solution is referred to as the "basic matrix". This solution uses a printed circuit board to perform the x and y axis translation. The probes which contact the electronic components are mounted directly to the top of the printed circuit board and the scanner pins contact the bottom of the printed circuit board to complete the connection. This solution is expensive requiring a custom printed circuit board for each fixture and special probes. Furthermore, this solution causes scanner pins located directly under probes to be made unusable, a very undesirable feature.
A need exists for a low cost, easy to build test fixture for which assembly is automatable. The test fixture should minimize the loss of scanner pins and provide for translation in the x and y axis directions between probe and scanner pin.
SUMMARY
In accordance with the preferred embodiment of the present invention, an apparatus is described for interfacing an automatic board test system to an electronic circuit card. This interface permits reliable electrical connections between the test system and electronic components located on the circuit card. The apparatus differs from the prior art in that the connections maximize the quality of the connection to the test system while permitting easy and automatic assembly of the test fixture. This apparatus works equally well with both vacuum actuated and mechanically actuated systems.
The present invention is superior to the prior art in several ways. First, the apparatus is a vertical fixturing scheme which minimizes the interconnection lead length. Second, the apparatus is easy to assemble and the assembly may be automated to further reduce the cost. Third, the apparatus avoids where possible making the interconnection points to the test system unusable. Finally, the apparatus does not require the electronic components to be located on a grid of any sort; the electronic components may be located anywhere on the card.
DESCRIPTION OF DRAWINGS
FIG. 1 is a fragmentary elevational view of the preferred embodiment of the present invention in a first position with an electronic circuit card.
FIG. 2 is a fragmentary elevational view of the preferred embodiment of the present invention in a second position with the electronic circuit card.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 is a fragmentary elevational view of the preferred embodiment of the present invention in a first position with an electronic circuit card. The test fixture comprises an alignment plate 22, probe plate 23, two probe assemblies 50 and 51, two interconnecting pins 53 and 54, interconnect wire 55 and 56, walls 41 and 42, alignment pins 84 and 85, and vacuum seal 80. The electronic circuit card to be tested consists of a printed circuit board 90, component 92, and printed circuit trace 91. The printed circuit board 90 has two tooling holes which may be used for alignment. A vacuum chamber is formed by the board 90, vacuum seal 80, and probe plate 23. A vacuum manifold, not shown, is attached over a hole in the probe plate to draw the air from the vacuum chamber. Vacuum is used in the preferred embodiment to force the electronic circuit card against the probe assembly, although mechanical means may also be used. The test fixture is mounted on the test system scanner. The scanner consists of a plate 21 with scanner pins 70. The construction of scanners is well known in the prior art as are various mounting and locking mechanism for holding the test fixture to the scanner. The present invention is capable of operating with a wide variety of scanners and mounting and locking mechanisms.
The probe assembly typically consists of a probe socket which is mounted into the hole in the probe plate and a probe mechanism having probe tip 94 which is inserted into the probe socket. The probe mechanism may be replaced as the probe tip 94 wears out. The probe socket consists of a tube which accepts the probe mechanism and a square wire wrap post. The probe mechanism consists of a probe tip 94 and a spring to bias the probe tip 94 to its maximum extended position in a housing which fits in the probe socket. Both probe sockets and probe mechanisms, including a variety of probe tips, are well known in the art.
The interconnecting pin 53 or 54 consists of insulated body about the same length as the probe assembly and a wire wrap post 58 or 59 which is considerably longer than the wire wrap post of the probe assembly 50 or 51. In the preferred embodiment of the present invention, the wire wrap post 58 or 59 of the interconnecting pin is approximately one inch long.
The probe plate 23 is constructed from a strong insulating material. In the preferred embodiment of the present invention, a sheet of plastic approximately one-half of an inch thick is used as the probe plate. In the preferred embodiment of the present invention, the plate 23 has a manifold hole which is not shown. The plate 23 is then drilled for the probe assemblies 50 and 51, interconnecting pins 53 and 54 and alignment pins 84 and 85. The locations of the probe assemblies 50 and 51 and the alignment pins 84 and 85 are determined by the locations of the components and traces on the electronic circuit card 90. These locations are often available from CAD/CAM systems as points. This permits a fixture builder to select the points from the CAD/CAM files for the electronic circuit card to be tested and to have the probe plate automatically drilled at these points. Automatic drilling is considerably less expensive than manual drilling. The location of the interconnecting pins is determined, with one important exception, from the location of the scanner pins. The scanner pins are on a fixed grid which may also be automatically drilled. The exception occurs when a probe assembly is located directly over a scanner pin as shown by probe assembly 51 in FIG. 1. For these cases, the hole for interconnecting pin is drilled off to one side. The maximum distance to offset the hole for the interconnecting pin is determined by the length of the interconnecting pin and the tolerances of the scanner pins and fixture For the preferred embodiment of the present invention, a 0.100 of an inch is used for the offset. The holes for the interconnecting pins do not need to pass completely through the probe plate, although in the preferred embodiment they do for convenience of drilling. Drilling the holes for the interconnecting pins may also be computerized by the CAD/CAM system since the system knows the location of both the components and the scanner grid.
After the probe plate is drilled, the alignment pins, the probe assemblies and the interconnecting pins are installed by pressing the pin or assembly into the probe plate, a process which lends itself to automation. The probe plate must then be wired. The x and y axis translation features, as well as the multiple connection capabilities of the fixture are provided by wiring each probe assembly to one or more interconnecting pins. In the preferred embodiment of the present invention, the method of wiring is by wire wrapping. Wire wrapping is fast and lends itself to automation. FIG. 1 illustrates the interconnect wires 55 and 56 used for connecting the interconnecting pin to the probe assembly in the preferred embodiment of the present invention.
After the probe plate has been wired, the fixture is assembled by connecting the probe plate 23 to the alignment plate 22. The primary requirement is to position the alignment plate 22 at a constant fixed distance, from the probe plate 23. In the preferred embodiment of the present invention, the alignment plate is located approximately an one and one-eighth inches plus or minus one sixteenth of an inch, from the probe plate. The preferred embodiment of the present invention uses a wall 41 and 42 to position the alignment plate with respect to the probe plate. Walls offer the added advantage of keeping dirt out, reducing the possibility of accidental damage to the fixture, and adding stiffness to the probe plate to reduce deflection. Alternate methods, including posts, may be used.
The alignment plate 22 has holes 26 on a grid which corresponds to the location of the scanner pins 70. The wire wrap posts of the interconnecting pins 58 pass through these holes in the alignment plate to make contact with the scanner pins. The holes 26 in the alignment plate 22 are bored out to a tapered shape to assist in assembly. These tapered holes 26 are especially important in the special case described above where a probe assembly lies directly above the scanner pin. In this case as shown in FIG. 1, the wire wrap post 59 of the interconnecting pin 54 which has been offset to on side of probe pin 51 is bent as it is passes through the the hole 26 in the alignment plate 22. The tapered bore of the hole 26 makes assembly of the offset interconnecting pins possible and permits easy disassembly for maintenance and repair.
Accurate alignment of the test fixture is essential for reliable operation. Alignment for the printed circuit board 90 to probe plate 23 is maintained by the alignment pins 84 and 85. Two or more alignment pins may be used depending on the size of the board. Alignment between the probe plate 23 and the alignment plate 22 is not critical since the wire wrap posts of the interconnecting pins are free to bend although it does determine the required length of the wire wrap post of the interconnecting pin. The alignment between the alignment plate 22 and the scanner 21 is controlled through the mounting and locking hardware well known in the prior art.
The method of operation of the test fixture is as follows. The printed circuit board is placed on the fixture with the alignment pins 84 and 85 of the test fixture passing through the tooling holes in the printed circuit board 90. The component 92 and trace 91 of the electronic circuit card must now be brought into contact with the probe tips 93 and 94. This may be achieved in several ways including vacuum and mechanical actuating means. The Preferred embodiment of the present invention uses a vacuum actuating means. Air is removed from the vacuum chamber created between the electronic circuit card and the probe plate 23. A seal 80 is used to maximize the force and reduce noise. As the electronic circuit card is drawn toward the probe plate, the probe tips 93 and 94 of the spring loaded probe assemblies 50 and 51 push against the ends of the component 92 and the trace 91 making a good low resistance contact.
FIG. 2 is a fragmentary elevational view of the preferred embodiment of the present invention in a second position with the electronic circuit card. FIG. 2 illustrates the printed circuit board with the vacuum applied in position for testing. When the vacuum is released the card returns to the position in FIG. 1 and may be easily removed and the next card to test installed.
Mechanical means may also be used for driving the electronic circuit card against the probe tips. This may be accomplished, for example, by placing a weight on top of the board. The present invention works well with any method of forcing the electronic circuit card against the probe tips.
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An apparatus is described for interfacing an automatic board test system to an electronic circuit card. This interface permits short and reliable connections between the test system and electronic components located on the circuit card for the electronic signals which test these components. This apparatus works equally well with vacuum actuated and mechanically actuated systems.
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CROSS-REFERENCE
This is a continuation-in-part of application Ser. No. 10/262,161, filed on Sep. 30, 2002, now U.S. Pat. No. 7,404,979.
BACKGROUND
1. Field of the Invention
This invention relates to a method for spin coating implantable medical devices such as stents.
2. Description of the State of the Art
Percutaneous transluminal coronary angioplasty (PTCA) is a procedure for treating heart disease. A catheter assembly having a balloon portion is introduced percutaneously into the cardiovascular system of a patient via the brachial or femoral artery. The catheter assembly is advanced through the coronary vasculature until the balloon portion is positioned across the occlusive lesion. Once in position across the lesion, the balloon is inflated to a predetermined size to radially compress against the atherosclerotic plaque of the lesion to remodel the lumen wall. The balloon is then deflated to a smaller profile to allow the catheter to be withdrawn from the patient's vasculature.
A problem associated with the above procedure includes formation of intimal flaps or torn arterial linings which can collapse and occlude the conduit after the balloon is deflated. Moreover, thrombosis and restenosis of the artery may develop over several months after the procedure, which may require another angioplasty procedure or a surgical by-pass operation. To reduce the partial or total occlusion of the artery by the collapse of arterial lining, and to reduce the chance of the development of restenosis, a stent is implanted in the lumen to maintain the vascular patency.
Stents are used not only as a mechanical intervention but also as a vehicle for providing biological therapy. As a mechanical intervention, stents act as scaffoldings, functioning to physically hold open and, if desired, to expand the wall of the passageway. Typically, stents are capable of being compressed, so that they can be inserted through small vessels via catheters, and then expanded to a larger diameter once they are at the desired location. Examples in patent literature disclosing stents which have been applied in PTCA procedures include stents illustrated in U.S. Pat. No. 4,733,665 issued to Palmaz, U.S. Pat. No. 4,800,882 issued to Gianturco, and U.S. Pat. No. 4,886,062 issued to Wiktor.
Biological therapy can be achieved by medicating the stents. Medicated stents provide for the local administration of a therapeutic substance at the diseased site. In order to provide an efficacious concentration to the treated site, systemic administration of such medication often produces adverse or toxic side effects for the patient. Local delivery is a preferred method of treatment in that smaller total levels of medication are administered in comparison to systemic dosages, but are concentrated at a specific site. Local delivery thus produces fewer side effects and achieves more favorable results.
One proposed method for medicating stents involves the use of a polymeric carrier coated onto the surface of a stent. A solution which includes a solvent, a polymer dissolved in the solvent, and a therapeutic substance dispersed in the blend is applied to the stent. The solvent is allowed to evaporate, leaving on the stent surface a coating of the polymer and the therapeutic substance impregnated in the polymer.
One conventional technique of coating a stent is by spraying the stent with the coating composition. If the coating solvent is sufficiently volatile, the spray process can spray continuously, building up coating thickness. However, if the solvent evaporates more slowly than it is being applied, the resulting stent coating may have undesirable imperfections such as formation of “webbing” of the coating between the stent struts. One current solution to this problem is to spray coat in a pulsed mode, interleaving brief spray blasts with forced-air drying. Spray coating processes, therefore, can be lengthy and have a greater opportunity for coating variability due to the complexity of the process.
Accordingly, a stent coating process that is rapid, produces a uniform coating, and is highly reproducible is needed. The embodiments of the invention provide an apparatus for fabricating coatings for implantable devices, such as stents, and methods of coating the same.
SUMMARY
Briefly and in general terms, the present invention is directed to a method of coating a stent.
In aspects of the present invention, a method comprises conducting the following acts at the same time: applying a coating substance to the stent, rotating the stent about a first axis of rotation, and rotating the stent about a second axis of rotation, wherein the first axis of rotation is not parallel and not perpendicular to the second axis of rotation.
In other aspects, the first axis of rotation intersects a center of the mass of the stent and the second axis of rotation is along a longitudinal central axis of the stent.
In other aspects, the first axis of rotation intersects a part of the body of the stent and the second axis of rotation is along a longitudinal central axis of the stent.
In other aspects, the stent is positioned off-set, at a distance away from the first axis of rotation.
In other aspects, the first axis of rotation intersects the second axis of rotation at an angle. In aspects of the present invention, a method comprises conducting the following acts at the same time: applying a coating substance to the stent, rotating the stent about a first axis of rotation, and rotating the stent about a second axis of rotation, wherein the first axis of rotation intersects the second axis of rotation at an angle.
In other aspects, the first axis of rotation is perpendicular to the second axis of rotation.
In other aspects, the first axis of rotation intersects a center of the mass of the stent and the second axis of rotation is along a longitudinal central axis of the stent.
In other aspects, the first axis of rotation intersects a part of the body of the stent and the second axis of rotation is along a longitudinal central axis of the stent.
In other aspects, the first axis of rotation intersects a center of the mass of the stent, the second axis of rotation is along a longitudinal central axis of the stent, and the first axis of rotation is perpendicular to the second axis of rotation.
In other aspects, the stent is positioned off-set, at a distance away from the first axis of rotation.
In other aspects, the first axis of rotation is perpendicular to a longitudinal axis of the stent.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates one embodiment of the apparatus for coating implantable medical devices;
FIG. 2 illustrates another embodiment of the apparatus;
FIG. 3 illustrates another embodiment of the invention; and
FIG. 4 illustrates a close-up view of a stent during the process of coating using the apparatus according to an embodiment of the present invention.
DETAILED DESCRIPTION
I. Apparatus
FIG. 1 illustrates one embodiment of a coating apparatus 10 . The coating apparatus 10 includes a mandrel 14 on which a stent 12 can be securely positioned. The mandrel 14 is mounted above a round table 16 using mandrel arms attached to the table 16 . The table 16 can be rotated about a shaft 18 using a motor (not shown). A longitudinal axis 20 of the stent can be substantially perpendicular to an axis of rotation 22 of the table 16 . The axis of rotation 22 of table 16 can extend along the center of the table 16 . The stent 12 can be positioned in such a way that the axis of rotation 22 intersects the center of mass of the stent 12 . The mandrel 14 can be connected to a second motor (not shown) using suitable bearings and gears and rotated about the longitudinal axis 20 . The table 16 can have a radius of between about 2 cm and about 20 cm, for example about 4 cm. The mandrel 14 is selected so as to accommodate stents of various sizes. For example, coronary stents having the length of between about 8 and about 38 mm, and peripheral stents having a length of about 76 mm can be used.
FIG. 2 illustrates another embodiment of the coating apparatus. The stent 12 is positioned offset from the axis of rotation 22 . An offset distance 24 can be measured as the distance between the axis of rotation 22 and the composite center of mass for the stent 12 . The offset distance 24 can be within a range of between about 0.1 cm and about 20 cm, for example about 15 cm. At least one counterweight 26 can be mounted on the table 16 . Those having ordinary skill in the art can determine the appropriate mass and location of the counterweight 26 . For example, the mass of the counterweight 26 can made be equivalent to the composite mass of the stent 12 , the mandrel 14 , and the mandrel arms. The counterweight radius 28 can be made equivalent to the offset distance 24 . The counterweight radius 28 can be measured as the distance between the axis 22 and the center of mass of the counterweight 26 .
As best illustrated by FIG. 2 , although the stent 12 is in an offset position, the longitudinal axis of the stent 20 intersects the axis of rotation 22 at about a 90 degree angle. The longitudinal axis 20 of the stent 12 need not intersect the axis of rotation 22 . The axis of rotation 22 remains perpendicular to a plane parallel to the surface of the table 16 and extending along the longitudinal axis 20 of the stent 12 .
In yet another embodiment, as illustrated by FIG. 3 , the longitudinal axis 20 of the stent 12 is parallel to the rotational axis 22 . The mandrel 14 can be also optionally offset from the axis of rotation 22 . If the stent 12 is positioned at the offset distance 24 away from the axis of rotation 22 , the counterweight 26 should be used to balance the system. The mandrel 14 can also be rotated about the longitudinal axis 20 by a motor.
In some embodiments, the longitudinal axis 20 of the stent 12 can be non-parallel to the rotational axis 22 . In some embodiments, the longitudinal axis 20 can be not parallel as well as not perpendicular, such that it is positioned at an angle to axis 22 . The angle between 20 and 22 can be for example 60, 45, or 30 degrees.
II. Method
A coating system can be applied to the stent 12 by any suitable method known to those having ordinary skill in the art, such as, for example, by spraying, dip-coating, brushing or wiping. Preferably it is by spraying. The coating system can be applied before the stent 12 has been mounted onto the apparatus 10 . Alternatively, the stent 12 can be coated after being mounted onto the apparatus 10 . The coating can be applied before the rotation of the stent 12 on the table 16 and along the axis 20 of the stent 12 such that the application of the coating (e.g., by spray) is completely terminated before the rotation of the stent 12 along one or both axis. A coating composition or substance is sprayed and the spraying is terminated. This is followed by rotation of the stent 12 about one or more of the described axis. Rotation about two axis can be contemporaneous or sequential.
In one embodiment, the stent 12 is rotated during the application of the coating composition. A coating composition or substance is sprayed contemporaneously/during the rotation of the stent 12 about one or more of the described axis. For example, referring to FIG. 1 , the stent 12 is sprayed with the coating composition (e.g., polymer, solvent and/or drug) while the table 16 and stent 12 , along axis 20 , are rotated concomitantly or, alternatively, while the table 16 and stent 12 are rotated in sequence. In some embodiments, during the application process, only the table 16 is rotated or only the stent 12 , along axis 20 , is rotated while the other remains stationary.
The thickness of the wet coating system before drying can be between about 5 and 500 micrometers, for example, 450 micrometers.
“Coating system” can be defined as a liquid composition which includes a polymeric material. Optionally, the coating system can also contain a therapeutic substance, an agent or a drug. The polymeric material can be dissolved in a solvent. The polymeric material can also form a colloid system, e.g., by being emulsified in a carrier such as water. The colloid system can contain between about 2 mass % and about 25 mass % of the polymeric material.
Using a motor, the table 16 can then be rotated about the axis 22 . The speed of rotation of the table 16 can be between about 300 revolutions per minute (rpm) and about 10,000 rpm, for example, about 4,000 rpm. The stent 12 can also be optionally rotated about the longitudinal axis 20 at a stent speed. The stent speed can be between about 100 rpm and about 5,000 rpm, for example, about 1,000 rpm.
When the table 16 is rotated, the wet coating system on the stent 12 flows along the surface of the stent 12 and the excess wet coating 30 is discharged by the centrifugal force ( FIG. 4 ), until a desired coating thickness is reached. Typically all of the solvent or colloid system carrier present in the wet coating system can be evaporated, and only trace amounts of the solvent or carrier may remain. As a result, an essentially dry coating is solidified on the stent. The remainder of the solvent or the carrier can be subsequently removed by drying the coating at an elevated temperature. The drying can be conducted under a vacuum condition.
The desired thickness of the resulting coating can be estimated according to the equation (I):
T=V p (3μ/4ρω 2 t ) 1/2 (I),
where T is the coating thickness;
V p is the volume fraction of polymer in the coating;
μ is the viscosity of the coating;
ρ is the density of the coating;
ω is the angular velocity of rotation of the table 16 ; and
t is the time for which the table 16 is rotated.
Accordingly, to reach the desired thickness of the dry coating, those having ordinary skill in the art can first formulate the desired wet coating system. The wet coating system will have fixed values of V p , μ, and ρ. Then, ω and t can be selected, depending on what value of T is desired.
The value of thickness T estimated according to the equation (I) is only approximate, because equation (I) presumes the stent as a smooth cylinder and does not take into account variables such as solvent evaporation, gravitational effects, or rotation of the stent 12 about the longitudinal axis 20 . For example, rotating the stent 12 about the axis 20 can increase the rate of airflow around the stent 12 , thereby increasing the evaporation rate of the solvent which, in turn, speeds solidification of the coating. Therefore, the value of thickness that can be achieved in the same time period can be higher than the value calculated according to the equation (I).
Representative examples of polymers that can be used in the coating system include poly(ethylene-co-vinyl alcohol) (EVAL), poly(hydroxyvalerate), poly(L-lactic acid), polycaprolactone, poly(lactide-co-glycolide), poly(hydroxybutyrate), poly(hydroxybutyrate-co-valerate), polydioxanone, polyorthoester, polyanhydride, poly(glycolic acid), poly(D,L-lactic acid), poly(glycolic acid-co-trimethylene carbonate), polyphosphoester, polyphosphoester urethane, poly(amino acids), polyacetals, cyanoacrylates, poly(trimethylene carbonate), poly(iminocarbonate), co-poly(ether-esters) (e.g. PEO/PLA), polyalkylene oxalates, polyphosphazenes, biomolecules (such as fibrin, fibrinogen, cellulose, starch, collagen and hyaluronic acid), polyurethanes (such as CORETHANE available from Pfizer Corp. of New York or ELASTEON available from AorTech Biomaterials Co. of Chatswood, Australia), silicones, polyesters, polyolefins, polyisobutylene and ethylene-alphaolefin copolymers, acrylic polymers and copolymers (such as poly(butyl methacrylate), poly(ethyl methacrylate) or poly(hydroxyethyl methacrylate)), vinyl halide polymers and copolymers (such as polyvinyl chloride), polyvinyl ethers other than polyacetals, polyvinylidene halides (such as polyvinylidene fluoride and polyvinylidene chloride), polyacrylonitrile, polyvinyl ketones, polyvinyl aromatics (such as polystyrene), polyvinyl esters (such as polyvinyl acetate, acrylonitrile-styrene copolymers, ABS resins, and ethylene-vinyl acetate copolymers), polyamides (such as Nylon 66 and polycaprolactam), alkyd resins, polycarbonates, polyoxymethylenes, polyimides, polyethers, epoxy resins, polyurethanes, rayon, rayon-triacetate, cellulose, cellulose acetate, cellulose butyrate, cellulose acetate butyrate, cellophane, cellulose nitrate, cellulose propionate, cellulose ethers, and carboxymethyl cellulose.
Examples of suitable solvents include, but are not limited to, dimethylsulfoxide (DMSO), chloroform, acetone, water (buffered saline), xylene, methanol, ethanol, 1-propanol, tetrahydrofuran, 1-butanone, dimethylformamide, dimethylacetamide, cyclohexanone, ethyl acetate, methylethylketone, propylene glycol monomethylether, isopropanol, isopropanol admixed with water, N-methylpyrrolidinone, toluene, and combinations thereof.
The drug can include any substance capable of exerting a therapeutic or prophylactic effect for a patient. The drug may include small molecule drugs, peptides, proteins, oligonucleotides, and the like. The drug could be designed, for example, to inhibit the activity of vascular smooth muscle cells. It can be directed at inhibiting abnormal or inappropriate migration and/or proliferation of smooth muscle cells to inhibit restenosis.
Examples of drugs include antiproliferative substances such as actinomycin D, or derivatives and analogs thereof (manufactured by Sigma-Aldrich of Milwaukee, Wis., or COSMEGEN available from Merck). Synonyms of actinomycin D include dactinomycin, actinomycin IV, actinomycin I 1 , actinomycin X 1 , and actinomycin C 1 . The active agent can also fall under the genus of antineoplastic, anti-inflammatory, antiplatelet, anticoagulant, antifibrin, antithrombin, antimitotic, antibiotic, antiallergic and antioxidant substances. Examples of such antineoplastics and/or antimitotics include paclitaxel (e.g. TAXOL® by Bristol-Myers Squibb Co., Stamford, Conn.), docetaxel (e.g. Taxotere®, from Aventis S.A., Frankfurt, Germany) methotrexate, azathioprine, vincristine, vinblastine, fluorouracil, doxorubicin hydrochloride (e.g. Adriamycin® from Pharmacia & Upjohn, Peapack N.J.), and mitomycin (e.g. Mutamycin® from Bristol-Myers Squibb Co., Stamford, Conn.). Examples of such antiplatelets, anticoagulants, antifibrin, and antithrombins include sodium heparin, low molecular weight heparins, heparinoids, hirudin, argatroban, forskolin, vapiprost, prostacyclin and prostacyclin analogues, dextran, D-phe-pro-arg-chloromethylketone (synthetic antithrombin), dipyridamole, glycoprotein IIb/IIIa platelet membrane receptor antagonist antibody, recombinant hirudin, and thrombin inhibitors such as Angiomax™ (Biogen, Inc., Cambridge, Mass.). Examples of such cytostatic or antiproliferative agents include angiopeptin, angiotensin converting enzyme inhibitors such as captopril (e.g. Capoten® and Capozide® from Bristol-Myers Squibb Co., Stamford, Conn.), cilazapril or lisinopril (e.g. Prinivil® and Prinzide® from Merck & Co., Inc., Whitehouse Station, N.J.); calcium channel blockers (such as nifedipine), colchicine, fibroblast growth factor (FGF) antagonists, fish oil (omega 3-fatty acid), histamine antagonists, lovastatin (an inhibitor of HMG-CoA reductase, a cholesterol lowering drug, brand name Mevacor® from Merck & Co., Inc., Whitehouse Station, N.J.), monoclonal antibodies (such as those specific for Platelet-Derived Growth Factor (PDGF) receptors), nitroprusside, phosphodiesterase inhibitors, prostaglandin inhibitors, suramin, serotonin blockers, steroids, thioprotease inhibitors, triazolopyrimidine (a PDGF antagonist), and nitric oxide. An example of an antiallergic agent is permirolast potassium. Other therapeutic substances or agents which may be appropriate include alpha-interferon, genetically engineered epithelial cells, tacrolimus, dexamethasone, and rapamycin and structural derivatives or functional analogs thereof, such as 40-O-(2-hydroxy)ethyl-rapamycin (known by the trade name of EVEROLIMUS available from Novartis), 40-O-(3-hydroxy)propyl-rapamycin, 40-O-[2-(2-hydroxy)ethoxy]ethyl-rapamycin, and 40-O-tetrazole-rapamycin.
The apparatus and method of the present invention have been described in conjunction with a stent. However, the apparatus and method can also be used with a variety of other medical devices. Examples of the implantable medical device, that can be used in conjunction with the embodiments of this invention include stent-grafts and grafts. The underlying structure or scaffolding design of the device can be of virtually any design. The device can be made of a metallic material or an alloy such as, but not limited to, cobalt-chromium alloys (e.g., ELGILOY), stainless steel (316L), “MP35N,” “MP20N,” ELASTINITE (Nitinol), tantalum, tantalum-based alloys, nickel-titanium alloy, platinum, platinum-based alloys such as, e.g., platinum-iridium alloy, iridium, gold, magnesium, titanium, titanium-based alloys, zirconium-based alloys, or combinations thereof. Devices made from bioabsorbable or biostable polymers can also be used with the embodiments of the present invention.
“MP35N” and “MP20N” are trade names for alloys of cobalt, nickel, chromium and molybdenum available from Standard Press Steel Co. of Jenkintown, Pa. “MP35N” consists of 35% cobalt, 35% nickel, 20% chromium, and 10% molybdenum. “MP20N” consists of 50% cobalt, 20% nickel, 20% chromium, and 10% molybdenum.
Some embodiments of the present invention can be further illustrated by the following Examples.
Example 1
A 13 mm PENTA stent (available from Guidant Corp.) can be placed on a mandrel and the mandrel can be mounted onto a coating apparatus as shown by FIG. 1 .
A first composition can be prepared, comprising:
(a) about 4 mass % of EVAL; and
(b) the balance, a solvent blend, the blend comprising about 80 mass % of dimethylacetamide (DMAC) and about 20 mass % of pentane.
With the table stationary, the EVAL composition can be applied in a drop-wise manner to the stent to form a primer layer. A sufficient amount of the EVAL solution can be added to ensure the entire stent is wetted. Immediately after application of the EVAL composition, the table can be accelerated to a speed of about 8,000 rpm at a ramp rate of about 8,000 rpm/s (about 133.3 r/s 2 ). The term “ramp rate” is defined as the acceleration rate of the spinner. The ramp rate of 8,000 rpm/s means that in 1 second the spinner would accelerate to 8,000 rpm from a standstill.
The table speed of about 8,000 rpm can be held for about 8 seconds and then the table can be decelerated at a ramp rate of about 4,000 rpm/s until the table comes to a complete stop. This means that the table speed is reduced from about 8,000 rpm to 0 within about 2 seconds. Residual solvent can be removed by baking the stent at about 140° C. for about 1 hour.
Next, the stent can be reinstalled in the same spinning apparatus. A second composition can be prepared, comprising:
(c) about 6 mass % of poly(butyl methacrylate);
(d) about 3 mass % of 17-β-estradiol; and
(e) the balance, a solvent blend, the blend comprising about 60 mass % of acetone and about 40 mass % of xylene.
With the table stationary, the second composition can be applied in a drop-wise manner to the stent to form a drug-polymer layer. Application of the drug in a drop-wise manner mitigates the safety requirements that are needed as compared to the precautions that are taken during the handling of atomized pharmaceuticals. A sufficient amount of the second solution can be added to ensure the entire stent is wetted. Immediately after the second composition has been applied, the table can be accelerated at a rate of about 4,000 rpm/s to a speed of about 4,000 rpm, held for about 9 seconds, and then decelerated at a rate of about 4,000 rpm/s until the table comes to a complete stop. The stent can be baked at about 80° C. for about 30 minutes to remove residual solvent.
Example 2
A 13 mm PENTA stent can be mounted on a mandrel and the mandrel can be mounted onto an apparatus as shown in FIG. 2 . The mandrel can be mounted in such a way that the mandrel is free spinning. For example, the mandrel can be attached to the arms using bearings located on the arms. As the table turns, the mandrel spins due to greater air friction on the top surfaces of the stent than the bottom surfaces. The offset distance can be about 50 mm, and the counterweight can weigh between about 10 grams and about 100 grams, for example, about 32 grams.
A first composition can be prepared, comprising:
(a) about 4 mass % of poly(butyl methacrylate); and
(b) the balance, a solvent blend, the blend comprising about 60 mass % of acetone and about 40 mass % of xylene.
With the table stationary, the first composition can be applied in a drop-wise manner to the stent for forming a primer layer. A sufficient amount of the poly(butyl methacrylate) solution can be added to ensure the entire stent is wetted. Immediately after application of the first composition, the stent can be accelerated to a speed of about 4,000 rpm at a ramp rate of about 8,000 rpm/s. The 4,000 rpm speed can be held for about 8 seconds and then decelerated at a rate of about 4,000 rpm/s. Residual solvent can be removed by baking the stent at about 80° C. for about 1 hour.
Next, the stent can be reinstalled in the same spinning apparatus. A second composition can be prepared, comprising:
(c) about 2 mass % of poly(butyl methacrylate);
(d) about 1.6 mass % of EVEROLIMUS; and
(e) the balance, a solvent blend, the blend comprising about 60 mass % of acetone and about 40 mass % of xylene.
With the table stationary, the second composition can be applied in a drop-wise manner to the stent to form a drug-polymer layer. A sufficient amount of the second solution can be added to ensure the entire stent is wetted. Immediately after the second composition has been applied, the table can be accelerated at a rate of about 2,000 rpm/s to a speed of about 4,000 rpm, held for about 9 seconds, and then decelerated at a rate of about 4,000 rpm/s until the table comes to a complete stop. The stent can be baked at about 80° C. for about 30 minutes to remove residual solvent.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications can be made without departing from this invention in its broader aspects. Therefore, the appended claims are to encompass within their scope all such changes and modifications as fall within the true spirit and scope of this invention.
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A method is disclosed for spin coating a stent. The method comprises conducting the following acts at the same time: applying a coating substance to the stent; rotating the stent about a first axis of rotation; and rotating the stent about a second axis of rotation.
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CROSS REFERENCE TO RELATED APPLICATION
This invention is utilized with an outer air seal support system that is described and claimed in a co-pending patent application entitled OUTER AIR SEAL SUPPORT STRUCTURE, filed by G. Chaplin, F. DeTolla and J. Griffin on even date and assigned to the same assignee as this patent application.
BACKGROUND OF THE INVENTION
This invention relates to active clearance controls for a turbofan engine and particularly to the spray-bar configuration.
U.S. Pat. No. 4,019,320 granted on Apr. 26, 1977 to I. H. Redinger, D. Sadowsky and P. S. Stripinis, and assigned to the same assignee as this patent application discloses and claims spray bars that are externally and circumferentially mounted around the casing of the engine. Air bled from the fan through a manifold feeds these spray bars which in turn judiciously squirts air on the case to control its expansion and contraction. The purpose being is to position the outer air seals relative to the tips of the rotating engine machinery so as to control the gap therebetween. Obviously, the gap should be maintained at a minimum at all modes of engine operation for the entire flight envelope since the gap is a leakage path that adversely affects the efficiency of the rotating machinery, which in turn is reflected in loss of fuel economy. Of course, it is abundantly important to achieve optimum thrust specific fuel consumption. This patent, supra, discloses a spray bar (that is circular in cross section) with discretely located air holes. To satisfy certain ACC applications, it becomes necessary to increase the diameter of the tube which necessitates the tube to be spaced further from the engine case with a consequential loss in cooling effectiveness.
Further the circular cross section does not lend itself to create an optimum film of cooling air between it and the case and hence doesn't take full advantage of the further cooling obtainable from the spent air from the cooling jets that would otherwise scrub the case.
These square pipes not only allow for the more effective distribution of cooling air but also provide a more compact assembly while increasing cooling flow capacity. Thus it is contemplated by this invention that the cooling air is utilized as effectively and efficiently as possible, thereby only utilizing the amount of cooling air necessary to accomplish optimum ACC. This assures that the energy extracted from the engine for ACC purposes does not unduly penalize engine performances which is a consequence of extracting cooling air. Amongst the advantages afforded by the employment of this invention, but not limited thereto are:
(1) the distance between the pipe and the engine case being controlled say, the turbine case, is optimized which places the pipe at 6 to 10 hole diameters from the surface to be cooled;
(2) the spent air lies closer to the engine case surface which scrubs the case which results in better cooling;
(3) cooling air holes can be drilled at locations that allow the cooling jets to strike more responsive points of the engine case; and
(4) the overall spray bar configuration is more compact for the amount of flow capacity they encompass because they follow the engine case contour more effectively.
SUMMARY OF THE INVENTION
A feature of this invention is to provide for a turbofan engine improved active clearance control. The cross section of the spray bars externally circumscribing the engine case are square, rectangular or substantially those geometries.
Other features and advantages will be apparent from the specification and claims and from the accompanying drawings which illustrate an embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view partly in elevation and partly in section illustrating the invention, and
FIG. 2 is a partial view in section showing a portion of the engine case, the outer seal support structure and the spray bar.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention is currently being utilized on the JT9D-59, 70 and 7Q engine models manufactured by Pratt and Whitney Aircraft Manufacturing Group, a Division of United Technologies Corporation, the assignee, and for further details reference should be made thereto. For the purpose of this description the terms, square, rectangular, or similar shaped cross sections, refer to the spray bar and that it should be understood that the term as used herein encompases all shapes so long as the wall adjacent the engine case is substantially flat and its attached side wall is generally perpendicular thereto and generally parallel to the adjacent flange of the engine case.
Similar to the ACC described in the U.S. Pat. No. 4,019,320 patent, supra, the ACC generally indicated by reference numeral 10 comprises a plurality of spray bars 12 wrapped around the engine case 14 at a strategic location. Air discharging from the fan 16 of the turbofan engine in the annular duct 18 is bled through the passageway 20, collected in a manifold (not shown) and distributed to the spray bars 12. A suitable valve 22 is incorporated to feed the air to the spray bars in an operational mode described in U.S. Pat. No. 4,019,320 and reference should be made thereto for further details. Suffice it to say that typically the valve turns on the air at a predetermined mode in the flight envelope, say cruise, at which time there is a transient of growth of the metal components at different rates that tend to cause the gap between the outer air seal and tips of the rotor blades, say turbine, to increase. The purpose of the ACC, of course, is to prevent, or minimize this gap.
In the enlarged view of FIG. 2 it can be seen that the square pipes 12, each being slightly configured differently although such is not necessary and geometrically shaped squares or rectangles are within the scope of this invention, are fitted between the flanges 26 of engine case 14 and the contour of wall 28 is substantially parallel to the outer wall of casing 14 as viewed in the plane of the sheet of the drawing and is secured therein to define a predetermined gap A. This gap is selected to achieve optimum heat transfer from the impingement and film of cooling air supported therebetween. The film of cooling air is formed from the spent air egressed from the spray bars, scrubbing the case and enhancing the cooling effectiveness. The apertures 30 in the tubes are discretely located in order to maximize the heat transfer effect effectuated by impingement cooling and, where possible are sized in relationship to the pipe so that the pipe is at 6 to 10 aperture diameters from the surface to be cooled. Of course at certain locations this may not be possible to achieve, but the use of the flat-like wall 28 of the spray bar attains a higher number of impingement cooling holes than could be otherwise attained.
As is apparent from the foregoing, the square pipes at the bolted flanges spray air effectively behind the bolts, which is an improvement over other spray bar configurations because the bolts partially block the jets from the turbine case surface. The striking distance of the jets are located at an optimum, particularly in the middle pipes running only 0.150 inches from the case. The square tubes do not take up as much room as the other heretofore known systems even though they have three times the flow capacity.
It should be understood that the invention is not limited to the particular embodiments shown and described herein, but that various changes and modifications may be made without departing from the spirit and scope of this novel concept as defined by the following claims.
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An active clearance control (ACC) for a turbofan engine is disclosed herein where the cross section of the external spray bars are fabricated in square or substantially square configurations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 12/192,215 filed Aug. 15, 2008 herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates generally to delay-locked loops (DLL). More specifically, the present invention relates to an apparatus and method for mitigating switching jitter in a DLL.
BACKGROUND OF THE INVENTION
A digital delay-locked loop (DLL) generally includes a phase detector which detects the phase difference between a system clock and a feedback clock, and causes adjustment of a time delay circuit in a loop which causes a DLL output clock to be adjusted to lock with the system clock. The time delay is generally provided by an adjustable delay line.
Since the adjustable delay line is typically adjusted in steps, the finest delay resolution depends on the delay line step increments. In order to hold the locked condition, the adjustable delay line is continuously increased and decreased in step increments around a lock point, which results in inherent tracking jitter. In order to reduce the jitter, the adjustable delay line includes a plurality of coarse delay elements (CDE), forming a coarse delay line (CDL), in series with a plurality of fine delay elements (FDE) forming a fine delay line (FDL). After power-up of the circuit, the CDL is adjusted, and once a lock point has almost been determined, the FDL is adjusted, which narrows the window or eye around the lock point, which represents a nominal amount of jitter in a typical application.
The FDL preferably includes enough steps for providing a maximum time delay which is equal to or slightly greater than a time delay of a step of the CDL. Once the DLL has stabilized to the lock point, the adjustable delay line will automatically compensate for variations in delay caused by changing temperature and voltage conditions, by varying the FDL.
In case of major drift, adjustments in the FDL will underflow/overflow its minimum/maximum delay. In that case, another CDE is switched out/in series, and at the same time the FDL is adjusted to compensate for the CDL decrease/increase to provide the same total delay as before. However, now the FDL can be used again to compensate changes without immediate danger of underflow/overflow.
It is assumed in the prior art that exchanging (or switching) a predetermined number FDL steps for a CDL step provides an equivalent delay. However, any differences between the two appear as switching jitter on the DLL output.
DLL jitter includes factors such as inherent tracking jitter, power supply noise, and substrate noise induced jitter. The inherent tracking jitter is caused by the up and down adjustments to the fine delay while the DLL is in the locked condition, and as described above, is a variation equivalent to the delay achieved through a single step in the FDL. The jitter caused by switching between the CDL and FDL elements caused by the mismatch between the elements is referred to as switching jitter. This mismatch is highly dependent on the manufacturing process, and thus is hard to predict in the design stage. As operating frequencies continue to increase, the switching jitter can undesirably reduce data eye significantly. In addition, since this switching occurs only infrequently, it is inherently difficult to detect during testing and can cause apparently randomly dropped bits when the DLL is in use in the field.
Analog techniques can be used to achieve a wide range of fine resolution tracking for various applications. In particular DLLs based on phase mixers have been shown to achieve high fine resolution tracking range through quadrature mixing. However, most analog based DLL designs employ some form of charge pumps for voltage controlled delay lines and as such they suffer from a limited resolution of the delay steps since the controlling element affects an entire delay line. In addition such DLLs often require a large acquisition time due to loop bandwidths being limited to a small fraction of the clock frequency to ensure stability of the loop. This effect also causes a poor jitter performance in analog DLLs.
Furthermore, analog DLL designs are inherently more susceptible to all sources of noise as their control variables (usually voltage) are reduced to achieve finer resolutions. In particular, synchronous dynamic random access memories (SDRAM) provide a very noisy environment for analog blocks in form of supply and substrate noise, which when combined with area restrictions in SDRAMs, sometimes preventing adequate implementation of noise prevention techniques through layout, can result in unreliable DLLs in noisy field environments.
Clearly, there is a need for an improved DLL having reduced switching jitter compared to conventional DLLs.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a method for determining a number of steps of a fine delay line (FDL) which are substantially equivalent to a step of a coarse delay line (CDL), the method including steps of: providing a clock signal; delaying the clock signal by a first delay substantially equivalent to a predetermined delay plus an adjustable number of steps of the FDL to provide a first delayed clock signal; delaying the clock signal by a second delay substantially equivalent to the predetermined delay plus a step of the CDL to provide a second delayed clock signal; and adjusting the number of adjustable steps of the FDL so that the first delay is substantially equal to the second delay to provide the number of steps of the FDL that are substantially equivalent to the step of the CDL.
According to another aspect of the present invention there is provided a method for determining a number of steps of a fine delay line (FDL) that are substantially equivalent to a step of a coarse delay line (CDL), the method including steps of: providing a clock signal; delaying the clock signal by a first delay substantially equivalent to a first predetermined delay plus an adjustable number of steps of the FDL; delaying the clock signal by a second delay substantially equivalent to a second predetermined delay; adjusting the number of adjustable steps of the FDL so that the first delay is substantially equal to the second delay and providing a first number of adjustable steps of the FDL; delaying the clock signal by a third delay substantially equal to the second predetermined delay plus a step of the CDL; adjusting the number of adjustable steps of the FDL so that the first delay is substantially equal to the third delay and providing a second number of adjustable steps of the FDL; subtracting the first number from the second number of adjustable steps of the FDL to provide the number of steps of the FDL that are substantially equivalent to a step of a CDL.
According to still another aspect of the present invention there is provided a reference circuit for determining a number of steps of a fine delay line (FDL) that are substantially equivalent to a step of a coarse delay line (CDL), the reference circuit including: a first path for receiving a clock signal including: a first CDL for providing a first predetermined delay; and a first FDL for providing an adjustable number of delay steps plus a second predetermined delay, a second path for receiving the clock signal including: a second CDL for providing a third predetermined delay substantially equal to the first predetermined delay plus a step of the CDL; and a second FDL for providing a fourth predetermined delay that is substantially equal to the second predetermined delay, a phase detector for receiving outputs from the first and second paths and providing a phase difference of the outputs from the first and second paths, and a controller for: receiving the phase difference from the phase detector; providing a plurality of control signals for adjusting the number of steps of the first FDL so that a total delay of the first path is substantially equal to a total delay of the second path; and providing the number of steps of the FDL that are substantially equivalent a step of the CDL.
According to still another aspect of the present invention there is provided a delay-locked loop (DLL) including: a main coarse delay line (CDL) for delaying a main clock signal by zero or more steps of the main CDL; a main fine delay line (FDL) for further delaying the main clock signal by zero or more steps of the main FDL; and a reference circuit for determining a number of steps of the main FDL that are substantially equivalent to one step of the CDL, the reference circuit including: a first path for receiving a divided clock signal including: a first CDL for providing a first predetermined delay; and a first FDL for providing an adjustable number of delay steps plus a second predetermined delay, wherein one step of the first FDL is substantially equivalent one step of the main FDL, a second path for receiving the divided clock signal including: a second CDL for providing a third predetermined delay that is substantially equal to the first predetermined delay plus a step of the main CDL greater the first predetermined delay; and a second FDL for providing a fourth predetermined delay that is substantially equal to the second predetermined delay, a phase detector for receiving outputs from the first and second paths and providing a phase difference of the outputs from the first and second paths, and a controller for: receiving the phase difference from the phase detector; providing a plurality of control signals for adjusting the number of steps of the first FDL so that a total delay of the first path is substantially equal to a total delay of the second path; and providing the number of steps of the FDL that are substantially equivalent a step of the CDL.
A reference circuit for determining a number of steps of a fine delay line (FDL) that are substantially equivalent to a step of a coarse delay line (CDL), the reference circuit including: a FDL for receiving a clock signal, and for providing a first predetermined delay plus an adjustable number of delay steps; a CDL for receiving the clock signal, and for providing a second predetermined delay plus an adjustable number of delay steps; a phase detector for receiving outputs from the first and second paths and providing a phase difference of the outputs from the first and second paths; a controller for: receiving the phase difference from the phase detector, providing a control signal to the CDL for setting a first number of steps of the CDL, providing a plurality of control signals for adjusting a first number of steps of the FDL so that a total delay of FDL is substantially equal to a total delay of the CDL, providing the control signal to the CDL for setting a second number of steps of the CDL wherein the second number of delay steps is equal to the first number of delay steps plus one, providing the plurality of control signals for adjusting a second number of steps of the FDL so that the total delay of FDL is substantially equal to the total delay of the CDL, and subtracting the first number of steps of the FDL from the second number of steps of the FDL, and providing the number of steps of the FDL that are substantially equivalent a step of the CDL.
According to another aspect of the invention there is provided a delay-locked loop (DLL) including: a main coarse delay line (CDL) for delaying a main clock signal by zero or more steps of the coarse delay line; a main fine delay line (FDL) for further delaying the main clock signal by zero or more steps of the FDL; and a reference circuit for determining a number of steps of a fine delay line (FDL) that are substantially equivalent to a step of a coarse delay line (CDL), the reference circuit including: a FDL for receiving a clock signal, and for providing a first predetermined delay plus an adjustable number of delay steps; a CDL for receiving the clock signal, and for providing a second predetermined delay plus an adjustable number of delay steps; a phase detector for receiving outputs from the first and second paths and providing a phase difference of the outputs from the first and second paths; a controller for: receiving the phase difference from the phase detector, providing a control signal to the CDL for setting a first number of steps of the CDL, providing a plurality of control signals for adjusting a first number of steps of the FDL so that a total delay of FDL is substantially equal to a total delay of the CDL, providing the control signal to the CDL for setting a second number of steps of the CDL wherein the second number of delay steps is equal to the first number of delay steps plus one, providing the plurality of control signals for adjusting a second number of steps of the FDL so that the total delay of FDL is substantially equal to the total delay of the CDL, and subtracting the first number of steps of the FDL from the second number of steps of the FDL, and providing the number of steps of the FDL that are substantially equivalent a step of the CDL.
Advantageously, the present invention therefore provides a reference circuit and method for mitigating switching jitter and a DLL having reduced switching jitter compared to conventional DLLs.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:
FIG. 1 is a block diagram an embodiment of a delay-locked loop (DLL) in accordance with the present invention;
FIG. 2 is a schematic diagram of an embodiment of a main coarse delay line (CDL) shown in FIG. 1 ;
FIG. 3 is a schematic diagram of an embodiment a main fine delay line (FDL) shown in FIG. 1 ;
FIG. 4 is a block diagram of a first embodiment of a reference circuit shown in FIG. 1 ;
FIG. 5 is a block diagram of a second embodiment of the reference circuit shown in FIG. 1 ;
FIGS. 6 to 9 are flowcharts of a first method of determining a number of steps of a FDL that are equivalent to a step of a CDL; and
FIGS. 10 to 15 are flowcharts of a second method of determining a number of steps of the FDL that are equivalent to a step of the CDL.
It will be noted that throughout the appended drawings, like features are identified by like reference numerals.
DESCRIPTION OF EMBODIMENTS
FIG. 1 illustrates a delay-locked loop (DLL) 100 in accordance with an embodiment of the present invention. A main phase detector 102 receives a main clock (CLK) signal 104 and a feedback clock (F_CLK) signal 106 , compares a phase of the F_CLK signal 106 with a phase of the CLK signal 104 , and issues up 108 and down 110 count control signals to a coarse adjust state machine 112 , and fine adjust state machine 114 . The up and down signals 108 , 110 are also monitored by a main controller 116 , which controls the state machines 112 , 114 .
The main coarse adjust state machine 112 preferably includes a one state per flip-flop type state machine for providing a fully decoded output 125 to a main coarse delay line (CDL) 122 . Alternatively, the main coarse adjust state machine 112 may include an up/down counter and thermometer decoder for providing a fully decoded output 125 to the main CDL 122 .
The main fine adjust state machine 114 also preferably includes a one state per flip-flop type state machine for providing a fully decoded output to a main fine delay line (FDL) 124 . Alternatively, the main fine adjust state machine 114 may include an up/down counter and thermometer decoder for providing a fully decoded output 126 to the main FDL 124 .
The outputs 125 , 126 of the main coarse adjust state machine 112 and fine adjust state machine 114 are preferably tri-state logic signals. A low impedance output enables a respective coarse delay element (CDE) or fine delay element (FDE) (described herein below). A high impedance output disables a respective CDE 206 or FDE 306 thereby reducing a number of steps of the CDL 122 or FDL 124 .
The CLK signal 104 is provided to an input of the main CDL 122 , and an output 123 of the main CDL 122 is provided to the input of the main FDL 124 . The main FDL 124 provides the F_CLK signal 106 to the main phase detector 102 . The F_CLK signal 106 is also provided as an output of the DLL 100 having substantially zero delay from the CLK signal 104 .
Referring to FIG. 2 , the main CDL 122 includes a plurality of CDEs 206 , each CDE is preferably a substantially equal valued capacitor based RC delay element. A buffer driver 202 receives the CLK signal 104 and drives a series resistor 204 followed by a plurality of substantially equal valued capacitors 206 which are selectable by tri-state logic signals 125 output from the coarse adjust state machine 112 . A step of the CDL 122 is defined as a incremental delay provided by enabling a CDE 206 .
Referring to FIG. 3 , the main FDL 124 includes a plurality of FDEs 306 , each FDE is preferably a substantially equal valued capacitor based RC delay element. A buffer driver 302 receives an output 123 from the main CDL 122 and drives a series resistor 304 followed by a plurality of substantially equal valued capacitors 306 which are selectable by tri-state logic signals 126 output from the fine adjust state machine 114 . A step of the FDL 124 is defined as a incremental delay provided by enabling a FDE 306 .
The embodiments of the CDL 122 and FDL 124 shown in FIGS. 2 and 3 are simplified for clarity. Those skilled in the art will appreciate that the CDL 122 and FDL 124 may include more buffers, resistors, and transistors than those shown in order to provide specified maximum delays of the CDL 122 and FDL 124 . For example, U.S. Pat. No. 7,190,202, “TRIM UNIT HAVING LESS JITTER”, to OH, issued Mar. 13, 2007, which is hereby incorporated by reference, provides a delay line wherein each delay element includes a select transistor and a load capacitor coupled in series between the delay line and ground potential, and includes a filter circuit having an input to receive an enable signal and having an output coupled to a gate of the select transistor.
Referring again to FIG. 1 , the main controller 116 controls the coarse adjust state machine 112 and fine adjust state machine 114 to adjust a number of steps of the main CDL 122 and main FDL 124 in order to lock the phases the CLK 104 and F_CLK 106 signals together as closely as possible.
The main controller 116 senses overflow of the main fine adjust state machine 114 . Overflow is defined as a number of the signals 126 to the main FDL 124 in the low impedance state being greater than a predefined upper limit. Thereupon the main controller 116 controls the coarse adjust state machine 112 to increase the number of coarse delay elements enabled by one by increasing the number of the signals 125 to the main coarse adjust line 122 in low impedance state by one, and controls the fine adjust state machine 114 to lower the number of fine delay elements enabled by M 128 by reducing the number of signals 126 to the main fine adjust delay line 124 in the low impedance state by M 128 , where M 128 is substantially equal to a number of steps of the main FDL 124 needed to provide a delay substantially equal to one step of the main CDL 122 . A value of M 128 is provided by a reference circuit 130 (described herein below).
The main controller 116 also senses underflow of the main fine adjust state machine 114 . Underflow is defined as a number of the signals 126 to the main fine adjust line 120 in the low impedance state being less than a predefined lower limit. Thereupon the main controller 116 controls the coarse adjust state machine 112 to decrease the number of coarse delay elements 206 enabled by one by decreasing the number of the signals 125 to the main CDL 122 in low impedance state by one, and controls the fine adjust state machine 114 to increase the number of fine delay elements enabled by M 128 by increasing the number of signals 126 to the main FDL 124 in the low impedance state by M 128 .
A range of the main FDL 124 , defined as a difference between the predefined upper limit and the predefined lower limit, preferably chosen to be greater than or equal to a step of the main CDL 122 over all specified operating conditions.
A DIV_CLK signal 120 is provided to the coarse adjust state machine 112 , main controller 116 , fine adjust state machine 114 , and reference circuit 130 . A frequency the DIV_CLK signal 120 is preferably a submultiple (that is, divided by N) of a frequency of the main clock 104 for reducing power requirements.
Referring to FIG. 4 , a block diagram of a first embodiment of the reference circuit 130 is shown. A first delay path 402 receives the DIV_CLK signal 120 . A first CDL 406 provides a first predetermined delay. The first CDL 406 is similar (that is, having substantially equal delay steps but preferably having a fewer number of CDEs than the main CDL 406 for reducing circuit area requirements) to the main CDL 122 but having its inputs 407 preferably set to “0” (that is, all inputs are hardwired a high impedance state). Alternatively, a small number (X) compared to a total number of CDEs of the main CDL 122 , of the inputs 407 of the first CDL 406 may be set to a low impedance state.
The first delay path 402 also includes a first FDL 408 that is similar (that is, having substantially equal delay steps and preferably a substantially equal number of FDEs) to the main FDL 124 . The first FDL 408 receives a plurality of signals 418 from a reference circuit controller 416 for adjusting a number of steps of the first FDL 408 .
A total delay of the first path 402 is substantially equal to a delay of the first CDL 406 plus a delay of the first FDL 408 . An output of the first path 402 is provided to a reference circuit phase detector 414 . It should be noted that the order of the first CDL 406 and the first FDL 408 may be reversed from that shown in FIG. 4 and still be within the present invention.
A second delay path 404 also receives the DIV_CLK signal 120 . A second CDL 410 provides a second predetermined delay. The second CDL 410 is similar (that is, having a substantially equal intrinsic delay and having substantially equal delay steps) to the first CDL 406 but having its inputs 411 preferably set to “1” (meaning that all but one inputs are set to a high impedance state, the other set to a low impedance state). Generally, a number of steps of the second CDL 410 is chosen to be one greater (X+1) than the first CDL 406 .
The second delay path 404 also includes a second fine delay line 412 that is substantially similar (that is, having a substantially equal intrinsic delay and having substantially equal delay steps) to the first FDL 408 but having all of its inputs 413 set to “0” (that is, all inputs 413 are set to a high impedance state).
A total delay of the second delay path 404 is substantially equal to a delay of the second CDL 410 plus a delay of the second FDL 412 . An output of the second path 408 is provided to the reference circuit phase detector 414 . It should be noted that the order of the second CDL 410 and the second FDL 412 may be reversed from that shown in FIG. 4 and still be within the present invention.
Since the delay lines 406 , 408 , 410 , 412 in the reference circuit 130 are preferably manufactured simultaneously with the main CDL 122 and main FDL 124 , and are preferably located on the same integrated circuit in close proximity and same orientation, they will exhibit substantially the same characteristics over time, temperature, and process variation.
Outputs of the first delay path 402 and the second delay path 404 are connected to inputs of a phase detector 414 that is preferably substantially identical to the main phase detector 102 . The phase detector 414 provides a phase difference 415 preferably as up count and down count signals to the reference circuit controller 416 .
The reference circuit controller 416 provides a fully decoded set of control signals 418 to the first FDL 408 . The reference circuit controller 416 may include a one-state per flip-flop type state machine wherein outputs of the flip-flops directly provide the control signals to the first FDL 408 . Alternatively, the reference circuit controller 416 may include an up/down counter and a thermometer decoder for providing the control signals 418 to the first FDL 408 .
The reference circuit controller 416 adjusts the control signals 418 provided to the first FDL 408 so that the phase difference 415 is substantially zero and therefore the total delay of the first delay path 402 is substantially equal to the total delay of the second delay path 404 . M 128 is continually updated as the temperature and voltage conditions change, thereby providing an accurate count of the FDEs that ensures a minimum mismatch between the steps of the main CDL 122 and the steps of the main FDL 124 across process parameters and temperature and voltage drifts.
Referring to FIG. 5 , a block diagram of a second embodiment of the reference circuit 130 is shown. The reference circuit 130 includes a reference FDL 508 that is similar (that is, having substantially equal delay steps and preferably a substantially equal number of delay steps) to the main FDL 124 and first FDL 408 . The reference FDL 508 receives a plurality of signals 418 from a reference circuit controller 516 for adjusting a number of steps of the reference FDL 508 .
A reference CDL 510 also receives the DIV_CLK signal 120 . The reference CDL 510 is similar (that is, having a substantially equal intrinsic delay and having substantially equal delay steps) to the main CDL 122 . The second CDL 510 also receives a signal 504 from the reference circuit controller 516 for adjusting a number of steps of the reference circuit CDL 510 .
Outputs of the reference circuit FDL 508 and the reference circuit CDL 510 are connected to inputs of a phase detector 414 that is preferably substantially identical to the main phase detector 102 . The phase detector 414 provides a phase difference 415 preferably as up count and down count signals to the reference circuit controller 516 .
The reference circuit controller 516 provides a fully decoded set of control signals 418 to the reference circuit FDL 508 . The reference circuit controller 516 may include a one-state per flip-flop type state machine wherein outputs of the flip-flops directly provide the control signals to the first FDL 508 . Alternatively, the reference circuit controller 516 may include an up/down counter and a thermometer decoder for providing the control signals 418 to the reference circuit FDL 508 .
Firstly, a number of steps of the reference circuit CDL 510 is set to “0” (that is, the input 504 is set to a high impedance state). A reference circuit controller 516 adjusts the control signals 418 provided to the reference circuit FDL 508 so that a delay of the reference circuit FDL 508 is substantially equal to a delay of the reference circuit CDL 510 by setting a first number of control lines 418 to a low impedance state and the rest to the high impedance state.
Secondly, a number of steps of the reference circuit CDL 510 is set to “1” (that is, the input 504 is set to a low impedance state). The reference circuit controller 516 adjusts the control signals 418 provided to the reference circuit FDL 508 so that a delay of the reference circuit FDL 508 is substantially equal to a delay of the reference circuit CDL 510 by setting a second number of control lines 418 to a low impedance state and the rest to the high impedance state.
Thirdly, the reference circuit controller 516 subtracts the first number from the second number thereby providing a third number M 128 which is substantially equal the number of steps of the main FDL 124 that are equivalent to a steps of the main CDL 122 . It should be noted that the first and second number can be determined in any order and still be within the present invention.
M 128 is continually updated as the temperature and voltage conditions change, thereby providing an accurate number of the FDEs that ensures a minimum mismatch between the CDL 122 and the FDL 124 across process parameters and temperature and voltage drifts.
Referring to FIG. 6 , a method 600 for determining a number of steps of a FDL that are substantially equivalent to a step of a CDL according to the present invention is provided.
The method 600 includes steps of i) 602 delaying a clock signal 120 by a first delay 402 substantially equivalent to a predetermined delay plus an adjustable number of steps of the FDL thereby providing a first delayed clock signal, ii) 604 delaying the clock signal by a second delay 404 substantially equivalent to the predetermined delay plus a step of the CDL thereby providing a second delayed clock signal, and iii) 606 adjusting the number of adjustable steps of the FDL so that the first delay is substantially equal to the second delay thereby providing the number of steps 128 of the FDL that are substantially equivalent to the step of the CDL.
In step i) 602 ( FIG. 7 ), the clock signal 120 is preferably delayed by a delay substantially equal to an intrinsic delay of the CDL 702 , plus a delay substantially equal to an intrinsic delay of the FDL, plus the adjustable number of steps of the FDL 704 .
In step ii) 604 ( FIG. 8 ), the clock signal 120 is preferably delayed by delay substantially equal to an intrinsic delay of the CDL plus the step of the CDL 802 , plus a delay substantially equal to an intrinsic delay of the FDL 804 .
In step iii) 606 ( FIG. 9 ), if the first delay is less than the second delay then the number of adjustable steps of the FDL is preferably adjusted up 902 and if the first delay is greater than the second delay the number of adjustable steps of the FDL is preferably adjusted down 904 .
Referring to FIG. 10 , another method 1000 for determining a number of steps of a FDL that are substantially equivalent to a step of a CDL according to the present invention is provided.
The method 1000 includes steps of i) 1002 delaying the clock signal 120 by a first delay substantially equivalent to a first predetermined delay plus an adjustable number of steps of the FDL, ii) 1004 delaying the clock signal by a second delay substantially equivalent to a second predetermined delay, iii) 1006 adjusting the number of adjustable steps of the FDL so that the first delay is substantially equal to the second delay and providing a first number of adjustable steps of the FDL, iv) 1008 delaying the clock signal by a third delay substantially equal to the second predetermined delay plus a step of the CDL, v) 1010 adjusting the number of adjustable steps of the FDL so that the first delay is substantially equal to the third delay and providing a second number of adjustable steps of the FDL, and vi) 1012 subtracting the first number from the second number of adjustable steps of the FDL thereby providing the number of steps of the FDL that are substantially equivalent to a step of a CDL.
In step i) 1002 ( FIG. 11 ) the clock signal is preferably delayed by a delay substantially equal to in intrinsic delay of the FDL plus the adjustable number of steps of the FDL.
In step ii) 1004 ( FIG. 12 ) the clock signal is preferably delayed by a delay substantially equal to an intrinsic delay of the CDL.
In step iii) 1006 ( FIG. 13 ) if the first delay is less than the second delay the number of steps is preferably adjusted up, and if the first delay is greater than the second delay the number of steps is preferably adjusted down.
In step iv) 1008 ( FIG. 14 ) the clock signal is preferably delayed by a delay substantially equal to an intrinsic delay of the CDL plus the step of the CDL.
In step v) 1010 ( FIG. 15 ) if the first delay is less than the third delay the number of steps is preferably adjusted up, and if the first delay is greater than the third delay the number of steps is preferably adjusted down.
While the above embodiments have been described using the DLL as the circuit to which they are applied in order to reduce switching jitter, the concepts can be used in other applications that involve tracking delays with respect to any reference delay path. For example, the invention can be used in clock recovery circuits, pin timing tuners used in integrated circuit testers, etc.
The DLL 100 provided is especially useful for clock tree management in field programmable gate arrays (FPGAs) and application specific integrated circuits (ASICs). Also, synchronous integrated circuits such as synchronous dynamic random access memories (SDRAMs), synchronous static random access memories (SSRAMs), serially connected memories such as FLASH may benefit using the DLL 100 for synchronizing an external clock signal to internal operations.
The embodiments of the invention described above are intended to be exemplary only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.
Table of Elements
Element Name
Reference Number
delay-locked loop (DLL)
100
main phase detector
102
main clock (CLK)
104
feedback clock (F_CLK)
106
up count control line
108
down count control line
110
coarse adjust state
112
machine
fine adjust state machine
114
main controller
116
divided clock (DIV_CLK)
120
main coarse delay line
122
(CDL)
main CDL output/main FDL
123
input
main fine delay line (FDL)
124
coarse adjust state
125
machine outputs/main CDL
inputs
fine adjust state machine
126
outputs/main FDL inputs
reference circuit output
128
(M)
reference circuit
130
main CDL input buffer
202
main CDL resistor
204
main CDL delay elements
206
(CDE)
main CDL output buffer
208
main FDL input buffer
302
main FDL resistor
304
main FDL delay elements
306
(FDE)
main FDL output buffer
308
first delay path
402
second delay path
404
first CDL
406
first CDL input
407
first FDL
408
second CDL
410
second CDL input
411
second FDL
412
second FDL input
413
reference circuit phase
414
detector
reference circuit phase
415
difference
reference circuit
416
controller
reference circuit
418
controller output/first
FDL input
reference circuit CDL
504
control signal
reference circuit FDL
508
reference circuit CDL
510
reference circuit FDL
518
control signal
first method for
600-904
determining number of
steps
second method for
1000-1504
determining number of
steps
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A reference circuit and method for mitigating switching jitter and delay-locked loop (DLL) using same are provided. The reference circuit and method determine a number of steps of a fine delay line (FDL) that are equivalent to a step of a coarse delay line (CDL). Switching jitter of the DLL is reduced since the delay of the step of the CDL that is switched when on an underflow or overflow condition of the FDL is detected is equivalent to the delay of the provided number of steps of the FDL.
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This application is a divisional of application Ser. No. 09/776,123 (U.S. Pat. No. 6,585,854) filed on Feb. 2, 2001.
BACKGROUND OF THE INVENTION
This invention relates generally to apparatus and processes for aerating dispersions. More particularly, the present invention relates to apparatus and processes for aerating pulp suspensions during de-inking.
De-inking flotation is a mechanical process for removing impurities and ink particles from pulp suspensions produced particularly in waste paper treatment. This process requires the generating of gas bubbles in the appropriate quantity and size distribution. Hydrophobic substances or substances to which ampholytics are added to make them hydrophobic, such as ink particles or stickies, are carried to the surface of the liquid by the gas bubbles adhering to them and can be removed from the surface as scum. This is referred to as selective flotation because the pulp is discharged with the accept due to its hydrophile nature. Processes of this type are known in numerous geometric modifications, for example from DE 41 16 916 C2 or EP 0 211 834 B1, and have reached a high technical standard. Further, it has also proved successful to use self-priming injectors to generate gas bubbles and mix these with the pulp suspension. These injectors basically comprise a propulsive jet nozzle, a mixing or impulse exchange pipe, and a diffuser. Here, the liquid flow emerging from the propulsive jet nozzle according to the open jet principle generates under pressure. As a result, gas is sucked in and mixed with the liquid as a result of the impulse exchange between liquid and gas in the mixing pipe. At the exit from the diffuser used for energy recovery a dispersion of pulp and bubbles is formed. Use of the known processes and injectors, however, has shown several disadvantages in selective flotation of pulp suspensions.
The suction effect of the known injectors in operation with pulp suspensions is too weak and the bubble size distribution generated by the injector known does not have the optimum design to meet the requirements of selective flotation.
SUMMARY OF THE INVENTION
The invention is, therefore, based on the task of designing an injector with greater suction effect and optimum bubble size distribution for use in de-inking flotation.
The process according to the invention is thus characterized by the gas, particularly air, being sucked in by the effect of the injector at a minimum of two successive points and mixed with the suspension. Due to suction taking place in stages, the pulp can be loosened by the gas in the first stage, thus achieving a better spread of the free jet in the second stage, resulting in improved suction effect and corresponding bubble generating, particularly with a reduction in the fine bubble portion to avoid solids losses.
An advantageous further development of the invention is characterized by some 20 to 95% of the entire quantity of gas, particularly air, sucked in being taken in the first stage. Since intake of the quantity of gas, particularly air, is divided over several suction points, more even mixing of the suspension with the gas is obtained. This allows a specific suitable bubble size to be set.
A favorable configuration of the invention is characterized by the gas and liquid flow obtained by suction and mixing being transferred in a free jet after the first stage. As a result, use of the kinetic energy of the jet, in particular, can be improved for renewed intake of gas.
A favorable further development of the invention is characterized by the gas or air loading of the pulp suspension directly after being sprayed in amounting to approximately 50-150%.
The invention also refers to a device for aerating dispersions, particularly a flotation device for de-inking pulp suspensions with an injector, characterized by at least two suction points being arranged in series in flow direction. Due to suction taking place in stages, the pulp can be loosened by the gas in the first stage, thus achieving a better spread of the free jet in the second stage, resulting in improved suction effect and corresponding bubble generating, particularly with a reduction in the fine bubble portion to avoid solids losses.
A favorable further development of the invention is characterized by the injection channel widening after the first suction point. Thus, the kinetic energy of the jet can be put to good use in a favorable manner.
An advantageous further development of the invention is characterized by a panel being mounted at the end of the injector channel across the flow direction. This panel acts as a radial diffuser to recover energy from the liquid jet.
An advantageous configuration of the invention is characterized by the panel being mounted on a slant to the flow direction.
A favorable further development of the invention is characterized by the panel containing internals for targeted guidance of the flow. As a result, the injector can also be mounted in any desired position in the flotation cell.
A favorable configuration of the invention is characterized by a minimum of two injectors being mounted in parallel in the form of an injector group. With this design it is also possible to handle large throughputs accordingly.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings in which:
FIG. 1 is a cross section view of a flotation unit having an aerating device in accordance with the invention;
FIG. 2 is a cross section view of a second embodiment of an aerating device in accordance with the invention;
FIG. 3 is a cross section view of a third embodiment of an aerating device in accordance with the invention;
FIG. 4 is a cross section view of a fourth embodiment of an aerating device in accordance with the invention;
FIG. 5 is a cross section view of a fifth embodiment of an aerating device in accordance with the invention;
FIG. 6 is a graph comparing the bubble diameter distribution pattern of an aerating device in accordance with the invention to that of a conventional aerating device;
FIG. 7 is a graph comparing the air loading, as a function of the Froude number, of an aerating device in accordance with the invention to that of a conventional aerating device; and
FIG. 8 is a graph comparing the overall fiber loss, at a given air intake, of an aerating device in accordance with the invention to that of a conventional aerating device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a diagram of the flotation unit in which the device according to the invention is installed. The flotation cell 9 is largely filled with suspension 8 , on the surface of which scum 10 forms, which contains as large a portion as possible of impurities and ink particles to be removed by flotation. This scum flows through a conduit 11 as overflow U. The pulp suspension S enters the injector through the propulsive jet nozzle 1 . Due to the open jet principle, air is added at the first suction point 2 and mixed into the pulp suspension in the first impulse exchange pipe 3 . The pulp suspension loosened in this way by the air bubbles sucks in more air 4 at the second suction point and this air is mixed into the suspension in the second impulse exchange pipe 5 . The air suction points are connected in this case to a pipe protruding out of the suspension and into which air L enters at the surface of the suspension. The dispersion 7 of bubbles and pulp leaves the injector after passing through a radial diffuser 6 for energy recovery purposes. The bubbles formed in this way adhere to the hydrophobic impurities and carry them to the surface. The suspension cleaned by flotation leaves the flotation cell as accept pulp G.
FIG. 2 contains an alternative variant of an injector according to the invention, where the gas intake fittings, for example, are mounted on different sides. A significant difference to FIG. 1 , however, is that a conically widening diffuser is installed after the second stage.
FIG. 3 shows a device according to the invention with a conically shaped first impulse exchange pipe 3 , where a second propulsive jet nozzle is used analogous to the propulsive jet nozzle 1 so that high suction efficiency is also achieved in the second stage.
FIG. 4 contains a design according to the invention in which three air intake points 2 , 4 , 12 are provided, with a diffuser shown after the third impulse exchange pipe 13 .
FIG. 5 shows a variant as injector group, where two injectors are mounted here in parallel beside each other. This arrangement comprises a top section, in which the propulsive jet nozzles 1 are mounted, a common intermediate area into which the air intake fitting 2 leads, also a block with impulse exchange pipes 3 operating in parallel. This block is connected in turn to a common intermediate area into which the gas intake pipe 4 leads. This is adjoined by a common block where the second impulse exchange pipes 5 are mounted. Finally, both impulse exchange pipes 5 lead into a radial diffuser 6 . It would also be possible basically to combine several injectors in an injector group of this kind.
FIG. 6 now shows the bubble diameter distribution pattern of a conventional injector compared with that of an injector according to the invention. This shows that the injector according to the invention contains significantly fewer bubbles with a diameter <0.5 mm than the state-of-the-art injector. Here the reduction is approximately 50%. Unlike the conventional injector, however, the distribution spectrum is still retained. Overall there are fewer solids (fiber) losses as a result.
The suction effect of an injector is determined by the propulsive jet throughput, the diameter of the propulsive jet nozzles, the liquid cover and the density of the propulsive jet. Suction characteristics of this type are illustrated in FIG. 7 . Here the air loading q G /q L is shown as a function of the Froude number. The illustration shows that, compared with conventional injectors, this air loading can be increased significantly with the device according to the invention.
FIG. 8 contains a diagram of a flotation result at the same air intake compared with that of a conventional injector. The diagram shows that the overall fibre loss could be reduced by approximately one third. With the present invention, however, it is possible to inject much more air and thus, also improve removal of impurities.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
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A device and process for aerating dispersions, particularly for flotation of pulp suspensions, in a de-inking process where the pulp suspension containing dirt particles is sprayed into a tank together with air. The air is injected at a minimum of two successive points and mixed with the suspension.
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BACKGROUND OF THE INVENTION
The present invention relates to winning machines for winning coal, minerals, and the like.
More particularly, the present invention is concerned with a rotating head for such a winning machine.
It is known in the prior art to provide a power loader which has a cutting tool such as a rotating head (usually a drum or drums) armed with picks or some form of cutter bits. Such a rotating head includes a tubular support and one or more blades which may extend helically about the circumference of the tubular support. The blades are rigidly connected (e.g., welded) to the outer surface of the support. A plurality of cutting units are mounted equally spaced on the blades. Each of the cutting units includes a pick holder rigidly connected (e.g. welded) to the blade and a pick detachably fixed in the holder. Cutting is achieved by the picks which extend from the periphery of the blades towards a working (i.e., mining) face of the material to be mined. The tubular support has one open end which faces the working face and which is closed by an end face plate.
It has been also suggested to provide the rotating head with a conical locking ring which is welded to the end face plate and extends outwardly away therefrom towards the working face. The outer periphery of the locking ring may also be provided with a plurality of the cutting units similar to those provided on the blades. The picks, which are fixed in the corresponding holders welded to the outer periphery of the locking ring, extend towards the working face. Due to the conical locking ring the contact of the end face of the rotating head with the working face is considerably reduced as opposed to a rotating head having the end face entirely planar. Obviously, the forces of the engagement between the end face of the rotating head and the working face and the frictional losses in such an engagement are considerably reduced in the case of the rotating head having the conical locking ring. Accordingly, the effectiveness of the cutting process is increased, whereas the dust development during the cutting process is reduced.
It has been recognized, that any inclination of the end face of the rotating head from the planar configuration leads to improving of the cutting process. It is further advantageous to maintain a cone angle of the end face, that is an angle between any imaginable line extending radially along the end face and the axis of the rotating head, substantially below 90°. In practice, the cone angle is between 30° and 85°; however, a preferable range of inclination would be between 50° and 70° . Quite sufficient results have been obtained with the cone angle of 60°.
It is very difficult and time consuming to displace such a rotating head in the mine. However, it is often necessary to remove the head from the mine to the ground surface, for example, for repairing purposes.
However, such displacement is not always possible or very easy to accomplish, for example, due to the unpredictable and, therefore, uncontrollable swelling of the floor of the mine which leads to narrowing of the main passage of the mine. Thus, in order to remove the head from the mine, it becomes necessary to excavate additional material from the mine only to widen the main passage. Obviously, any additional excavation is relatively complicated and expensive. Thus, the cutting (i.e. mining) process, which is quite expensive by itself, becomes even more expensive due to the above-mentioned additional excavations.
The blades on the tubular support have the same outer diameter, so that the picks which are mounted on the blades constitute a common generatrix. Therefore, the spaces defined by the corresponding surfaces of the blades on the one hand and the respective portions of the outer surface of the tubular support on the other hand are equal to one another. This leads to the fact that the removed material moves along a relatively wide section all the way until it reaches a conveyor which results in an undesired comminuting of the removed material into small particles. Besides, since the removed material moves always along the passage of the same cross-section there might be a situtation where the removed material develops a plug in this passage, which plug unavoidably results in negative consequences for the whole power loader.
In German Offenlegungsschrift No. 2647171 it has been suggested to provide the tubular support with a conical linear outer surface having a first end which faces the working surface and an axially spaced second end which faces away from the working face of the mine. In this case, the first end has the largest outer diameter, whereas the second end has the smallest outer diameter. Thus, the passage for the removed material at the first end of the tubular support is smaller than that at the second end of the support. Advantageously, the transporting of the removed material in direction from the first end, that is from the working face, towards the second end of the tubular support and onto the conveyor located adjacent to the second end of the tubular support is considerably facilitated due to the cone angle of the outer surface of the support.
However, it has been recognized, that the linear extension of the outer surface of the tubular support is not always satisfactory with respect to the requirements made to a reliable, simple and fast transporting of the removed material from the working surface towards the conveyor. In fact, the linear increase of the cross-section of the passage for the removed material has been found to be the reason of the unsatisfactory conditions during transporting of the removed material from the working face.
The rotating head in accordance with the German Offenlegungsschrift No. 2647171 consists of two halves which may be connected to each other right in front of the working face. Obviously, this fact considerably facilitates the displacement of the head itself. Especially, the displacement of the head back onto the ground surface becomes considerably less complicated.
However, in order to repair such a head, the latter still has to be moved from the mine onto the ground surface. Such a displacement of the head causes significant expenses comparing with an initial purchase-cost of the head. Thus, for example, the repair- and displacement expenses may sometimes exceed the purchase-cost of a new head. Nevertheless, it has never been suggested, even in the case of the one-piece head, to provide such a rotary head that can be assembled underground and left there, for example, after being broken.
The assembling of the rotating head in accordance with the above-mentioned German Offenlegungsschrift No. 2647171 is very complicated. The tubular-support halves are connected to each other by screws which after a relatively short time of use corrode significantly due to the direct contact with underground water. Thus, the corroded screws can be moved (i.e. unscrewed) only upon applying thereto a significant pulling force (i.e. torque) which is a quite difficult task to accomplish, especially if considered the limited free space in the mine.
Moreover, the separate conical locking ring additionally increases the cost of the rotating head, since the ring has to be connected to the conical tubular support. Obviously, additional operations of making (or purchasing) the locking ring and welding this ring onto the support correspondingly increase the overall cost of the rotating head.
SUMMARY OF THE INVENTION
It is a general object of the present invention to avoid the disadvantages of the prior art cutting tools, such as rotating heads.
More particularly, it is an object of the present invention to provide a disposable rotating head for winning machine, particularly for an underground mining.
Another object of the present invention is to provide such a rotating head having a support with an outer surface thereof and one or more blades, which are so shaped as to facilitate the displacing of the removed material from a working face of a mine.
In pursuance of these objects and others which will become apparent hereafter, one feature of the present invention resides in a cutting tool, particularly for a winning machine, which comprises an elongated support having a first end, an axially spaced second end, and an outer circumferential surface which has at the first end a first outer dimension and at said second end a second outer dimension which is smaller than said first dimension. The outer surface further includes a portion adjacent to one of said ends and having a non-linear configuration with an exterior dimension which gradually decreases in direction from said one end towards the other of said ends.
In accordance with another feature of the invention, a plurality of cutting units which are located on said outer circumferential surface of said support along a line circumferentially embracing said support.
In yet another feature of the invention, the support includes two halves which are connectable to each other so as to constitute together the elongated support. Each half of the support is provided with formations which, when the halves are in assembly with each other, constitute a conical locking ring, passages for supplying a hydraulic fluid onto the outer surface of the support and a blade which circumferentially embraces the support along said line. All these formations may be integrally connected to the respective halves of the supports, so that when the halves are in assembly with each other all the above-mentioned additional parts, such as the locking ring, the hydraulic fluid passages, etc. are formed without any additional labor or expenses. The halves may be welded to each other, as well as, for example, parts of the blade located on each of the respective halves of the support.
In still another feature of the invention, the separate half of the support may be integrally connected with the corresponding parts of the conical locking ring, the blade, etc. It is possible, for example, to cast a workpiece which would constitute the above-mentioned half with all above-mentioned parts. Obviously, this feature considerably reduces the relatively high cost of a prior art cutting tool all parts of which, such as the locking ring, the blade, etc., are separate and, therefore, have to be somehow connected to the support.
The cutting tool (i.e., head) in accordance with the present invention is quite inexpensive, so that it becomes less expensive to dispense with a broken tool, for example, to leave it in an exhausted (i.e., finished) working passage, rather than to remove this tool from the mine, and repair the same on the ground surface.
Since the cutting tool in accordance with the present invention practically does not have any screws, bolts or the like, the service and the maintenance of the tool is considerably reduced. Obviously, the cutting tools, which have the screws or any other similar connecting elements, have to be periodically cleaned or the corroded connecting elements to be replaced so as to prevent potential interlocking of the separate parts. Since, in the underground conditions corrosion (in more or less active form) is unavoidable, then it becomes very time consuming and rather expensive to maintain and serve such a cutting tool. However, in accordance with the present invention, the above mentioned periodical attention and maintenance of the connecting elements become unnecessary since substantially all the connecting elements are eliminated and the separate halves of the support are welded together.
In a further feature of the invention, the support has a first end portion, including said first end, of a relatively thick cross-section so as to facilitate formation of the conical ring thereon. The conical ring is also provided with the cutting units.
In yet another feature of the present invention, the outer surface of the support is so curved, that said portion adjacent to said first end constitutes with the conical ring and the respective end face of the blade the smallest passage for displacing the removed material from the working face. This passage increases towards the second end of the outer surface of the support. Such a configuration facilitates the displacement of the removed material from the section having a relatively small free space (i.e. from the section adjacent to said first end) to the section having a relatively large free space for accommodating the removed material therein. Obviously, the cutting tool having the curved outer surface of the support is considerably more effective in displacing the removed material from the working face than the cutting tool having the linear conical outer surface of the support as described, for example, in the above-mentioned German Offenlegungsschrift No. 2647171.
In still further feature of the invention, each cutting unit must include a pick holder rigidly mount on the respective blade (e.g. welded thereto) and a pick installed in said pick holder and extending outwardly away therefrom. The support may be cast with at least one groove. This groove may be covered from outside by a covering plate which is welded to the support so as to constitute with the groove the hydraulic fluid passage.
In yet a further feature of the invention, the support may be integrally connected with a mounting flange which may be so shaped and dimensioned as to receive driving means, e.g. an output shaft of a motor.
The flange may be adapted to receive an intermediate element which, for example, compensates for the difference between the corresponding dimensions of the flange cast together with the support and the output shaft of the motor.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a cutting tool in accordance with the present invention; and
FIG. 2 is a schematic longitudinal sectional view of a portion of the cutting tool shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and first to FIG. 1 thereof, it may be seen that the reference numeral 1 designates a tubular support having an outer circumferential surface 2. The support 1 has a length designated by L--see FIG. 2. Along the length L, the outer surface 2 of the support 1 constitutes an exponential curve. The outer surface 2 has a first end (a left-hand end as viewed in FIGS. 1 and 2) which faces a working face (not shown) of the material to be mined and which has an outer diameter designated by D. The outer surface 2 has a second end (a right-hand end as viewed in FIGS. 1 and 2) which faces oppositely to the first end, i.e. away from the working face and which has an outer diameter d. The first outer diameter D of the first end is the largest outer diameter of the outer surface 2. The second outer diameter d of the second end is the smallest outer diameter of the outer surface 2. Thus, the outer surface 2 gradually decreases in direction from the first end towards the second end thereof.
It may be seen in FIG. 2, that the outer surface 2 along a portion having a length K decreases in a non-linear sudden manner, for example, constituting a hyperbolic curve starting at the first end having the largest outer diameter D and decreasing until this portion reaches the outer diameter d, that is at the end of the portion having the length K. In a preferred embodiment of the present invention, the length K of this portion constitutes one-third of the length of the whole support 1, measured from the first end having the largest outer diameter D. Along a remaining portion having a length L-K, the outer surface 2 may remain horizontal (see FIG. 2), that is having the outer diameter d. However, it is also possible to reduce the outer diameter of the remaining portion having the length L-K gradually unitl it reaches the smallest outer diameter d at the second end of the surface 2.
The outer surface 2 is provided with helical blades 5 and 6 which extend circumferentially outwardly away from the surface 2. Thus, a free space 3 constituted by the first end, the corresponding curved portion of the outer surface 2 and the respective end face of the blade 5 is considerably smaller than a free space 4 constituted by the respective opposite end faces of the blades 5 and 6 and the substantially horizontal portion of the outer surface 2. Obviously, the removed material contained in the relatively smaller space 3 moves fast along the outer surface and the helical blades 5 and 6 towards and into the relatively larger space 4, that is in direction away from the working face and onto a conveyor (not shown).
The blades 5 and 6 constitute an upright plate which is rigidly connected, for example welded, to the outer surface 2 of the support 1. Each blade is provided at its outer periphery with a plurality of pick holders 7 and 8 which are equally spaced on the respective blades 5 and 6. The holders 7 and 8 may be welded to the outer periphery of the blades 5 and 6.
The support 1 is provided with an annular portion 9 which is conically open towards the working face. The annular portion 9 is integrally connected to the rest of the support 1. The outer periphery of the annular portion 9 is also provided with a plurality of pick holders 10. Each pick holder, of the holders 7, 8 and 10, is provided with a pick (only two picks 11 and 12 are shown for the sake of simplicity of the drawing) which extends outwardly away from the respective pick holders. The picks are designed to conduct cutting of the material, e.g. coal. The tips of the picks are arranged at one end the same cylindrical generatrix 13. It is to be noted, that the outer peripheries of the blades 5 and 6 and the outer periphery of the annular portion 9 are also arranged at a common generatrix which is not shown in the drawing for the sake of simplicity of the same.
The reference numeral 14 is used to designate a locking ring which may be welded to the support 1. A connecting flange 15 may also be welded to the inner surface of the support 1 for supporting a motor (not shown). The open end of the support 1 may be closed by a closing plate (see FIG. 1).
The references 16 and 17 are used to designate passages for supplying a hydraulic fluid (e.g. water) through respective spraying nozzles so as to prevent dust development during transporting the removed material. For the sake of simplicity of the drawing, the reference numeral 18 designates only one spraying nozzle. The hydraulic fluid passages 16 and 17 constitute grooves closed by respective plates 19 and 20 (see FIG. 2).
In the preferred embodiment of the present invention the hydraulic-fluid-spraying passages are formed during casting of the support 1. Obviously, it is advantageous to form the locking ring 14 and the connecting flange 15 also during the casting process, that is of one piece with the support 1. Any other connecting openings for the hydraulic fluid may be formed. Thus, it is not necessary any more to form the conical ring 9 as a separate element from the support 1.
The support 1 may consist of two separate parts, i.e. halves, which can be cast separately. It is to be understood, that the respective halves of the support may be cast in one part with the respective parts of the blades 5 and 6. In this case, when the respective halves of the support are in assembly with each other, the respective parts of the blades constitute together the blades 5 and 6. The respective parts of the blades 5 and 6 are welded together when the halves of the support 1 are in assembly, thus holding the halves of the support 1 together in the assembled position.
Instead of welding the respective parts of the blades 5 and 6 together or in addition thereto, the respective halves of the support 1 may be screwed together by means of screws (not shown) which connect the inner flanges of the respective halves of the support to each other. These screws do not have to be unscrewed (i.e. detached) for the sake of making repair of the cutting tool (i.e. rotating head). Moreover, the separate halves of the support 1 can be brought underground and then be assembled right in front of the working face of the material to be mined. In this case, the blades may be welded also underground during assembling the halves of the support 1. However, the respective parts of the blades 5 and 6 may be welded (if they were not cast together therewith) to the respective halves of the support 1, before the same is brought underground. In the case of assembling the whole arrangement underground, the parts of the blades 5 and 6 have to be prepared beforehand, so that operators have only to weld the blades 5 and 6 (or the parts thereof) on the halves of the support 1, which parts may be, for example, additionally connected to each other by means of the abovementioned screws or any other similar connecting elements.
It must be understood that the present invention is by no means limited to the number of blades. Obviously, there may be provided a greater (i.e. more than two) or a smaller (i.e. one) number of blades. It is also possible, to cast the halves of the support 1 in one piece with only portions of the blades. In this case, the portions are cast with connecting elements for connecting thereto the remaining portions of the blades. Obviously, the remaining portions of the blades may be attached to the support 1 in a fast and simple manner.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of a cutting tool, differing from the types described above.
While the invention has been illustrated and described as embodied in a cutting tool, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A cutting tool, particularly for a mining machine includes an elongated support having a first end and an axially spaced second end. The support also includes an outer circumferential surface having at the first end a first outer dimension and at the second end a second outer dimension which is smaller than the first dimension. The outer surface includes a portion adjacent to one of the ends and having a non-linear configuration with an exterior dimension which gradually decreases in direction from the above-mentioned one end towards the other of the first and second ends. A plurality of cutting units are located on the outer circumferential surface of the support along a line circumferentially embracing the support.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Stage Application of International Application No. PCT/EP2011/067388 filed Oct. 5, 2011, which designates the United States of America, and claims priority to DE Application No. 10 2010 043 150.8 filed Oct. 29, 2010, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The disclosure relates to a method and system for monitoring the condition of a piezo injector that is used in conjunction with the fuel injection system in motor vehicles.
BACKGROUND
[0003] A piezo injector of this type comprises a piezoelectric actuator that converts an electrical control signal into a mechanical stroke movement. A nozzle needle is controlled by means of this stroke movement and it is possible using said nozzle needle to release through the injection holes of a nozzle unit the quantity of fuel flow more or less required in order to be able to inject in an appropriate manner into a cylinder of the motor vehicle a desired quantity of fuel that is dependent upon the electrical control signal.
[0004] Fuel injection systems of this type contribute greatly to the demanding wishes of customers being fulfilled and to the legal requirements with respect to fuel consumption and toxic emissions of the motor vehicle being fulfilled. This applies in particular to auto-ignition combustion engines having piezo-pump-nozzle systems and to piezo-common-rail systems.
[0005] Error indications, for example fuel leakages, sticking valves, deposits, leakage currents, etc., that occur in these systems generally result in a vehicle behaving in a manner that is undesirable, such as loss of power, increased toxic emissions or else also in an error memory lamp being activated. These error indications can occur both in the hydraulic system and also in the electrical system.
[0006] First and foremost, when using on-board diagnostic strategies in the dynamic operation of a vehicle, there is a limit as to how close the cause of errors in the injection system can be defined, let alone being able to ascertain precisely such causes, without during the course of the diagnosis having a negative influence on the manner in which the system behaves. In addition, the manufacturer of the motor vehicle frequently does not wish intrusive tests to be performed during the vehicle operation. Furthermore, the extent to which the location of the respective cause of the error can be ascertained is limited as a result of the limited amount of sensor information available on board.
[0007] Moreover, particularly moderate error indications in an injection system only influence the driving behavior in dependence upon the operating point. For example, a relatively high-ohm leakage resistance between the electrical connection of the piezoelectric actuator and the electrical ground has only a slight influence on short fuel injection operations and in fact is dependent upon the time constant that is obtained from the value of the leakage resistance and the capacity of the piezo element. In addition, the extent of the influence is still compensated by the system in dependence upon the value of the short circuit resistance and upon the actual operating point, for example depending upon whether the prevailing rotational speed or loading is in the low or middle range. This can be achieved, for example, by providing greater control energy for the piezoelectric actuator.
[0008] Moderate error indications only influence the manner in which the system behaves if it is necessary to provide a comparatively large fuel flow for the prevailing operating mode of the motor vehicle, in other words to provide a comparatively long period of control. In such cases, any loss of charge of the piezo actuator can over time result in an undesired reduction of the injection rate and consequently in a reduction of the quantity of fuel being injected. This reduction of the quantity of fuel being injected causes a loss of power that in many cases is associated with an increased exhaust emission.
[0009] Error indications of this type cannot be reproduced in a workshop or can only be reproduced at great expense, for example using a power-absorption roller and/or additional sensors, and it consequently represents a great challenge in a workshop when searching for errors.
[0010] Components that are still functional are frequently replaced unnecessarily in a workshop owing to a lack of precise knowledge of the cause of a prevailing error. Also, frequently too many components are replaced. For example, a still functional control unit (ECU) or an entire injector set is unnecessarily replaced although a prevailing undesired behavior of the system had been caused, for example, by a single defective injector or by a contaminated male connector in the cable harness.
[0011] Furthermore, manual interventions in the injection system of a motor vehicle frequently results undesirably in contaminants being introduced into the injection system and as a result components being damaged.
[0012] In addition, unless an initially moderate error is discovered, it can become a major error during the course of time. The consequence of a major error of this type is in many cases a total failure of the injection system and consequently the respective motor vehicle comes to a standstill.
[0013] An additional problem is that legal requirements for monitoring the functions of a motor vehicle have recently become more stringent. This applies both for the automotive market in Europe and also in the USA. It was previously sufficient to recognize and indicate serious errors in the system, for example, short circuits to the electrical ground of the motor vehicle. The fundamental tenor of current legislation is on the other hand the requirement to recognize any error that affects in any way the exhaust gas emission of the motor vehicle. This also includes recognizing the above mentioned moderate errors.
[0014] DE 10 2006 036 567 B4 discloses a method for ascertaining the functioning condition of a piezo injection of a combustion engine, in which the input variables of a control circuit for injecting fuel are the voltage value and the charge value. Furthermore, the continued capacity progression for the measured piezo injector is calculated based on a new capacity and the last stored capacity values with the aid of a mathematical approximation method. An actual malfunction of the piezo injector is recognized by virtue of the fact that a measured capacity value is outside a first upper and lower tolerance range by the calculated capacity progression. The piezo injection is immediately switched off if the measured capacity value is outside a second upper and lower threshold range by the calculated capacity progression, wherein the threshold range includes the tolerance range.
[0015] DE 103 36 639 A1 discloses a method and a device for diagnosing the function of a piezo actuator of a fuel measuring system of an internal combustion engine. The piezo actuator is charged using a pre-determinable electrical voltage and the charge quantity available in the case of this voltage is compared with a desired charge quantity that is to be expected in the case of this voltage. The functionality of the piezo actuator is ascertained from the difference between said charge quantities.
SUMMARY
[0016] One embodiment provides a method for monitoring the condition of a piezo injector of a fuel injection system, wherein fuel is injected during injection cycles that include in each case a charging phase, a holding phase and a discharging phase, wherein the leakage resistance of the piezo injector is ascertained during the holding phase and conclusions relating to the functionality of the piezo injector are drawn using the ascertained leakage resistance.
[0017] In a further embodiment, the piezo injector is charged to a predetermined voltage during the charging phase by means of a voltage source, said voltage is measured at the commencement of the holding phase and at the end of the holding phase and a difference value is calculated from the measured voltages.
[0018] In a further embodiment, the leakage resistance is calculated from the difference value, the duration of the injection operation and the capacity of the piezo injector.
[0019] In a further embodiment, during the holding phase further voltage values are measured and using the measured voltage values a straight line is calculated that describes the drop in voltage that occurs during the holding phase.
[0020] In a further embodiment, a plurality of measured voltage values are subjected to a mean determining process and the straight line is calculated from the mean values.
[0021] In a further embodiment, the gradient of the straight line is calculated based on a quotient that is formed from a time difference and a difference of the mean values.
[0022] In a further embodiment, the leakage resistance is calculated in accordance with the equation R=U0/I, wherein U0 is the voltage that is measured at the commencement of the holding phase and I is the mean leakage current.
[0023] In a further embodiment, the mean leakage current is calculated in accordance with the equation I=ΔQ/t, wherein ΔQ is the amount of charge that has been lost and t is a time difference.
[0024] In a further embodiment, the amount of charge that has been lost is calculated in accordance with the equation ΔQ=C·ΔU, wherein C is the capacity of the piezo injector and ΔU is the difference value of the measured voltages.
[0025] Another embodiment provides a system comprising a piezo injector configured to inject fuel during injection cycles that include a charging phase, a holding phase, and a discharging phase, and a monitoring system for monitoring the condition of the piezo injector as disclosed above. The monitoring system may include computer instructions stored in non-transitory computer-readable media and executable by a processor to determine a leakage resistance of the piezo injector during the holding phase, and determine a functionality of the piezo injector based on the determined leakage resistance, and to perform any of the other method steps and calculations disclosed above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Exemplary embodiments will be explained in more detail below on the basis of the schematic drawings, wherein:
[0027] FIG. 1 illustrates a simplified equivalent circuit diagram for explaining a method in accordance with one embodiment, and
[0028] FIG. 2 illustrates a diagram for explaining an injection cycle in accordance with one embodiment, and
[0029] FIG. 3 illustrates a diagram for explaining a method in accordance with one embodiment.
DETAILED DESCRIPTION
[0030] Embodiments of the present disclosure provide an improved method and system for monitoring the condition of a piezo injector.
[0031] Advantages of certain embodiments include, for example, the fact the condition of the piezo injector can be monitored using variables that are often already available in known injection systems and are used for other purposes. These variables are linked together in new combinations in such a manner that new information is obtained that indicates the condition of the piezo injector. This new information is the leakage resistance of the piezo injector. If the leakage resistance has a higher value that a predetermined threshold value, then it is recognized that the piezo injector is functioning in a fault-free manner. If, on the other hand, the value of the leakage resistance is less than the predetermined threshold value, then it is recognized that the piezo injector is no longer functioning in a fault-free manner, in particular, that the value of the leakage resistance of the piezo injector has, as a result of environmental and/or aging influences, dropped to such an extent that there is the risk of a short circuit or of a voltage flashover.
[0032] A method for monitoring the condition of a piezo injector of a fuel injection system in accordance with one embodiment is suitable, for example, for auto-ignition combustion engines having piezo-pump-nozzle systems and for piezo-common-rail systems. It can, in particular, also be used during the usual vehicle operation. However, it can also be implemented in stable operating conditions that prevail in particular in the case of a stationary vehicle or in a workshop. Thus, a method can, for example, be performed during a switch-on test routine in the case of a stationary vehicle, during the overrun phase in the normal vehicle operation, within the scope of a switch-off test routine when parking the vehicle and also within the scope of a service stop in a workshop.
[0033] In one embodiment, the method can be performed at regular time intervals or in an event-based manner.
[0034] Furthermore, the time intervals between successive performances of the method can be varied based on statistics. If a performance of a method has resulted in an initial suspicion that there is a prevailing moderate error, then the time intervals between successive performances of the method can be shortened.
[0035] A piezo injector of a fuel injection system comprises a piezo actuator that is capable of storing the charge being provided. In contrast to coil-operated injectors, it is not necessary to supply a continuous holding current to the piezo actuator. The leakage resistance of a piezo injector that occurs between the high-side connection of the piezo injector and the electrical ground is in the megohm range when the piezo injector is new. As a result, it can be assumed that the piezo injector holds the voltage level, which it achieves during the charging phase, at least almost constant for the entire duration of the subsequent holding phase until the commencement of the discharging phase. However, environmental and/or aging influences in particular in conjunction with long injection times can cause the leakage resistance to drop in such a manner that said leakage resistance lies only in the two-digit ohm range. This drop in leakage resistance can result in the piezo injector becoming non-functional as a result of short circuits or rather voltage flashovers to ground and can result in the vehicle being damaged. In order to prevent this, the leakage resistance of the piezo injector is ascertained during the holding phase of an injection cycle and conclusions relating to the functionality of the piezo injector are drawn from the ascertained value of the leakage resistance, so that, if necessary, the necessary measures can be initiated in good time, for example the piezo injector can be replaced.
[0036] FIG. 1 illustrates a simplified equivalent circuit diagram for explaining a method in accordance with one embodiment. This equivalent circuit diagram illustrates a driver 1 , piezo injectors P 1 , . . . ,Pn and a leakage resistance R.
[0037] The driver 1 comprises a high-side driver unit 1 a and a low-side driver unit 1 b . The output of the high-side driver unit 1 a is connected in each case to a connection of the piezo injectors P 1 , . . . ,Pn and to the connection, remote from ground, of the leakage resistance R. The low-side driver unit 1 b is connected to the gate connections G 1 , . . . ,Gn of in total n field effect transistors, wherein the drain connection D 1 , . . . ,Dn is connected to the respective other connection of the piezo injectors P 1 , . . . ,Pn. The source connections S 1 , . . . ,Sn of the field effect transistors are in each case connected to ground.
[0038] The individual piezo injectors are controlled by the driver 1 in each case in injection cycles, wherein each injection cycle includes a charging phase LP, a holding phase HP and a discharging phase EP. This is illustrated in figure 2 that illustrates a diagram for explaining an injection cycle. The piezo injector is charged to a voltage value U0 during the charging phase LP by means of a voltage source. When the respective injector is new, the leakage resistance lies in the megohm range and this voltage value is held until the end of the holding phase HP. There then follows the discharging phase EP during which the piezo injector is discharged.
[0039] However, environmental and aging influences cause the leakage resistance of an injector to drop as time progresses. Nonetheless, it is still possible in the case of sufficient leakage resistance, for example where the resistance values are in the kiloohm range, to fully charge a piezo injector since as yet there has been no short circuit and also no voltage flashover to ground. However, the piezo injector does lose charge, for example, by way of a carbon track. This is evident in FIG. 2 from the straight line that drops off with a comparatively slight gradient during the holding phase HP.
[0040] If the voltage at the piezo injector is then measured at the commencement and at the end of the holding phase and the difference value between the measured voltages is then ascertained, then it is possible, by taking into additional consideration the duration of the injection operation and the capacity of the piezo injector, to draw conclusions relating to the amount of charge that has been lost and/or to a mean leakage current. Moreover, the leakage resistance can be calculated in the first approximation. Conclusions relating to the functionality of the piezo injector are drawn from the ascertained value of the leakage resistance, as explained hereinunder.
[0041] In order to avoid unnecessary erroneous entries, a plausibility check may be performed on the calculated value of the leakage resistance. This is explained hereinunder with reference to FIG. 3 . FIG. 3 illustrates a diagram for explaining a method in accordance with one embodiment.
[0042] In the case of this method, a plurality of voltage values are ascertained during the holding phase HP and a straight line function is calculated from said voltage values. A value for the leakage resistance is ascertained using this straight line function and said value is compared with the value for the leakage resistance that is ascertained in the first approximation. In the event that the values match at least to a great extent, the ascertained value is regarded as being correct and conclusions relating to the functionality of the piezo injector are drawn using the ascertained value for the leakage resistance.
[0043] When ascertaining the straight line function, a straight line gradient is ascertained using the equation:
[0000]
y=m·x+b
[0044] In order to compensate for the influence of anomalies and/or measuring errors, a mean value is formed from the subsequent measured values. The straight line gradient m is produced by calculating the quotient from the time difference and the difference of the mean values that have been formed.
[0045] A plausibility check is performed using the said formula by virtue of the fact that the value V_INJ_BEG_TEST_PLS_CLC is ascertained at the point in time T_CHA+trigger delay, in other words at approximately t=275 μs. This value must then be approximately equal to the value V_INJ_BEG_TEST_PLS, wherein a tolerance that can be calibrated is permitted.
[0046] A difference ΔU between the value U0, which is present at the commencement of the holding phase, and the value U, which is present at the end of the holding phase is formed from the measured voltage value U0=V_INJ_BEG_TEST_PLS and the mean value of the last three measured values of the BURST vector (cf. FIG. 3 ). The time t that is used when calculating the leakage resistance is obtained from the time difference between the measured voltage value U0 and the said mean value.
[0047] Accordingly, the following applies:
[0000]
y
=
mx
+
b
,
wherein
m
=
(
T_sample
-
T_sample
2
)
(
V_INJ
_BURST
_SOI
_mean
_
0
…
2
-
V_INJ
_BURST
_SOI
_mean
_
37
…
39
b
=
V_INJ
_BURST
_SOI
_mean
_
0
…
2
-
m
*
T_sample
T_sample
=
Burst
delay
+
1
*
7
μ
s
T_sample
2
=
Burst
delay
+
38
*
7
μ
s
[0000] where the point in time zero corresponds to the point in time SOI (start of injection).
[0048] For the purpose of calculating an example, it is assumed that the voltage at the piezo injection drops from 120V by 10V to 110V over a period of time of 1 ms in the case of a 6 μF capacity of the piezo injector.
[0049] In this case, the following equation applies for the amount of charge that has been lost:
[0000] ΔQ=C·ΔU= 60 μAs.
[0050] The following is obtained for the mean leakage current:
[0000]
I
=
Δ
Q
t
=
60
μ
As
1
ms
=
60
mA
.
[0051] Consequently, the following applies for the leakage resistance:
[0000]
R
=
U
I
=
120
V
60
mA
=
2
kOhm
.
[0052] The conclusion is drawn from a value of this type for the leakage resistance that the piezo injector is still functional.
[0053] In contrast, if the ascertained value of the leakage resistance is less that 1 kOhm, it is assumed that massive negative influences have affected the functionality of a piezo injector and consequently the operation of the respective engine of the motor vehicle. In particular, the time constant that is obtained from the product of the leakage resistance and the prevailing capacity of the piezo injector must be somewhat smaller than 10 times the duration of the injection operation in order to exert an undesired influence on the engine of the motor vehicle.
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A method for monitoring the condition of a piezoinjector of a fuel injection system is disclosed. The fuel injection is carried out in injection cycles, each of which comprises a filling phase, a holding phase, and an emptying phase. The discharge resistance is ascertained during the holding phase of the piezoinjector. Conclusions about the working order of the piezoinjector are drawn using the ascertained discharge resistance.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a divisional patent application of co-pending application Ser. No. 14/551,669, filed Nov. 24, 2014, which is incorporated herein by reference.
BACKGROUND
Field
The present method and system relates generally to a digital communication system and more particularly to the use of error correcting codes in digital communications systems, and particularly relates to the use of LDPC (low density parity check) codes in digital communications systems. Examples of such systems include digital television broadcast systems, cellular telephone systems and the like.
Description of the Related Art
Like all linear block codes, an LDPC (low density parity check) code can be described in terms of a matrix. In the case of an LDPC code the matrix contains a first portion consisting of information bits and a second portion containing parity bits, the matrix commonly being referred to as an H-matrix, or a parity check matrix. The LDPC code gets its name from the H-matrix which contains relatively few 1's in comparison to the number of 0's.
Many modern communications systems require the use of error correction codes that can accommodate different code rates and different lengths of information bits. It is well known that longer code lengths improve error correcting performance, while shorter code lengths are characterized by reduced processing delays. Likewise it is known that increasing code rates improves the data rate and bandwidth efficiency, while reducing code rates increases information robustness in noisy channels. However, designing separate error correction codes for each different code length and code rate that may be used in a particular communications system is a very complicated process and often not practical.
It would therefore be highly desirable to provide a novel error correction system using error correction codes capable of adapting to different information lengths and different code rates. Such a system would be designed with the goal of providing performance that is equal or close to the performance of systems using separately designed codes and would inherently be of low complexity since it would obviate the need to design a separate code for each condition and would employ encoder and decoder hardware that can be reused in different situations without extra cost.
SUMMARY
The present invention achieves these and other objects by specially modifying a first LDPC code H matrix, referred to a “mother code,” to become a smaller size LDPC code H matrix, referred to as a daughter code, and using the daughter code to encode and decode the information bits of transmitted and received digital signals. Another aspect of the invention employs code puncturing to improve code error correcting performance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment of an encoder according to the present invention;
FIG. 2 is a block diagram showing an embodiment of a decoder according to the present invention; and;
FIGS. 3 a , 3 b , 4 a , 4 b , 5 a and 5 b are matrix diagrams that illustrate an LDPC H matrix as used by the encoder and decoder of FIGS. 1 and 2 .
DETAILED DESCRIPTION
FIG. 1 is a block diagram showing an embodiment of an encoder 10 according to a certain embodiment of the present invention. The encoder 10 may be provided in a transmitter of a digital communication system, for example. The encoder 10 comprises a shortening and puncturing sets allocator 12 which largely controls the operation of the encoder 10 . The allocator 12 includes four outputs; a first output 14 connected to the input of a mother LDPC (low density parity check) code shortening unit 16 , a second output 18 connected to an information bits puncturing unit 20 , a third output 22 connected to a parity bits puncturing unit 24 , and a fourth output 26 connected to a combiner 28 . The allocator 12 also includes an input 30 for receiving a control signal reflecting a target SNR (signal to noise ratio) for the transmitted signal and the payload length of the transmitted information bits. The control signal on the control signal input 30 may be generated by another piece of equipment or may be manually inserted by the user on the encoder 10 . The allocator 12 , in response to the control signal supplied on the control signal input 30 , derives and provides a first message on the first output 14 defining an information shortening set, a second message on the second output 18 defining an information puncturing set and a third message on the third output 22 defining a parity puncturing set. The allocator 12 also provides the control signal at the fourth output 26 for application to the combiner 28 .
The purpose of the information shortening set provided on the output 14 of the allocator 12 is to shorten as necessary the mother LDPC H matrix stored in the code shortening unit 16 to match the length of the data payload supplied over an input 32 to a daughter LDPC code encoder 34 . The information shortening set in certain embodiments identifies portions of the mother matrix to be removed to obtain the daughter matrix. Taking for example the simple case where the payload data is 800 bits and the mother LDPC code H matrix is 1000 bits, the information shortening set would instruct the shortening unit 16 to shorten the mother LDPC code H matrix by 200 bits and supply the resulting shortened daughter LDPC code H matrix for storage in the encoder 34 . The daughter LDPC code matrix thus corresponds to the size of the data payload to be encoded and the daughter matrix may be used to encode the payload data for transmission in a digital communication system, for example.
More realistic parameters for the operation just described above are shown in FIGS. 3 a and 3 b . FIGS. 3 a and 3 b illustrate a practical mother LDPC code H matrix 80 comprising an information bits portion 82 and a parity bits portion 84 . Each value in the information bits portion 82 of the chart 80 defines a unique smaller matrix of 1's and 0's characterized by a quasi-cyclic variation from one small matrix to the next. Each “0” value in the parity bits portion 84 of the chart 80 defines a smaller matrix of 1's and 0's characterized in that it consists of a single diagonal through the matrix. Although the H matrix 80 illustrated in FIGS. 3 a and 3 b is relatively complex, it is treated similar to the simple example given above. Thus, the mother LDPC code H matrix 80 illustrated in FIGS. 3 a and 3 b is shortened by reducing the number of bits comprising the matrix to match the number of bits in the data payload. Shortening is achieved in this example by dropping the bits in each column of the mother H matrix 80 identified by an “S” in the third row 86 of the matrix 80 (which corresponds to columns 2 , 3 , 7 , 15 , 21 and 27 in the illustrated example). The information shortening set on the output 14 as derived by the allocator 12 , the first message, therefore comprises the set {2, 3, 7, 15, 21, 27}, which identifies the columns to be removed. The allocator 12 also supplies the control signal reflecting the information on the input 30 to the output 26 for application to the combiner 28 for transmission to the decoder, which will be described in more detail hereinafter.
The illustrated example shows removal of columns to achieve shortening of the mother matrix. It is possible that other portions of the matrix may be removed for shortening, such as rows, a combination of columns and rows, or other arrangements or patterns for shortening to form the daughter matrix.
The shortened daughter LDPC H matrix is supplied from the code shortening unit 16 to the encoder 34 where the shortened matrix is used to process the input data payload, for example to provide encoded data. Referring back to the simple example where both the data payload and shortened LDPC code H matrix are 800 bits, the encoder 34 will output 800 information bits on an output 36 and, for example, 1000 parity bits on an output 38 . The parity bits on the output 38 are supplied to the input of the parity bits puncturing unit 24 and the information bits on the output 36 are supplied to the information bits puncturing unit 20 .
Referring to FIGS. 4 a and 4 b , which illustrates the same mother LDPC code H matrix 80 as FIGS. 3 a and 3 b , in response to the second message comprising the information puncturing set {1, 4, 5}, identified by the letter “P” in row 88 at the top of the respective columns in the chart 80 , on the output 18 of the allocator 12 , the puncturing unit 20 will puncture the information bits supplied on the output 36 of the encoder 34 by dropping columns 1 , 4 , and 5 from the H matrix. In the case of the simple example, if 100 information bits are thus punctured from the 800 information bits provided, 700 punctured information bits are supplied from the information bits puncturing unit 20 to the combiner 28 .
With reference now to FIGS. 5 a and 5 b , which also illustrates the same mother LDPC code H matrix 80 as shown in FIGS. 3 a and 3 b , in response to the third message comprising the parity puncturing set {1, 4, 5, 13, 18}, identified by the letter “P” in row 90 at the top of the respective columns in the parity portion of the chart 80 , on the output 22 of the allocator 12 , the puncturing unit 24 will puncture the parity bits supplied on the output 38 of the encoder 34 by dropping (or removing) columns 1 , 4 , 5 , 13 and 18 from the H matrix. The person of skill in this art understands how to select portions of the matrix for puncturing. In the case of the simple example, if 1000 parity bits are supplied on the output 38 and 300 bits are punctured by the puncturing unit 24 , 700 parity bits are supplied by the parity bits puncturing unit 24 to the combiner 28 .
The illustrated example shows removal of columns to achieve puncturing of the matrix. It is possible that other portions of the matrix may be removed for puncturing, such as rows, combinations of rows and columns, or other arrangements or patterns for forming the punctured matrix.
Referring back to FIG. 1 , the allocator 12 also supplies the control signal on the output 26 , from which the first, second and third messages are derived, for application to the combiner 28 . The combiner 28 , which may comprise a conventional multiplexer, combines the (700) punctured information bits from the information bits puncturing unit 20 , the (700) punctured parity bits from the parity bits puncturing unit 24 and the control signal from of the allocator 12 . The combined signal is applied to a modulator 40 and other appropriate transmission equipment for transmission to the decoder, such as a decoder at a receiver, for example.
It should be noted that in operation the encoder has adapted itself to encode a shorter payload than the mother LDPC code H matrix is configured to handle and has punctured (performed a data puncturing process on) both the shortened information bits as well as the parity bits, thereby improving bandwidth efficiency and improving robustness of the transmitted signal.
FIG. 2 is a block diagram showing an embodiment of a decoder 50 according to the present invention. The decoder 50 may be provided in a receiver of a digital communication system, for example. The decoder 50 , which may be implemented, for example, in the form of a field programmable gate array (FPGA), comprises a receiving unit 52 for receiving the signal transmitted from encoder 10 . Other implementations are of course possible within the scope of the invention. The receiving unit 52 comprises a tuner, a demodulator and other receiving circuits for providing a digital signal on an output 54 representing the bits provided in the signal transmitted from the encoder 10 . Continuing with the previously used example, 1400 bits are therefore supplied from the receiving unit 52 to a splitter 56 over the output 54 .
It will be recalled that the transmitted signal included a control signal (representing a target SNR for the transmitted signal and the payload length of the transmitted information bits) from which the information shortening set (the first message), the information puncturing set (the second message) and the parity puncturing set (the third message) are obtained by an allocator. The splitter 56 extracts the control signal from the signal supplied on the output 54 and supplies it to a shortening and puncturing allocator 58 . The splitter 56 also supplies a first portion of the bits on the output 54 containing the punctured information bits (700 bits in the example) to a first depuncturing unit 60 and supplies a second portion of the bits on the output 54 containing the parity bits (also 700 bits in the example) to a second depuncturing unit 62 . The allocator 58 derives the information shortening set (the first message), the information puncturing set (the second message) and the parity puncturing set (the third message) from the received control signal and supplies them on outputs 68 , 64 and 66 , respectively. The allocator 58 is operationally identical to the allocator 12 at the encoder, so that the same information shortening set, information puncturing set and parity puncturing set are derived from the same control signal (that includes the SNR and payload length, in the illustrated example). The depuncturing units 60 and 62 are controlled by the second and third messages representing the information and parity puncturing sets supplied by the allocator 58 to the depuncturing units 60 and 62 on the respective outputs 64 and 66 . The third message representing the information shortening set is supplied by the allocator 58 over the output 68 to a shortening LDPC mother code H matrix unit 70 . The output of the shortening LDPC mother code H matrix unit 70 comprises a shortened H matrix supplied over a line 72 for storage in a memory of a daughter LDPC code decoder 74 which provides the recovered payload data on a decoder output 76 . The mother code matrix is shortened to provide the smaller daughter code matrix, the daughter code matrix corresponding in size to the received data payload so that the data can be decoded using the daughter matrix.
It will be understood that much of the operation of the decoder 50 is reverse that of the operation of the encoder 10 . Thus, with reference again to the simplified example, 700 punctured bits of the received 1400 bits are depunctured by the first depuncturing unit 60 so that 800 expanded bits are provided thereby to the decoder 74 . The depuncturing operation performed by the depuncturing unit 60 adds a number of 0's (100 in the case of the simplified example) in the correct locations as defined by the second message corresponding to the information puncturing set supplied on the output 64 of the allocator 58 . A similar operation is performed by the depuncturing unit 62 which expands the 700 punctured parity bits supplied by the splitter 56 to 1000 expanded parity bits with 0's inserted in the correct locations as defined by the third message corresponding to the parity puncturing set supplied on the output 66 of the allocator 58 .
The 800 expanded information bits and 1000 expanded parity bits are supplied by the depuncturing units 60 and 62 to the daughter LDPC code decoder 74 . The decoder 74 comprises an H matrix corresponding in size to the supplied 800 expanded information bits (i.e. 800 bits) which is responsive to the expanded information bits together with the 1000 expanded parity bits to recover 800 error corrected payload data bits on the output 76 . Advantageously, the H matrix used in the decoder 74 is derived from the H matrix stored in the shortening LDPC mother code H matrix unit 70 . In particular, the H matrix stored in the matrix unit 70 is shortened by the matrix unit 70 in response to the first message corresponding to the information shortening set supplied on the output 68 of the allocator 58 from 1000 bits to 800 bits (matching the 800 expanded information bits in size) and supplied over the output 72 for storage in and use by the decoder 74 .
Of course, both the encoder portion and the decoder portion may be shortened to accommodate data payloads of different sizes by shortening the mother code matrix as needed to provide daughter code matrices of corresponding sizes. In this way the operation of the decoder 50 is compatible with different length LDPC codes by appropriately varying the first message corresponding to the information shortening set supplied to the shortening LDPC mother code H matrix unit 70 .
As in the case of the encoder 10 , more realistic parameters for the operation of the decoder 50 are shown in FIGS. 3 a -5 b which were previously described in connection with the operation of the encoder and will therefore not be described in detail again. Thus, it will be recalled that FIGS. 3 a and 3 b illustrate a practical mother LDPC code H matrix 80 used by the matrix unit 70 to create the daughter LDPC code H matrix contained in the decoder 74 , FIGS. 4 a and 4 b illustrate the use of the information puncturing set by the first depuncturing unit 60 to form the expanded information bits and FIGS. 5 a and 5 b illustrate the use of the parity puncturing set by the second depuncturing unit 62 to form the expanded parity bits.
Thus, there is shown and described a certain embodiment of a method and system for modifying the size of an encoding and decoding matrix to correspond to different sizes of data payloads. Other embodiments for modifying an encoding and/or decoding means and method to accommodate different sizes or characteristics of data payloads are within the scope of the present invention.
There is also shown and described a certain embodiment of a method and system for reducing data by puncturing both the information bits and the parity bits and for recovering the data by depuncturing the information bits and the parity bits. Other embodiments of a data reducing and data recovering means and method are within the scope of the present invention.
Although other modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.
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A method and apparatus for encoding data and for decoding data using LDPC (low density parity check) codes includes providing a mother LDPC matrix of a particular size. A data payload of a smaller size is encoded by shortening the mother matrix to a smaller daughter matrix corresponding in size to the data payload and using the smaller daughter matrix for the encoding. The portions of the mother matrix to be removed in the shortening are derived from a control signal. The encoded data is transmitted with the control signal so that the receiver can derive the portions of the mother matrix to be removed to obtain the daughter matrix. At the receiver, a mother matrix is shortened to a daughter matrix and is then used to decode the data. The data at the encoder may be further reduced by puncturing to remove selected information bits and selected parity bits. The decoder inserts the selected information bits and parity bits when decoding the data.
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FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to three-dimensional cameras and, more particularly, to systems for accurately determining the distance to various objects and portions of objects in the scene.
Various techniques are known for creating a three-dimensional image of a scene, i.e., a two-dimensional image which, in addition to indicating the lateral extent of objects in the scene, further indicates the relative or absolute distance of the objects, or portions thereof, from some reference point, such as the location of the camera.
At least three basic techniques are commonly used to create such images. In one technique, a laser or similar source of radiation is used to send a pulse to a particular point in the scene. The reflected pulse is detected and the time of flight of the pulse, divided by two, is used to estimate the distance of the point. To obtain the distance of various points in the scene, the source is made to scan the scene, sending a series of pulses to successive points of the scene.
In a similar technique, a phase shift, rather than time of flight, is measured and used to estimate distances. Here, too, the entire scene or relevant portions thereof must be scanned one point at a time.
In a third technique, which also involves scanning, at least a single radiation source and corresponding detector are used, with suitable optics which act on the light in a manner which depends on the distance to the object being examined, to determine the distance to a particular point in the scene using a triangulation technique.
The major disadvantage of all three of the above-described techniques is that each requires point by point scanning to determine the distance of the various objects in the scene. Such a scanning significantly increases the frame time of the system, requires expensive scanning equipment and necessitates the use of fast and powerful computational means.
There is thus a widely recognized need for, and it would be highly advantageous to have, a method and system for rapidly and easily determining the distance of various points in a scene without the need for scanning and complex computational capabilities.
SUMMARY OF THE INVENTION
According to the present invention there is provided a system and method for creating an image indicating distances to various objects in a scene. The system includes: (a) a source of radiation for directing source radiation at the scene; (b) a detector for detecting the intensity of radiation reflected from the objects in the scene; (c) a source modulator for modulating the source of radiation; (d) a detector modulator for modulating the detector; (e) a source modulator control mechanism for controlling the source modulator; and (f) a detector modulator control mechanism for controlling the detector modulator.
According to a preferred embodiment of the present invention, the source modulator control mechanism and the detector modulator control mechanism operate to simultaneously control the source modulator and the detector modulator.
According to further features in preferred embodiments of the invention described below, the modulator of the source radiation and the modulator of the reflected radiation serve to alternately block and unblock or alternately activate and deactivate the source radiation and detector, respectively.
According to still further features in the described preferred embodiments the source of radiation is a source of visible light, such as a laser and the detector includes photographic film, or a video camera sensor, such as a Charge Coupled Device (CCD.).
According to yet further features, the method further includes processing the intensity of radiation reflected from the objects in the scene to determine distances of the objects and, in a most preferred embodiment, comparing the intensities detected during a relatively continuous irradiation and detector period with intensities detected during modulation of the source and the detector.
Also according to the present invention there is provided a method for creating an image indicating distances to various objects in a scene, comprising the steps of: (a) directing source radiation at the scene using a radiation source; (b) detecting intensity of radiation reflected from the objects in the scene using a detector; (c) modulating the radiation source using a radiation source modulator; (d) modulating the detector using a detector modulator; and (e) controlling the radiation source modulator; and (f) controlling the detector modulator.
According to further features the method further includes processing the intensity of the radiation reflected from the objects in the scene to determine distances of the objects.
In a preferred embodiment, the processing includes comparison of intensities detected during a relatively continuous irradiation and detector period with intensities detected during modulation of the source and the detector.
The present invention successfully addresses the shortcomings of the presently known configurations by providing a system and method for quickly and readily determining distances to portions of a scene without the need for expensive and time consuming scanning of the scene.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 shows a typical set up of a system and method according to the present invention;
FIG. 2 shows a typical modulation scheme which might be employed in a system and method of the present invention;
FIG. 3 shows another modulation scheme which might be employed;
FIG. 4 illustrates yet another modulation scheme which can be used to enhance the accuracy of a system and method according to the present invention 1; and
FIGS. 5A and 5B respectively, show source and detector modulation signals that are shifted and that have different durations.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is of a system and method which can be used to determine the distance of various portions of a scene.
The principles and operation of a system and method according to the present invention may be better understood with reference to the drawings and the accompanying description.
Referring now to the drawings, FIG. 1 illustrates a typical setup of a system according to the present invention.
A system according to the present invention includes a source of radiation 10 for directing radiation at the scene being observed. In the case of FIG. 1, and for purposes of illustration, the scene depicted includes two three-dimensional objects denoted `A` and `B`. The radiation used may be any suitable radiation having a suitable wavelength for the distances examined and other suitable properties as will become more clear from the subsequent discussion. For most applications the radiation is visible or infrared radiation, such as laser radiation or stroboscopic light.
The system further includes a detector 12 for detecting the intensity of radiation reflected from the objects in the scene. The detected radiation is that portion of the source radiation which impinges upon the objects of the scene and which is reflected back toward detector 12. The location of detector 12 may be any suitable location, for example, as shown in FIG. 1. Detector 12 may also be located closer to, or even substantially coincident with, radiation source 10, if desired. The detector used may be any suitable detector with a suitable resolution and suitable number of gray levels including, but not limited to, a photographic film camera and a video camera, such as a CCD camera.
The system includes a radiation source modulator, depicted schematically as item 16, for modulating radiation source 10 or the source radiation and a detector modulator 18 for modulating the reflected radiation which is headed for detector 12 or detector 12 itself. The word `modulate` as used herein is intended to include any varying of the level of operation or any operating parameters of radiation source 10 or of the source radiation itself and/or of detector 12 or of the reflected radiation itself, as appropriate, including, but not limited to, the alternate blocking and unblocking and the alternate activating and deactivating of radiation source 10 or the source radiation and detector 12 or the reflected radiation.
Various mechanisms may be used to modulate radiation source 10 or the source radiation and detector 12 or the reflected radiation. For example, the source radiation and/or reflected radiation may be physically blocked periodically using a suitable shutter or similar element. For example, a shutter 18 is depicted in FIG. 1 at the entrance of detector 12. The shutter may be in any suitable form, for example, in the form of a rotating disk with an opening such that reflected light can pass through to detector 12 whenever the opening and detector 12 are aligned but is blocked at other times during the rotation of the disk.
Other mechanisms which may be used to modulate radiation source 10 and/or detector 12 include various high frequency electronic modulation means for periodically deactivating radiation source 10 and/or detector 12, including, but not limited to, RF modulators. Depicted in FIG. 1 is a source modulator 16 which is shown as being internal to radiation source 10 and which is intended to convey the concept of electronically activating and deactivating radiation source 10. Similar principles apply for detector 12. In addition, various electro optical modulator may be used. These include KDP, lithium niobate and liquid crystals.
It is to be noted that whenever reference is made in the specification and claims to a radiation source modulator or to the modulation of the radiation source it is to be understood as involving the modulation of the radiation source itself and/or of the source radiation. Similarly, whenever reference is made in the specification and claims to a detector modulator or to the modulation of the detector it is to be understood as involving the modulation of the detector itself and/or of the reflected radiation.
Finally, a system according to the present invention includes mechanisms for controlling source modulator 16 and detector modulator 18. Preferably, the mechanisms for controlling source modulator 16 and detector modulator 18 operate together in a coordinated manner, or, most preferably, are the same mechanism 20, so as to simultaneously control source modulator 16 and detector modulator 18. The simultaneous control may be synchronous so that the operation of both radiation source 10 and detector 12 is affected in the same way at the same time, i.e., synchronously. However, the simultaneous control is not limited to such synchronous control and a wide variety of other controls are possible. For example, and without in any way limiting the scope of the present invention, in the case of blocking and unblocking control, radiation source 10 and detector 12 may be open for different durations during each cycle and/or the unblocking of detector 12 may lag the unblocking of radiation source 10 during each cycle.
A system according to the present invention further includes a suitable processor 22 which analyzes the intensity of radiation detected by detector 12 and determines the distances to various objects and portions of objects in the scene being examined. The operation of processor 22 is explained in more detail below.
In operation, a typical system according to the present invention, using a laser as the radiation source, a CCD sensor as the detector and modulating the source and detector by synchronous switching, would operate as follows. Laser 10 and CCD 12 are activated (or unblocked) and deactivated (or blocked) periodically in a synchronous manner, as depicted in FIG. 2 which shows a type of square wave modulation. Thus during each cycle, both laser 10 and detector 12 are active for a time `a` and are inactive for a time `b`. The times `a` and `b` may be the same or different. The wavelength of laser 10 and the time `a` are selected so that light from laser 10 will be able to travel to the most distant objects of interest in the scene and be reflected back to CCD 12.
The selection of the time `a` can be illustrated with a simple example. Let us assume that the scene to be examined is as in FIG. 1 with the maximum distance to be investigated being approximately 50 meters from the source or detector, i.e., both objects A and B are within about 50 meters from the detector and source. Light traveling from the source to the farthest object and back to the detector would take approximately 0.33 μsec to travel the 100 meters. Thus, the time duration `a` should be approximately 0.33 μsec.
Systems and methods according to the present invention are based on the idea that a near object will reflect light to the detector for a longer period of time during each cycle than a far object. The difference in duration of the detected reflected light during each cycle will translate to a different intensity, or gray level, on the detector. Thus, for example, if we assume that a certain point on object B is a certain number of meters away from the source and/or detector while a certain point on object A is a greater distance away, then reflected light from the point on B will start arriving at the detector relatively early in the active portion of the detector cycle (see FIG. 2) and will continue to be received by the detector until the detector is deactivated at the end of the active portion of the detector cycle. The reflected light from the point on B will continue to proceed toward the detector for a period `a` which corresponds to the period of irradiation (see the dot-dash-dot line in FIG. 2). However, the portion of this reflected radiation which falls beyond the deactivation or blocking of the detector will not be received by the detector and will not contribute toward the intensity sensed by the corresponding pixels of the detector.
By contrast, light reflected from the point on object A will start arriving at the detector later during the active portion of the detector cycle and will also continue to be received by the detector until the detector is deactivated.
The result is that reflected light from a point on object B will have been received for a longer period of time than reflected light from a point on object A (see the shaded areas in FIG. 2). The detector is such that the intensity of gray level of each pixel during each cycle is related to the amount of time in each cycle during which radiation was received by that pixel. Hence, the intensity, or gray level, can be translated to the distance, relative or absolute, of the point on the object.
As stated above, the synchronous on/off operation described in the example and depicted in FIG. 2, is not the only possible mode of operation. Other modulations may be used. For example, the radiation source and/or detector may be modulated harmonically as shown in FIG. 3.
To avoid obtaining false signals from distant objects which are beyond the region of interest, it may be desirable to increase the time duration `b` during which the source/detector are inactive so that the bulk of the reflected radiation from faraway objects which are of no interest reaches the detector when the detector is deactivated and therefore do not contribute to the intensity detected by the corresponding pixel of the detector. A proper choice of the duration `b` thus can be used to ensure that only reflected radiation from objects within the desired examination range are received during each specific cycle, thereby facilitating the interpretation of the intensity image.
As will readily be appreciated, in certain applications, different portions of the various objects in the scene may have different reflectivities. The different reflectivities result from different colors, textures, and angles of the various portions of the objects. Thus, two points which are the same distance from the source/detector will be detected as having different intensities which could lead to false distance readings which are based on intensities, as described above.
It is possible to readily compensate for differences in reflectivities of different objects or portions of objects being examined. As is well known, the intensity detected by a pixel of a detector receiving continuous radiation from a specific portion of a scene is directly proportional to the reflectivity of the portion being viewed and inversely proportional to the square of the distance between the portion of the scene being viewed and the detector.
It can readily be shown that when a pulsed radiation source, such as those described above, is used the intensity detected by a pixel of a detector receiving radiation from a specific portion of a scene is still directly proportional to the reflectivity of the portion of the scene being viewed but is inversely proportional to the distance between the portion of the scene being viewed and the detector raised to the third power.
Thus, to compensate for the effects of different reflectivities, one can use both continuous radiation and pulsed radiation. An example of such a cycle is shown in FIG. 4. Here the radiation source and detector are active for a relatively long period of time to provide the continuous intensity of the objects in the scene. Periodically, the source and detector are deactivated and the source and detector are pulsed, in the same way as described above with reference to the basic embodiment, using one or more, preferably a train, of pulses.
The detection during the pulsing portion of the cycle is used as described above. However, in addition, the continuous detection during the long active period of the cycle is used to correct, or normalize, the distances and compensate for differences in reflectivities. The compensation can be accomplished by any convenient method, for example, by dividing the intensity of each pixel during the continuous period by the intensity of the same pixel during the pulsed period, with the quotient between the two being directly proportional to the distance of the region being viewed by the pixel.
While the invention has been described with respect to a limited number of embodiments, it will be appreciated than many variations, modifications and other applications of the invention may be made.
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Apparatus for creating an image indicating distances to points in objects in a scene, comprising:
a modulated source of radiation, having a first modulation function, which directs radiation toward a scene such that a portion of the modulated radiation is reflected from the points and reaches the apparatus;
an array detector which detects radiation from the scene, modulated by a second modulation function, each element of the array detector being associated with a point in the scene, each element of the array detector generating a signal, responsive to a part of the reflected radiation reaching the apparatus, the magnitude of particular element's signal being dependent on the distance of a point in the scene, associated with that element's signal; and
a processor which forms an image, having an intensity value distribution indicative of the distance of each of the points in the scene from the apparatus, based on the magnitude of the signal associated with the point;
wherein the first and second modulation functions comprise repetitive pulsed modulation functions which are different from each other.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit under 35 USC §119(e) of U.S. Provisional Patent Application Ser. No. 61/242,466 filed 15 Sep. 2009 and U.S. Provisional Patent Application Ser. No. 61/346,490 filed 20 May 2010. Both applications are hereby incorporated fully herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a retractable system for protecting penetrations in buildings, and particularly to a retractable, flexible, low-profile, solar, insect, thermal, and storm protection system for windows and doors. The present invention enables a storage and deployment mechanism for roll-up storm protection screens that is approximately 70% smaller than conventional systems while containing approximately 50% greater vertical length of material. This smaller size eases installation and reduces the aesthetic impact of the system on the installation site. Space savings are maintained or improved as the size of the system increases, e.g., to protect larger openings.
[0004] 2. Background of Related Art
[0005] Systems exist that attempt to mitigate damage to structures during inclement weather such as hurricanes, cyclones, nor'easters, and thunderstorms. These types of weather systems can carry with them high winds, hail, sleet, and driving rain. High winds can damage structures not only by creating high pressure forces and, for example, blowing windows out, but also by causing loose material and debris to become missiles impacting the structure. In addition, high winds can create driving rain that can penetrate, among other things, window and door seals causing flooding and water damage to the structure.
[0006] “Bahama,” or colonial-type, conventional storm shutters have been used in an attempt to protect windows and doors during storms. These shutters are typically constructed of a rigid material such as, for example, wood, plastic, or metal, and are sized to cover the opening they protect. These types of shutters typically use a heavy and awkward safety bar to secure the shutters for use. Due in part to their custom construction, however, Bahama storm shutters tend to be expensive, heavy, and can be difficult to deploy.
[0007] Aluminum roll-up shutter systems are also available. These systems use multiple aluminum panels joined by hinges or pins to form a substantially solid but flexible curtain, similar to a roll-up garage door. These systems are generally available with electric or manual crank deployment. Due to the thickness of the aluminum panels, however, the systems tend to be heavy. Additionally, due to the limited range of motion of the hinges that join the panels, the take-up rolls that store aluminum shutters when not in use are large. As a result, the enclosures for these systems are necessarily large and cumbersome. This makes installation difficult and detracts from the aesthetics of the building on which they are installed. In addition, aluminum roll-up systems are opaque and block most, if not all, of the natural light from the building when deployed. This provides a dark and unpleasant experience to the user, especially given that the power to the building is likely out.
[0008] In an attempt to reduce cost and increase protection, retractable storm protection systems have been developed. These systems typically use a strong, flexible, fabric curtain or screen made of, for example, polypropylene, PVC, Kevlar®, Mylar®, or hybrids thereof. The systems can further comprise a retracting mechanism and a housing in which to store the screen when not in use. The screen is deployed to cover the window and is generally retained in vertical tracks installed in, or on, the window opening. Conventionally, the screen is retained in the track either by sewing a hem cord to the vertical sides of the curtain (as used herein, the “hem cord method”), or simply by folding the curtain over on itself to form a hem (as used herein, the “hem-only method”).
[0009] At one end of the spectrum, a hem cord sewn to the edges of the curtain enables the curtain to be retained in a slotted track because the slot is considerably smaller than the diameter of the hem cord. This method retains the curtain in the track at fairly high forces because the diameter of the hem cord is sufficiently large when compared to the slot in the track. Unfortunately, the thick, stiff hem cord requires a large diameter take-up roll on which to retract the curtain (i.e., when the curtain is not deployed). This, in turn, necessitates a large housing, increasing installation difficulty and detracting from the aesthetics of the building, among other things.
[0010] At the other end of the spectrum, the hem-only method involves a hem sewn into the edge of the curtain that can enable it to be retained in a sufficiently small slot in the track. Because the hem is generally only approximately twice the thickness of the fabric itself, this method has a limited ability to retain the curtain in the track. As a result, the application of such systems is limited to smaller openings to minimize pressure forces on the curtain. In other words, at larger opening sizes, such as a large door, the force created by high winds can exceed the ability of the system to retain the curtain. Additionally, the necessarily tight slot in the retaining track can cause jams and hinder operation when deploying or retracting the curtain.
[0011] What is needed, therefore, is a system that combines the retention strength of the conventional hem cord system, with the reduced storage requirements of the hem-only method. It is to such a system that embodiments of the present invention are primarily directed.
BRIEF SUMMARY OF THE INVENTION
[0012] Embodiments of the present invention relate generally to storm protection systems and more specifically to a flexible, retractable storm protection system with a reduced volume and increased protection. The system can comprise a curtain or screen made of a strong flexible material, or a composite of such materials. The screen material can comprise, for example and not limitation, Kevlar®, Mylar®, vinyl, PVC, nylon, or fiberglass, or combinations thereof. The screen can comprise a loop sewn into both vertical edges.
[0013] The present system can further comprise vertical channels for securing the vertical edges of the screen. The vertical channels can be substantially C-shaped with a hem rod located inside the channel. The loops in the vertical sides of the screen can encircle the hem rod such that the screen is both guided inside the channel, when being deployed or retracted, and retained in the channel when the screen encounters wind pressure or other forces. The hem rod acts to locate and secure the screen in substantially the same manner as a conventional hem cord, while significantly reducing storage requirements for the screen when retracted.
[0014] In some embodiments, the system can be installed on the outside of a building penetration, such as for example and not limitation, a door or a window. In this configuration, the system can also protect the door or window from solar heat gain, insect or pest infiltration, and thermal loss, in addition to storm and water damage. In some embodiments, the system can be installed on the inside of a building penetration. In this configuration, the system can provide the same protections for the building, and limited protection for the door or window, for example.
[0015] In some embodiments, the system can be mounted in the upper portion of a penetration and deployed from the top down (as used herein, the “top-down configuration”) and can be manually or electrically deployed. In other embodiments, the system can be mounted in the bottom end of a penetration and deployed from the bottom up (as used herein, the “bottom-up configuration”) and can be electrically or manually deployed.
[0016] The system can further comprise a horizontal support unit. The horizontal support unit can span all, or substantially all, of the free horizontal edge of the screen (i.e., the end of the screen not attached to the take-up roll). In some embodiments, such as when the top-down configuration is used, the horizontal support unit can be weighted and can facilitate the deployment of the screen. In other embodiments, such as when the bottom-up configuration is installed, the horizontal support unit can comprise a lightweight, rigid material. In some embodiments, the horizontal support unit can further comprise, for example and not limitation, latches, catches, or pins for securing the screen in the deployed, or partially deployed, position.
[0017] Embodiments of the present invention can also comprise a method for installing the system on a penetration. The method can comprise affixing one or more C-shaped channels on the sides of the building penetration. An enclosure can then be installed in the top or bottom of the penetration. A screen comprising a horizontal support bar can then be installed to protect the penetration. The system can be installed in a bottom-up configuration. The system can also be installed in a top-down configuration. The method can further comprise installing a manual or electric drive system.
[0018] These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 a depicts a top, detailed view of a retention track and enclosure for a storm shield system, in accordance with some embodiments of the present invention.
[0020] FIG. 1 b depicts a side view of a retention track and enclosure for a storm shield system, in accordance with some embodiments of the present invention.
[0021] FIG. 2 depicts a cross-sectional view of the enclosure with a roller-type deflector, in accordance with some embodiments of the present invention.
[0022] FIG. 3 depicts a cross-sectional view of the enclosure with a smooth-type deflector, in accordance with some embodiments of the present invention.
[0023] FIG. 4 depicts a detailed view of the enclosure and retention track installed in a trapped configuration, in accordance with some embodiments of the present invention.
[0024] FIG. 5 depicts a detailed view of the enclosure and retention track installed in a face-mounted configuration, in accordance with some embodiments of the present invention.
[0025] FIG. 6 depicts a side view of the screen and weight bar for the storm shield system, in accordance with some embodiments of the present invention.
[0026] FIG. 7 depicts a detailed, front view of the screen and weight bar for the storm shield system, in accordance with some embodiments of the present invention.
[0027] FIG. 8 depicts a top, detailed view of the retention track and cover for the storm shield system, in accordance with some embodiments of the present invention.
[0028] FIG. 9 depicts a cross-sectional view of the enclosure with the weight bar in a retracted position, in accordance with some embodiments of the present invention.
[0029] FIGS. 10 a and 10 b depict side and front views, respectively, of a remote drive mechanism for use with the storm shield system, in accordance with some embodiments of the present invention.
[0030] FIG. 11 a depicts a smooth loop opener for use with the storm shield system, in accordance with some embodiments of the present invention.
[0031] FIG. 11 b depicts a roller loop opener for use with the storm shield system, in accordance with some embodiments of the present invention.
[0032] FIG. 12 depicts a manually deployed storm shield system, in accordance with some embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Embodiments of the present invention relate generally to storm protection systems and more specifically to a flexible, retractable storm protection system with a reduced storage volume and increased protection than that conventionally provided. The system replaces a conventional hem cord design with a stationary hem rod located in a retention channel to provide the security of the hem cord system with the compact size of a hem-only system. The system can employ a retention channel with a hem rod disposed therein. The screen can have a loop sewn into each vertical edge sized to easily slip over the hem rod. The hem rod can retain the curtain in the retention track even when exposed to, for example, high wind, driving rain, and/or impacts from flying objects.
[0034] To simplify and clarify explanation, the system is described below as a system for protecting the windows and doors of residential and commercial buildings. One skilled in the art will recognize, however, that the invention is not so limited. The system can also be deployed to protect other penetrations in most structures during inclement weather or other environmental or man-made threats. Embodiments of the present invention can also be used, for example, to provide protection for residential and commercial properties against vandalism and break-ins.
[0035] The materials described hereinafter as making up the various elements of the present invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, materials that are developed after the time of the development of the invention, for example. The dimensions listed in the various drawings are for illustrative purposes only and are not intended to be limiting. Other dimensions and proportions are contemplated and intended to be included within the scope of the invention.
[0036] A problem with conventional storm protection systems has been that the housings required to store the screens for these systems are undesirably large. The relatively large enclosure for the Armor Screen® Hurricane Protection System by the Armor Screen Corporation, for example, is dictated by the fact that the hem cord product sewn into the edges of the screen requires that a material be wound on approximately a 6″ diameter take-up device. The large size of the take-up device is due predominantly to the stiff nature of the hem cord installed in the polypropylene screen material used by Armor Screen®. This hem cord is what guides the screen down each side of the door or window opening and secures the screen in a retention channel on both sides.
[0037] In response, as shown in FIGS. 1 a and 1 b , embodiments of the present invention relate to a system 100 in which the traditional rope bolt, or hem cord, can be replaced by inserting a side support unit 107 comprising a fixed rod 105 inside a C-channel extrusion 110 . A loop 115 can then be sewn into the vertical sides of the screen 120 to slide down the rod 105 and can secure the fabric inside the extrusions 110 . With the hem cord removed from the screen 120 , the material can be flexible enough to be wound onto, for example and not limitation, a 2″ diameter take-up device.
[0038] The hem rod 105 (as opposed to a hem cord) can enable a storage and deployment mechanism 200 that is approximately 70% smaller than conventional systems while containing approximately 50% greater vertical length of material. The result is a compact enclosure 130 that can, for example, contain approximately 90 vertical inches of screen in a box 130 that is smaller than 4″×4″. For comparison, the smallest Armor Screen® box is 7″×7″ and accommodates a maximum of 60 vertical inches of screen. The smaller enclosure 130 can ease installation and reduce the aesthetic impact of the system 100 on the installation site. Space savings are maintained or improved as the size of the system increases, e.g., to protect larger openings.
[0039] Various materials, and combinations of materials, can be used to construct the protection screen 120 . The screen 120 can provide, for example and not limitation, solar, insect, thermal, and storm (“SITS”) mitigation attributes. The screen 120 can comprise a material that meets local, national, or international hurricane, building, and safety codes.
[0040] In some embodiments, the screen 120 can be deployed using an extrusion 110 , e.g., an extruded C-channel 110 , such that the loop 115 sewn into, or attached to, the screen 120 can be slid down a hem rod 105 mounted inside the channel 110 . In this configuration, the loop 115 in the screen 120 can slide down over the hem rod 105 and can be retained in the slot 125 of the channel 110 by the hem rod 105 . In other words, the present hem rod 105 replaces the hem cord or similar material used in commercially-available hem cord-type products. The channel 110 can be extruded, formed, machined, or fabricated as a single or multi-piece device. The hem rod 105 can be retained at a first end 150 of the channel, e.g., the end 150 in which the screen is considered fully deployed.
[0041] When the box 130 is mounted in the top of an opening 135 and the screen 120 is vertically deployed downwardly, for example, the hem rod 105 can be anchored at the bottom end 130 of the channel 110 . The hem rod 105 can be made from many materials that enable it to stand vertically without support. The rod 105 can be made from, for example and not limitation, metal, plastic, fiberglass, composite material, wood, or combinations thereof. The diameter of the rod can be sufficiently larger than the slot in the channel such that the material cannot be pulled through the slot.
[0042] As shown in FIGS. 2 and 3 , the screen 120 can be wound onto a take-up cylinder 210 for storage. The take-up cylinder 210 can be rotated by, for example and not limitation, an electric motor inside the cylinder, a powered or manual end-mounted gear drive, or by a spring type device. A combination of one or more of these devices can also be utilized within a single operating unit to facilitate both powered and manual operation. This feature can be useful if, for example, the power to the building is interrupted. A spring, such as a torsional spring for example, can be added to provide assistance to the electric motor or manual gear drive. These driving mechanisms can be utilized when the screen 120 is deployed in the top-down configuration or the bottom-up configuration.
[0043] In some embodiments, the deployment mechanism 205 can comprise a deflector 215 . The deflector 215 can enable the material of the screen 120 to be deployed or retracted vertically such that the angle of the screen 120 is substantially constant, regardless of the length of screen 120 on the take-up roll 210 (i.e., the diameter of the take-up roll 210 increases as the screen 120 is retracted). In other words, the material 120 is always deployed such that the angle of entry or exit from the enclosure 130 is vertical. The deflector 215 can comprise many appropriate systems including, but not limited to, one or more rollers 220 ( FIG. 2 ) or a smooth, rounded surface or profile 320 ( FIG. 3 ). In some embodiments, the deflector 215 can further comprise non-friction or other coatings to facilitate screen 120 deployment. The deflector 215 enables the size of the box 130 to be further reduced by smoothly, but sharply, turning the screen 120 fabric from the roll 210 to a vertical position. This enables the screen 120 fabric to turn through a much larger angle than would otherwise be possible without damaging or tangling the fabric.
[0044] As shown in FIGS. 4 and 5 , the system 400 , 500 can be utilized in both a trapped configuration 400 face-mounted configuration 500 . A trapped configuration 400 can be installed inside a window or door opening 405 with the take up mechanism 410 and retention mechanisms 105 , 110 all being located within the opening 405 . The face-mounted installation 500 , on the other hand, can be attached to the outside surface, or trim 505 , of the opening 610 . Both the trapped 400 and face-mounted 500 units can be operated either with the box 130 on the top with the screen 120 going down (the “top-down configuration”) or the box 130 mounted on the bottom with the screen 120 going up (the “bottom-up configuration”).
[0045] As shown in FIG. 4 , a trap-mounted unit 400 is installed inside and at the top or bottom of a window or door opening 405 , for example, with the vertical extrusions 110 containing the hem rod 105 mounted inside the opening 405 . As shown in FIG. 5 , a face-mounted unit 500 is attached on the trim 505 above or below and outside the opening 510 with the extrusions 110 containing the fixed hem rod 105 mounted on the vertical trim 505 outside the opening 510 . Both of these installations can be made architecturally discreet and installed in a variety of ways that reduce, or eliminate, their visual impact on the structure. In the case of the new construction, the trap-mounted system 400 allows for the box 205 and extrusions 110 to be built into the window or door opening 405 in such a way that they are virtually indistinguishable from a regular opening.
[0046] The system 400 , 500 can also be installed on the inside or the outside of the opening. In other words, it can be installed in front of, or behind, the window or door. When installed on the outside of the window or door, the system 400 , 500 can provide additional protection against, among other things, storm damage caused by wind, wind driven missiles, and driving rain. The system 400 , 500 can also help reduce solar heat gain, thermal losses, and insect and pest infiltration. In some embodiments, the system 400 , 500 can also provide additional insulation value to the structure thereby reducing energy costs.
[0047] In some embodiments, the system 400 , 500 can be installed inside of the window or door (i.e., inside the building). The system 400 , 500 can provide the benefits listed above in this configuration, with the obvious exception of storm protection for the outside of the window or door itself. However, this configuration may be useful, for example and not limitation, with certain windows (e.g., casement windows) or out swinging doors. In addition, this configuration enables the screens to be easily deployed from inside the building.
[0048] As shown in FIGS. 6 and 7 , the system can further comprise a horizontal support unit 605 . The horizontal support unit 605 can be attached to the free end of the screen 120 (i.e., opposite the end of the screen 120 that is attached to the take-up cylinder 410 ). When the screen 120 is fully retracted into the enclosure 130 , the horizontal support unit 605 can either be fully retracted into the enclosure 130 or exposed just outside the enclosure 130 . See, FIG. 9 . This horizontal support unit 605 can be made of rigid materials such as, but not limited to, metal, plastic, fiberglass, composite material, wood or other compressed materials.
[0049] The horizontal support unit 605 can contain weight to assist in the deployment of the screen 120 and/or latching mechanisms 610 , 615 to assist in securing the screen 120 . In some embodiments, the horizontal support unit 605 can comprise locking latches 610 or pins 615 that enable the screen 120 to be secured in many positions between the fully deployed and the fully retracted position. In some embodiments, the latches 610 can, for example, engage a catch in the sill 630 of the opening. In other embodiments, pins 615 can be used to engage holes in the jambs 735 of the opening. Of course, other configurations are contemplated as other mechanisms could be used to secure the horizontal support unit 605 to the opening or the channels 110 , for example. The ability to secure the horizontal support unit 605 can be useful, for example, to let fresh air in through a partially open window, while maintaining substantial protection for the opening.
[0050] In some embodiments, the system 400 , 500 can further comprise a cable drive to positively deploy the screen 120 . The cable system can comprise, for example, a system of cables and pulleys to move the screen 120 and/or the horizontal support unit 605 up and down rather than relying solely on gravity. This can be useful, for example, during high winds, which tend to create side forces on the screen 120 , which can increase friction.
[0051] In some embodiments, the cable can be wound around the take-up cylinder 410 in the opposite direction of the screen 120 . The cable can then run to a pulley located in the bottom of the extrusion 110 and back up to the screen 120 . In this manner, when the take-up cylinder 410 is rotated to unfurl the screen 120 (either manually or with an electric motor, for example); the cable is wound onto the take-up cylinder 410 pulling the screen down. In some embodiments, two or more cables can be used, wound in opposite directions, to provide positive movement of the screen 120 in both directions. Of course, other cable and pulley configurations are possible and are contemplated herein.
[0052] As shown in FIG. 8 , the side support unit 107 can further define a compartment 805 sized and shaped to house remote control receivers and/or electrical connections for an electric motor. A cap, or cover, 810 can be clipped over the compartment 805 to cover the device and wires. In some embodiments, the cover 810 can be non-metallic to enable RF transmission to and from remote control receiver/transmitters. In other embodiments, the cover 810 can be transparent or translucent to enable the use of infrared remote transmitters. The cover 810 can have various profiles to meet various functional, aesthetic, or architectural needs. The cover 810 can also have various finishes to, for example and not limitation, match wall or trim colors or to simulate various finishes. The cover 810 can comprise, for example, plastic, aluminum, or pot metal, and can comprise the same material as the side support unit 107 , or a different material.
[0053] The material used for the screen 120 preferably has high strength and high light transfer with reasonable visibility and clarity, while still protecting the opening from wind driven rain and missiles, among other things. In some embodiments, the screen 120 can comprise a sandwich, or bonded layers, of materials comprising, for example and not limitation, clear vinyl, Mylar®, PVC, fiberglass, or Dynema®. In some embodiments, one or more layers of the screen 120 can include a scrim comprising, for example, square, rectangle, or diamond shapes. In one preferred embodiment, the following components can be layered in the following sequence to form the screen 120 material: Clear vinyl; Mylar; a fiberglass carrier grid supporting a Dynema® scrim forming square, rectangle, or diamond shapes; and clear vinyl. This sandwich of materials can be, for example, chemically bonded (glued) or mechanically bonded using pressure, with or without heat, during the manufacturing process.
[0054] A second preferred embodiment of the screen 120 comprises a woven material comprising high-tenacity polyester threads with a PVC coating in the warp direction and a Kevlar® (or generic equivalent) with a PVC coating in the fill direction. The diameter of the vinyl and Kevlar coated yarns can vary as well as the warp and fill construction (number of threads per inch) depending on intended use. The material can be thermally set to, among other things, prevent the threads from unraveling when cut. The PVC coating can be colored. This material can provide all four capabilities, i.e., solar, insect, thermal, and storm (or, “SITS”) in one material. The screen 120 can further comprise other commercially available fabric materials and can use the base material to establish the loop required for the side retention system.
[0055] In other embodiments, the vertical sides of the screens 120 can further comprise a band or edging 815 sewn vertical edges of the screen 120 . In some embodiments, the edging 815 can form the loops 115 . In other embodiments, the edging can be sewn over the loops 115 . In some embodiments, a fabric system such as, but not limited to, Dacron® luff tape can be used to reduce friction between the loop 115 , the hem rod 105 , and the retention channel 110 . In some embodiments, the luff tape can further comprise Teflon® thread, or other low friction materials, woven into, or adhered to, the banding for added lubricity.
[0056] In some embodiments, the side support unit 107 can further comprise closed cell foam or rubber backing 820 disposed between the side support unit 107 and the mounting surface 135 to prevent air and water leakage between side support unit 107 and the surface 135 . In a preferred embodiment, the side support unit 107 can be affixed to the structure 135 using a fastener 140 with a sealing washer 145 . The sealing washer 145 can comprise rubber, plastic, or other material suitable for forming a water tight seal between the fastener 140 and the side support unit 107 . In a preferred embodiment, the fastener 140 can comprise a stainless steel and EPDM rubber bonded washer 145 between the head of the fastener 140 and the side support unit 107 . The washer 145 can prevent both leaking and galvanic corrosion where the fastener 140 penetrates the side support unit 107 and the mounting surface 135 .
[0057] As shown in FIGS. 10 a and 10 b , the ability to deploy the system from the inside of the building can also be provided on an external mount installation with the proper hardware. The system can comprise a remote drive system 1000 comprising one or more driveshafts 1005 coupled to a drive mechanism 1020 . In some embodiments, the driveshafts 1005 can be coupled to the drive mechanism 1020 , and each other, by one or more universal joints 1025 . This can enable the drive handle for the screen 120 to be remotely located. This can be useful, for example, for a very tall window to enable the drive handle to be located at a lower, safer, more convenient location. This drive system 1000 can also enable a drive motor to be located remotely from the enclosure, if desired.
[0058] When the screen 120 is wound around the take-up cylinder 410 , the loop 115 sewn into the sides of the screen 120 tends to flatten. This is advantageous in that it minimizes the storage space required to store the screen 120 when not in use. When the screen 120 is deployed, however, it is desirable to open the loop 115 in the screen 120 to enable it to slide easily over the end 1105 of the hem rod 105 . As shown in FIG. 11 a , therefore, in some embodiments the system can further comprise a loop opener 1110 .
[0059] The loop opener 1110 can comprise a projection, or roller, disposed in one or both retention channels, proximate the upper ends 1105 of the hem rods 105 . 1 As the screen 120 is deployed past the loop opener 1110 , the edge of the screen 120 is pushed inward by the loop opener 1110 , causing the loop 115 to open as is comes off the roll 410 . This can enable the loop 115 to start over the top 1105 of the hem rod 105 and can prevent jams and bunching during initial deployment.
[0060] In some embodiments, the end of the hem rod 105 can comprise a tapered upper portion 1105 to help start the loops 115 in the screen 120 over the end 1105 of the hem rod 105 . The tapered portion 1105 can comprise a separate piece, or cap, placed on top, or inserted into the top end of the hem rod 105 . In other embodiments, the tapered portion 1105 can be cast, molded, or machined into the end of the hem rod 105 such that the hem rod and the tapered portion 1105 are unitary. In some embodiments, the tapered portion 1105 can be made from the same material as the hem rod 105 . In other embodiments, the tapered portion 1105 can comprise a different material than the hem rod 105 that has desirable properties such as, for example and not limitation, a low coefficient of friction. The tapered portion 1105 can be made from, for example and not limitation, metal, plastic, fiberglass, composite material, wood, or combinations thereof.
[0061] As shown, the loop opener 1110 can be a simple projection, or finger, disposed in the retention channel 110 near the top 1105 of the hem rod 105 . The loop opener 1110 can be part of the retention channel 110 or can be a separate part affixed to the retention channel 110 during manufacture. In some embodiments, the loop opener 1110 can comprise a low-friction material or can be coated in a low-friction material to reduce wear the screen 120 . As shown in FIG. 11 b , in other embodiments, the loop opener 1110 can further comprise a wheel or ball on the end of the projection to further reduce wear on the screen 120 .
[0062] Embodiments of the present invention can further comprise a method of installing the system 400 for a trapped configuration. In this configuration, the enclosure 130 can be mounted 1 Of course, the loop opener would be positioned in the bottom of the retention channel in the bottom-up configuration. inside the window or door opening. In some embodiments, the enclosure 130 can comprise a rubber, or high-density foam, backing 420 to seal adjacent surfaces of the enclosure 130 to the mounting surface 505 . The retention channels 110 can be installed on the vertical sides of the opening 405 . In some embodiments, the retention channels 110 can comprise a rubber, or high-density foam, backing 425 to seal adjacent surfaces of the channels 110 to the mounting surface 405 . In some embodiments, installation may further comprise installing and/or connecting remote control electronics, remote drive systems, and/or additional trim pieces.
[0063] The retention channels 110 and/or the enclosure 130 can be affixed to the structure using, for example and not limitation, screws, bolts, or rivets. In some embodiment, the fasteners 140 can further comprise a sealing washer 145 to prevent air and water leaks and galvanic corrosion between the fastener 140 , channels 110 , enclosure 130 , and structure 505 . Installation for the face-mounted configuration 500 is substantially similar with the exceptions that the enclosure 130 and channels 110 are mounted on the outside of the window or door opening, e.g., on the window trim 505 .
[0064] In some embodiments, the system can be installed with the enclosure 130 on the left or right side of an opening and the retention channels 110 on the top and bottom of the opening. This may be necessary due to the type of opening or the type of window or door in the opening. The installation procedure can be substantially the same, though rotated 90 degrees in all respects. A system installed in this manner would not have the benefit of gravity, as in the top-down system, and thus may need to be manually deployed. The system would nonetheless function as intended.
[0065] As shown in FIG. 12 , in still other embodiments, the system 1200 can be completely manually deployed. In other words, the system 1200 can comprise retention channels 110 and the screen 120 with no enclosure 130 or deployment mechanisms 1020 . In this configuration, the user can simply install the retention channels 110 on either side of the penetration 1205 , and then slide the screen 120 down over the hem rods 105 and into the retention channels 110 . The screen 120 can then be secured at the bottom and/or the top of the penetration 1205 as desired.
[0066] This configuration can be useful if the subject building is, for example, a summer home. The user can deploy screen 120 over some or all of the external building penetrations at the end of the season. The user can then remove the screens 120 at the beginning of the season when reopening the house. Because there is no hem cord, the screens 120 can be stacked and stored flat, or rolled up, for storage in minimal space. In addition, because the system is somewhat simplified (e.g., there is no enclosure 130 or deployment mechanisms 1020 ), the cost of purchasing, installing, and maintaining the system 1200 is reduced. Finally, the aesthetic impact to the structure is minimized because, when removed, only the retention channels 110 remain on the building. In some embodiments, the retention channels 110 can also be removable, further reducing aesthetic impact.
[0067] While several possible embodiments are disclosed above, embodiments of the present invention are not so limited. For instance, while several possible configurations of materials for the screen have been disclosed, other suitable materials and combinations of materials could be selected without departing from the spirit of embodiments of the invention. In addition, the location and configuration used for various features of embodiments of the present invention can be varied according to a particular opening or building design that requires a slight variation due to, for example, the materials used and/or space or power constraints. Such changes are intended to be embraced within the scope of the invention.
[0068] The specific configurations, choice of materials, and the size and shape of various elements can be varied according to particular design specifications or constraints requiring a device, system, or method constructed according to the principles of the invention. Such changes are intended to be embraced within the scope of the invention. The presently disclosed embodiments, therefore, are considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.
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A system for protecting building penetrations is disclosed. The system can include a screen comprising flexible, strong fabric-like material suitable for resisting high winds, driving rain, and wind-driven missiles. The screen can further include loops sewn, or otherwise manufactured, into the span sides of the screen. The system can further include one or more retention channels having an internal hem rod. The loops in the screens can slide over the hem rod to guide and retain the screen in the retention channels. The hem rod can include a tapered end and a loop opener to facilitate the loops sliding over the end of the hem rod. The system can further include an enclosure for housing a take-up roll and a powered or manual rotating system. The system can include a deflection device to enable the screen to unroll off the take-up roll smoothly and vertically.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Related U.S. Pat. applications include Ser. No. 217,525 , by Lauren F. Calaby (one of the co-inventors of this application), entitled "Movable- Fiber Array Optical Switch With Liquid Guiding"; Ser. No. 217,526, by Lauren F. Calaby (the same inventor as identified hereinabove), entitled "Movable Planar Waveguide Array Optical Switch"; and Ser. No. 217,521 by Barry J. Opdahl (another co-inventor of the instant application) entitled "Movable Fiber Array Optical Switch", all of which are filed contemporaneously herewith with and assigned to related assignees and all of which are now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a moving "S" fiber array optical switch and, in particular, to a fully-reversing 2×2 electromechanical optical switch apparatus in which input optical signals carried on input optical fibers can be selectively transmitted to output optical fibers. Accordingly, it is a general object of this invention to provide new and improved switch apparatus of such character.
2. General Background
Mechanical optical switching devices have been described in the literature. For example, U.S. Pat. No. 4,239,331 to Aoyama, issued Dec. 16, 1960, discusses an optical switching device for use with optical fibers. The fibers are positioned on input and output sides of the switch, with each fiber terminated by a lens for collimating incident light emitted from an input optical fiber. At least one transparent dielectric plate, with a uniform refractive index, is disposed between lenses associated with the input and the output sides of the switch. The transparent plate changes the optical transmission path of the collimated light beam when present in a light transmission path. When the transparent dielectric plate is driven into the light transmission path, the optical axis is switched from one to a different output optical fiber.
Mechanical optical switching devices are disclosed in U.S. Pat. No. 4,322,126 to Minowa et al. There, a mechanical optical switching device has a plurality of input optical fibers coupled to the input side thereof for receiving incoming light beam signals. Individually associated with each optical fiber is an input collimating lens which is positioned to receive the incoming light beam and to convert it into parallel light beams. Optical path-switching means, having uniform refractive index, are disposed at the rear or output of the input lens for switching the optical paths of the collimated light beams emerging from the input lens beam. A plurality of output optical fibers have individually associated output lenses for focusing the parallel light beams, after they have passed through the position controlled by the optical path-switching means. An electrically controlled, mechanical switching device selectively inserts or removes the optical path-switching means into or away from a predetermined position in order to switch light from any incoming fiber to any outgoing fiber.
U.S. patent application Ser. No. 129,502, filed Dec. 7, 1987, entitled "Fiber Optical Switch", (U.S. Pat. No. 4,790,621) assigned to GTE Products Corporation, discloses a 2×2 optical switch which employs a six-faced prism that can be moved from a first position to a second position. Mechanical latching means were used to maintain the second position without the necessity of applying continuous power to the moving means which preferably is a solenoid.
SUMMARY OF THE INVENTION
Another object of the invention is to provide a new and improved fiber array optical switch in which switching time and power dissipation is minimal.
Still another object of the invention is to provide a new and improved movable fiber array optical switch in which fewer fiber segments (than the prior art) need to be aligned and mated, thus reducing overall device insertion loss.
In accordance with one aspect of the invention, a fully-reversing 2×2 electromechanical optical switch apparatus, having input optical signals that are carried on input optical fibers, selectively transmits to output optical fibers. The optical switch apparatus includes a pair of bases, two pairs of optical fibers, and two fiber segments. The first base has a planar surface having a pair of continuous parallel V-grooves formed therein. The V-grooves have a fixed depth and are spaced apart a fixed distance terminating at a linear side of the planar surface. The surface further has a discontinuous semicircular V-groove having a pair of ends terminating at a linear side of the planar surface. The pair of ends are spaced apart the fixed distance. The discontinuous V-groove, at the pair of ends, has a depth equal to the fixed depth. The semicircular V-groove encroaches on one of the continuous parallel V-grooves but is discontinuous thereat. One of the ends is located a short distance from one of the parallel V-grooves. The second base has a planar surface terminating at a linear side thereof. The second base is movable with respect to the first base, with the two sides being in abutting but sliding relationship along a linear direction along the sides. A pair of continuous parallel V-grooves, having a fixed depth corresponding to the first base fixed depth and being spaced apart a fixed distance corresponding to the first base fixed distance, is formed in the surface of the second base, terminating at a linear side thereof. The surface of the second base has a discontinuous semicircular V-groove formed therein having a pair of ends terminating at the foregoing linear side thereof. The latter pair of ends is spaced apart the fixed distance. The second base discontinuous semicircular V-groove, at the second base pair of ends, has a depth equal to the fixed depth. The second base semicircular V-groove encroaches on one of the second base continuous parallel V-grooves, but is discontinuous thereat. One end of the second base discontinuous semicircular V-groove is located a short distance from one of the second base parallel V-grooves. One of the pairs of optical fibers is cemented in place in the parallel V-grooves of the first base, the fibers having end faces thereof terminating at the linear side of the first base. A first fiber segment is coupled to the discontinuous semicircular V-groove of the first base, with end faces of the segment terminating at the linear side. The first fiber segment is cemented to rest within the discontinuous semicircular V-groove at its linear side. The second pair of optical fibers is cemented in place in the parallel V-grooves of the second base having end faces thereof terminating at the linear side of the second base. A second fiber segment is coupled to the discontinuous semicircular V-groove of the second base, with end faces of the second segment terminating at the linear side of the second base. The second fiber segment is cemented to rest within the discontinuous semicircular V-groove at the latter linear side.
In accordance with certain features of the invention, the fiber end faces lie in parallel planes. The apparatus can further include means for limiting movement of the second base with respect to the first base and means for moving the second base with respect to the first base.
In accordance with another aspect of the invention, a fully-reversing 2×2 electromechanical optical switch apparatus, having input optical signals that are carried on input optical fibers, selectively transmits to output optical fibers. The apparatus includes a base, two pairs of optical fibers, a V-block, a third pair of optical fibers, and two fiber segments. The base has a planar surface having a first V-groove formed therein. The surface has a pair of parallel V-grooves formed therein at an angle with the first V-groove. The parallel V-grooves have a depth less than that of the first V-groove, whereby the first V-groove interrupts the pair of parallel V-grooves and the parallel V-grooves intersect the first V-groove at both sides thereof. The first pair of optical fibers reside within the pair of parallel V-grooves that are wholly at one of the sides of the first V-groove. The first pair of optical fibers have fiber end faces that lie in a first common plane. The second pair of optical fibers reside within the pair of parallel V-grooves oriented wholly at the other of the sides of the first V-groove. The second pair of optical fibers have fiber end faces lying in a second common plane. The V-block is adapted for reciprocating movement from one position to another, linearly within the first V-groove. The V-block has a pair of parallel V-grooves formed therein at an angle with the first V-groove and spaced apart at a fixed distance, whereby when the V-block is at the one linear position within the first V-groove, the pairs of parallel V-grooves in the V-block and on the surface are co-aligned. The V-block has a first side in slidable engagement with the one side of the first V-groove and has a second side in slidable engagement with the other side of the first V-groove. The V-block has a first discontinuous semicircular V-groove which has a pair of ends terminating at the first side. The pair of ends of the first discontinuous semicircular V-groove has a depth equal to the depth of the parallel V-grooves. The semicircular V-groove encroaches one of the parallel V-grooves of the V-block but is discontinuous thereat. One of the ends of the first V-groove is located a short distance from one of the parallel V-grooves. A second discontinuous semicircular V-groove has a pair of ends terminating at the second side. The pair of ends of the second discontinuous semicircular V-groove are spaced apart the fixed distance. The second discontinuous semicircular V-groove at the second side has a depth equal to that of the fixed depth. The second semicircular V-groove encroaches one of the parallel V-grooves of the V-block, but is discontinuous thereat. One of the second discontinuous semicircular V-groove ends is located the short distance from one of the V-block parallel grooves. The third pair of optical fibers reside within the pair of parallel V-grooves that are formed in the V-block. The third pair of optical fibers have a first set of fiber end faces lying in a third common plane. The third plane is in close proximity to the first plane. The third pair of optical fibers have a second set of fiber end faces lying in a fourth common plane. The fourth plane is in close proximity to the second plane. A first fiber segment is coupled to the first discontinuous semicircular V-groove of the first V-block with ends of the segment terminating at the first side. The first fiber segment is cemented to rest within the first discontinuous semicircular V-groove at the first side and to overlap one of the third pair of optical fibers. A second fiber segment is coupled to the second discontinuous semicircular V-groove at the first V-block with ends of the second fiber segment terminating at the second side. The second fiber segment is cemented to rest within the second discontinuous semicircular V-groove at the second side, and to overlap that one of the third pair of optical fibers. The first segment has fiber end faces lying in a third common plane, and the second segment has fiber end faces lying in a fourth common plane.
In accordance with certain features of the invention, the angle of the parallel V-grooves formed in the base with the first V-groove and the angle of the parallel V-grooves formed in the V-block with the first V-groove are identical. The angle can be 90°. The fiber end faces can lie in parallel planes. The apparatus can further include means for limiting movement of the V-block with respect to the base and means for moving the V-block with respect to the base.
In accordance with still another embodiment of the invention, a fully-reversing 2×2 electromechanical optical switch apparatus, having input optical signals that are carried on input optical fibers, selectively transmits to output optical fibers. The apparatus includes a base, several pairs of optical fibers, a V-block, and four fiber segments. The base has a planar surface with a V-groove formed therein. The surface has a first pair of non-parallel V-grooves formed therein at one side of the first V-groove and converging thereat. The surface has a second pair of non-parallel V-grooves formed therein at the other side of the first V-groove converging thereat. The non-parallel V-grooves chimerically intersect at the first V-groove. The non-parallel V-grooves have a depth less than that of the first V-groove, whereby the first V-groove interrupts the pairs of non-parallel V-grooves and the non-parallel V-grooves intersect the first V-groove at both sides thereof. A first pair of optical fibers reside within the first pair of non-parallel V-grooves, wholly at one side of the first V-groove. The first pair of optical fibers have fiber end faces lying in a first common plane. A second pair of optical fibers reside within the second pair of non-parallel V-grooves wholly at the other side of the first V-groove The second pair of optical fibers have fiber end faces lying in a second common plane. The V-block is adapted for reciprocating movement from one position to another, linearly within the first V-groove. The V-block has opposing sides. The V-block has a straight V-groove,a first discontinuous V-groove, and a curved discontinuous V-groove. The straight V-groove is formed in the V-block from one of the opposing sides continuously to an opposite one of the opposing sides so aligned, when the V-block is in one position, with one of the first pair of non-parallel V-grooves and one of the second pair of non-parallel V-grooves. The first discontinuous V-groove is formed in the V-block and has a pair of ends terminating at the opposing sides thereof. The discontinuous V-groove at the pair of ends has a depth equal to the fixed depth. The discontinuous V-groove encroaches the continuous V-groove of the V-block but is discontinuous thereat. The discontinuous V-groove is so aligned, when the V-block is in the one position, with the other of the first pair of non-parallel V-grooves and the other of the second pair of non-parallel V-grooves. The curved discontinuous V-groove is formed in the V-block and has a pair of ends terminating at the opposing sides. The curved discontinuous V-groove at the pair of ends has a depth equal to the fixed depth. The curved discontinuous V-groove is discontinuous between the pair of ends thereof. The curved continuous V-groove that is formed in the V-block has a pair of ends that are terminated at the opposing sides of the V-block. The curved continuous V-groove has a depth equal to the fixed depth. The curved continuous V-groove is oriented, when the V-block is in the switched position, with the aforesaid one of the V-grooves of the first pair and the other of the V-grooves of the second pair. The curved discontinuous V-groove is oriented, when the V-block is in the switched position, with the other of the V-grooves of the first pair and the one of the V-grooves of the second pair. A first fiber segment resides in the straight continuous V-groove of the V-block having a first end at the one of the opposing sides and having a second end at the other opposing side. The second fiber segment is coupled to the first discontinuous V-groove of the V-block having a first end thereof at the one of the opposing sides, and having a second end thereof at the other opposing side. A mid-portion of the second fiber segment overlaps the first fiber segment. The third fiber segment is coupled to the curved discontinuous V-groove having a first end thereof at one of the opposing sides, and having a second end thereof at the other opposing side. A mid-portion of the third fiber segment overlaps both the first fiber segment and the second fiber segment. The fourth fiber segment resides in the curved continuous V-groove of the V-block and has a first end at one of the opposing sides and has a second end at the other opposing side. The fiber segments, at their first ends, have fiber end faces that lie in a third common plane. The third common plane is in close proximity to, and parallel with, the first common plane. The fiber segments, at their second ends have fiber end faces that lie in a fourth common plane. The fourth common plane is in close proximity to, and parallel with, the second common plane.
In accordance with certain features of the invention, the fiber end faces lie in parallel planes. The apparatus can further include means for limiting movement of the V-block with respect to the base and means for moving the V-block with respect to the base.
In accordance with still another aspect of the invention, a fully-reversing 2×2 electromechanical optical switch apparatus, in which input optical signals carried on input optical fibers 150 and 250 are selectively transmitted to output optical fibers 151 and 251 or to the optical fibers 251 and 151, respectively, is set forth. Such a switch apparatus includes a pair of bases, each base having a planar surface and a respective linear side thereto. The planar surface of the first base has two pairs of continuous parallel V-grooves formed therein parallel to each other. The first pair of continuous parallel V-grooves have a fixed depth and are spaced apart a fixed distance, terminating at the linear side of the first base. The second pair of continuous parallel V-grooves have a depth equal to the fixed depth, and are spaced apart the fixed distance, terminating at its linear side. One of the second pair of V-grooves is located a short distance from one of the first pair of V-grooves. The second base is movable with respect to the first base, with both of the sides being in abutting but sliding relationship along a linear direction along the sides. The second base has a first pair of continuous parallel V-grooves having a fixed depth corresponding to the first base fixed depth, being spaced apart a fixed distance corresponding to the first base fixed distance. The first pair of V-grooves of the second base terminate at its linear side. A second pair of continuous parallel V-grooves, having a fixed depth corresponding to the first base fixed depth, are spaced apart the fixed distance and terminate at the linear side of the second base. One of the second pair of V-grooves of the second base is located the short distance from one of the first pair of V-grooves of the second base. A first pair of optical fibers 150, 251 are cemented in place in the first pair of parallel V-grooves of the first base, their end faces terminating at the first linear side of the first base. One fiber segment is coupled to the second pair of parallel V-grooves of the first base, with end faces thereof terminating at the first linear side of the first base. The first fiber segment are cemented to the second pair of V-grooves of the first base to have end portions of the segment rest therewithin, with a mid, bight portion of the segment lying outside of the first base. A second pair of optical fibers 151, 250 are cemented in place in the first pair of parallel V-grooves of the second base, their end faces being terminated at the linear side of the second base. A second fiber segment is coupled to the second pair of parallel V-grooves of the second base, end faces of the second segment terminating at the linear side of the second base. The second fiber segment is cemented to the second pair of V-grooves of the second base, end portions of the second segment resting therewithin, with a mid, bight portion extending outside the second base.
In accordance with certain features, the fiber end faces lie in parallel planes. The apparatus can include means for limiting movement of the second base with respect to the first base, and means for moving the second base with respect to the first base. The apparatus can further include housing means for enclosing the two bases, the fiber segments, and the means for limiting movement.
BRIEF DESCRIPTION OF THE DRAWING
Other objects, advantages, and features of this invention, together with its construction and mode of operation, will become more apparent from the following description, when read in conjunction with the accompany drawing, in which:
FIG. 1A is a perspective view of one embodiment of the invention depicting the optical switch in a through position;
FIG. 1B is a perspective view of the embodiment depicted in FIG. 1A showing the optical switch in a switched position;
FIG. 1C is a top view of the embodiment depicted in FIG. 1A showing the optical switch in the normal through position, and further depicting means for positioning elements of invention;
FIG. 1D is a top view of the embodiment depicted in FIG 1A showing the optical switch in the bypassed, switched position, and further depicting the means for positioning elements of the invention;
FIG. 2A is a perspective view of another embodiment of the invention showing an optical switch in a through position;
FIG. 2B is a perspective view of the embodiment depicted in FIG. 2A showing the switch in a switched position;
FIG. 3A is a perspective view of still another embodiment of the invention showing the switch in a through position;
FIG. 3B is a perspective view of the device depicted in FIG. 3A showing the switch in a switched position; and
FIG. 4 is a top view of a preferred embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1A and 1B, there is shown, respectively, the normal through position and the bypassed switched position of a fully-reversing 2×2 electromechanical optical switch apparatus 11. As shown, the apparatus 11 includes a first base 12 and a second base 22. The bases 12, 22 have planar surfaces 13, 23, respectively, and have abutting linear sides 14, 24, respectively (see FIG. lB). A pair of continuous parallel V-grooves 16, 16, having a fixed depth and spaced apart a fixed distance, are formed in the planar surface 13 of the first base 12. Similarly, the planar surface 23 of the base 22 has a pair of continuous parallel V-grooves 26, 26 formed therein with a depth corresponding to the depth of the grooves 16, 16 and spaced apart the same distance.
A discontinuous semicircular V-groove 17 is formed on the planar surface 13 of the base 12 having a fixed depth at the end thereof at the linear side 14 and spaced apart the aforesaid fixed distance. In a similar fashion, a discontinuous semicircular V-groove 27 is formed in the planar surface 23 of the second base 22. The discontinuous V-groove 27 has a pair of ends at the linear side 24 of the second base 22 having a corresponding fixed depth and having their ends spaced apart the fixed distance.
A pair of optical fibers 100, 201 are cemented in place in the V-grooves 16, 16 of the first base 12. The fibers 100, 201 are of such diameter as to be comfortably positioned within the V-grooves 16, 16. Preferably, their diameters are such that the fibers do not raise substantially above the surface 13 of the base 12. This particular configuration is not critical as it would vary with the angle of the V-groove.
In a similar fashion, the base 22 has a pair of optical fibers 101, 200 cemented in place in the V-grooves 26, 26. Thus, when the base 22 is in the through position with relationship to the base 12 (FIG. 1A), end faces of the fibers 101 and 200 meet face to face with end faces of the fibers 100 and 201.
A fiber segment 31 is mounted in the discontinuous semicircular V-groove 17 in such a fashion that its end faces 32, 32 are planar with the linear side 14. The fiber segment 31, while resting in the discontinuous V-groove, overlaps the fiber 100, thus not directly intersecting therewith.
Similarly, the second base 22 has a fiber segment 41 whose end faces are planar with the linear side 24. The fiber segment 41 rests within the discontinuous V-groove 27 and overlaps the optical fiber 200.
Thus, as described hereinabove, as viewed in FIG. 1A, a signal sent on optical fiber 100 can be transmitted directly to optical fiber 101 and vice versa. Likewise, an optical signal transmitted on an optical fiber 201 can be transmitted to optical fiber 200 and vice versa.
Via means (see Figs 1C and 1D) for moving the base 22 with respect to the base 12 in a direction parallel to their linear sides 14, 24, the switch can be thrown to the switched position as indicated in FIG. 1B. As shown therein, a signal transmitted along the optical fiber 100 passes through the fiber segment 41 on the base 22 and is transmitted along the fiber 201 on the base 12. Alternatively (or simultaneously), a signal can be sent in the opposite direction, from the fiber 201 through the fiber segment 41 and back to the optical fiber 100. Likewise, the optical fiber 101 is coupled to the optical fiber 200 by means of the fiber segment 31, and a signal can be sent in either direction.
Thus, in operation, signals can be transmitted from fibers 100 and 201 to and from the optical fibers 101 and 200, in either direction. When desired, the switch apparatus 11 can be actuated so that the switched position (as indicated in FIG. 1B) occurs in which a signal on the fiber 100 is switched from the fiber 101 to the fiber 201, and whereby a signal on the fiber 200 is switched from the fiber 201 to the fiber 101.
FIGS. 1A and 1B, as indicated earlier, depict perspective views of one embodiment of the invention that show the optical switch 11 in the through position and in the switched position, respectfully. Means for limiting movement of one base with respect to the other base is not shown for simplicity of illustration. Likewise, means for moving one base with respect to the other base is not shown for simplicity of illustration.
In order to further clarity and illustrate the embodiment of the invention, reference is made to FIGS. 1C and 1D which conform to FIGS. 1A and 1B. FIGS. 1C and 1D are top views of the embodiment shown in FIGS. 1A and 1B, with the addition of the limiting means and moving means.
The moving "S" optical fiber switch 11 is retained within a housing or positioning frame 121. A solenoid 122 (or other means of translation), coupled to the frame 121 or to a reference return block, when excited, causes a solenoid plunger 123 to impact upon the base 22, positioning it against an adjustable block stop 124 held by the housing 121.
When the solenoid 122 is unexcited, the plunger 123 retracts, withdrawing the base 22 to the normal position shown in FIG. 1C.
The foregoing explanation is not intended to limit the means for movement of one base with respect to the other base, nor is it intended to limit the means for moving one base with respect to the other base. The foregoing illustrates one of many possibilities.
For ease of comprehension and simplicity of description, the embodiments shown in FIGS. 2A, 2B, 3A, 3B, and 4 and explanation referring thereto do not depict the moving means or movement limiting means, in order that the pertinent aspects of the invention be better understood. Such means, or equivalents, can be used.
Another embodiment of the invention is depicted in FIGS. 2A and 2B showing, respectively, the through position and the switched position of a moving "S" fiber array optical switch with V-block. A fully-reversing 2×2 electromechanical optical switch apparatus 51 is depicted in FIGS. 2A and 2B wherein input optical signals carried on input optical fibers 300 and 400 can be selectively transmitted to output optical fibers 301 and 401 or to the optical fibers 401 and 301, respectively. The apparatus includes a base 52 which has a planar surface 53. The planar surface 53 has a first V-groove 54 formed therein. The surface 53 has a pair of parallel V-grooves 56, 56 that are formed therein at an angle with the first V-groove 54. The parallel V-grooves 56, 56 have a depth less than that of the first V-groove 54 whereby the first V-groove 54 interrupts the pair of parallel V-grooves 56, 56. The parallel V-grooves 56, 56 intersect the first V-groove 54 at both sides thereof.
A first pair of optical fibers 300, 401 reside within the pair of parallel V-grooves 56, 56 formed in the surface 53 wholly at one side 57 of the first V-groove 54. The first pair of optical fibers 300, 401 have fiber end faces lying in a first common plane.
A second pair of optical fibers 301, 400 reside within the pair of parallel V-grooves 56, 56 formed in the surface 53 wholly at the other side 58 of the first V-groove 54. The second pair of optical fibers 301, 400 have fiber end faces that lie in the second common plane.
A V-block 59, formed to fit within the first V-groove 54, is adapted for reciprocating movement from one position to another linearly within the first V-groove 54. The V-block 59 has a pair of parallel V-grooves 61, 62 that are formed therein at an angle with the first V-groove 54. The parallel V-grooves 61, 62 are spaced apart a fixed distance whereby, when the V-block 59 is at the one linear position within the first V-groove 54, the pairs of parallel V-grooves 61, 62 and 56, 56 are co-aligned. The V-block 59 has a first side 63 in slidable engagement with the one side 57 of the first V-groove 54 and has a second side 64 in slidable engagement with the other side 58 of the V-groove 54.
The V-block 59 has a first discontinuous semicircular V-groove 66 formed therein having a pair of ends at the first side 63. The pair of ends of the first discontinuous semicircular V-groove 66 have a depth equal to the depth of the parallel V-grooves 56, 56. The semicircular V-groove 66 encroaches upon one of the parallel V-grooves 56 of the V-block 59 but is discontinuous thereat.
A second discontinuous semicircular V-groove 67 has a pair of ends that terminate at the second side 64 of the V-block 59. The pair of ends of the second discontinuous semicircular V-groove 67 are spaced apart a fixed distance. The second discontinuous semicircular V-groove 67, at the side 64, has a depth equal to the fixed depth. The second semicircular V-groove 67 encroaches upon one of the parallel V-grooves 56 of the V-block 59 but is discontinuous thereat. One end of the second discontinuous semicircular V-grooves 67 is located the short distance from one of the V-block parallel grooves 61, 62.
A third pair of optical fibers 302, 402 reside within the pair of parallel V-grooves 61, 62 formed in the V-block 59. The third pair of optical fibers 302, 402 have a first set of fiber end faces that lie in a third common plane. The third common plane is in close proximity to the first plane. The third pair of optical fibers 302, 402 further have a second set of fiber end faces that lie in a fourth common plane. The fourth plane is in close proximity to the second plane.
A first fiber segment 69 is coupled to the first discontinuous semicircular V-groove 66 of the V-block 59. Ends of the first fiber segment 69 terminate at the first side 63 of the V-block 59. The first fiber segment 69 is cemented to rest within the first discontinuous semicircular V-groove 66 at the first side 63 of the V-block 59 and to overlap one 402 of the third pair of optical fibers 302, 402.
A second fiber segment 71, in similar fashion, is coupled to the second discontinuous semicircular V-groove 67 of the V-block 59. Ends of the second fiber segment 71 terminate at the second side 64 of the V-block 59. The second fiber segment 71 is cemented to rest within the second discontinuous semicircular V-groove 67 at the second side 64 of the V-block 59. The second fiber segment 71 overlaps the one 402 of the third pair of optical fibers. The first segment 69 has fiber end faces that lie in the third common plane. The second segment 71 has fiber end faces that lie in the fourth common plane.
As indicated above, the angle of the parallel V-grooves 56, 56 formed in the base with the first V-groove 54 and the angle of the parallel V-grooves formed in the V-block 59 with the V-groove 54 should be identical. Desirably, the angle is perpendicular or 90°. Preferably, the fiber end faces all lie in parallel planes.
FIG. 3 depicts still another embodiment of the invention showing a moving arc fiber array optical switch. As shown therein, it includes a fully reversing 2×2 electromechanical optical switch apparatus 81 in which input optical signals that are carried on input optical fibers 500 and 600 can be selectively transmitted to output optical fibers 501 and 601 or to the output optical fibers 601 and 501, respectively. The apparatus 81 includes a base 82 which has a planar surface 83. The planar surface 83 has a first V-groove 84 formed therein. The surface 83 has a first pair of non-parallel V-grooves 86, 87 that are formed therein at one side 88 of the V-groove 84, with the non-parallel V-grooves 86, 87 converging thereat. The surface 83 has a second pair of non-parallel V-grooves 89, 91 formed therewithin at the other side 92 of the first V-groove 84 with those non-parallel V-grooves 89, 91 converging thereat. The non-parallel V-grooves 86, 87 and 89, 91 chimerically intersect at the first V-groove 84. The non-parallel V-grooves 86, 87, 89, 91 have depths not exceeding that of the first V-groove 84 whereby the first V-groove 84 interrupts the pairs 86, 87 and 89, 91 of the non-parallel V-grooves. The non-parallel V-grooves 86, 87 and 89, 91 intersect the first V-groove 84 at both sides 88, 92 thereof.
A first pair of optical fibers 500 and 600 reside within the first pair of non-parallel V-grooves 86, 87 wholly at one side 88 of the first V-groove 84. The first pair of optical fibers 500, 600 have fiber end faces that lie in the first common plane. A second pair of optical fibers 601, 501 reside within the second pair of non-parallel V-grooves 89, 91 wholly at the other side 92 of the first V-groove 84. The second pair of optical fibers 601, 501 at the side 92 of the V-groove 84 have fiber end faces that lie in the second common plane.
A V-block 93, adapted for reciprocating movement from one position to another linearly within the first V-groove 84, has opposing sides and has a straight V-groove 94 formed therein from one of the opposing sides continuously to the opposite opposing side such that, upon alignment, the V-block 93 is in the one (through) position with one of the first pair of non-parallel V-grooves 87 and one of the second pair of non-parallel V-grooves 89.
A first discontinuous V-groove 96 is formed in the V-block 93 having a pair of ends that terminate at the opposite sides of the V-block 93. The discontinuous V-groove 96, at the pair of ends, have a depth equal to the fixed depth. The discontinuous V-groove 96 encroaches upon the continuous V-groove 94 of the V-block 93 but is discontinuous thereat. The discontinuous V-groove 96 is aligned, when the V-block 93 is in the one position, with the other 86 of the first pair of non-parallel V-grooves 86, 87 and the other 91 of the second pair of the non-parallel V-grooves 89, 91.
A curved discontinuous V-groove 97 is formed in the V-block 93 with a pair of ends that terminate at opposing sides of the V-block 93. The curved discontinuous V-groove 97 at the pair of ends have a depth equal to the fixed depth. The curved discontinuous V-groove 97 is discontinuous between the pair of ends thereof.
A curved continuous V-groove 98 is formed on the surface of the V-block 93, having a pair of ends that terminate at the opposing sides of the V-block 93. The curved continuous V-groove 98 has a depth equal to the fixed depth, oriented, when the V-block 93 is in a switched position, with one of the V-grooves 87 of the first pair 86, 87 and the other 91 of the V-grooves of the second pair 89, 91.
The curved discontinuous V-groove 97 is oriented with the other V-groove 86 of the first pair 86, 87 and the one V-groove 89 of the second pair 89, 91.
A first fiber segment 551 resides in the straight continuous V-groove 94 of the V-block 93, and has an end at each of the opposing sides of the V-block 93.
A second fiber segment 552 is coupled to the first discontinuous V-groove 96. The second fiber segment 552 has a first end thereof at one of the opposing sides of the V-block 93, has another end thereof at the other opposing side of the V-block 93, and has a mid-portion thereof that overlaps the first fiber segment 551.
A third fiber segment 553 is coupled to the curved discontinuous V-groove 97 with its first end at one of the opposing sides of the V-block 93 and a second end thereof at the other opposing side of the V-block 93. A mid-portion of the third fiber segment 553 overlaps both the first and the second fiber segments 551, 552.
A fourth fiber segment 554 resides in the curved continuous V-groove 98 of the V-block 93, has a first end at one of the opposing sides of the V-block 93 and has a second end at the other opposing side thereof. The fiber segments 551, 552, 553, 554 at the first ends have fiber end faces that lie in a third common plane that is in close proximity to and is parallel with the first common plane. The fiber segments 551, 552, 553, 554 at their second ends have fiber end faces that lie in a fourth common plane that is in close proximity to and is parallel with the first common plane.
Desirably, all fiber end faces associated with this apparatus lie in parallel planes. Means are provided for limiting movement of the V-block 93 with respect to the base 82, and means are provided for moving the V-block 93 with respect to the base 82.
Referring again to the drawing, it is noted that with the switch apparatus 81 placed in a through position, as depicted in FIG. 3A, a signal on the input fiber 500 is transmitted directly to the output fiber 501, whereas the signal on the input fiber 600 is transmitted directly to the output fiber 601 (the signals can be transmitted in the opposite direction). When the switch apparatus 81 is actuated so that it is in the switched position as depicted in FIG. 3B, a signal on the input fiber 500 is transmitted to the output fiber 601, whereas a signal on the input fiber 600 is transmitted to the output fiber 501 (again, signals can be transmitted in the opposite direction, if desired).
FIG. 4 depicts yet another embodiment of the invention, which is believed to be the best mode contemplated by the inventors for its practice. The embodiment depicted therein illustrates, in a top view, a fully-reversing 2×2 electromechanical optical switch apparatus 401 in which input optical signals carried on input optical fibers 150 and 250 can be selectively transmitted to output optical fibers 151 and 251 or to the output optical fibers 251 and 151, respectively. The apparatus 401 includes a first base 402 having a planar surface 403 that terminates at a first linear side 404 thereof. The planar surface 403 of the base 402 has a first pair of continuous parallel V-grooves 406, 407 formed therein having a fixed depth and being spaced apart a fixed distance so as to terminate at the linear side 404 of the base 402.
A second pair of continuous parallel V-grooves 408, 409 have a depth equal to the fixed depth. The second pair of V-grooves 408, 409 (parallel to the first pair 406, 407) are spaced apart the fixed distance and are terminated at the linear side 404 of the first base 402. One 408 of the second pair of V-grooves 408, 409 is located a short distance from one 406 of the first pair of continuous parallel V-grooves 406, 407. The second base 411 of the apparatus 401 has a planar surface 412 that terminates at a linear side 413 of the second base 411. The second base 411 is movable with respect to the first base 402 along a direction parallel with both of the sides 404, 413. The surface 412 of the second base 411 has two pair of parallel V-grooves formed therein.
A pair of optical fibers 150, 251 are cemented in place in the first pair of parallel V-grooves 406, 407 of the first base 402 and have their end faces terminating at the first linear side 404 thereof.
A first fiber segment 421 is coupled to the second pair of parallel V-grooves 408, 409 of the first base 402 with end faces of the segment 421 terminating at the first linear side 404. The first fiber segment 421 is cemented to the second pair of V-grooves 408 and 409 of the first base 402 to have end portions thereof rest therewithin with a mid-bight portion of the fiber segment 421 lying without the first base 402.
A second pair of optical fibers 151 and 250 are cemented in place in the first pair of parallel V-grooves 414, 416 of the second base 411 having their end faces terminating at the linear side 413 of the second base 411.
A second fiber segment 422 is coupled to the second pair of parallel V-grooves 418, 419 of second base 411 with end faces thereof terminating at the linear side 413 of the second base 411. The second fiber segment 422 is cemented to the second pair of V-grooves 418, 419 of the second base 411 to have their end portions rest therewithin with a mid-bight portion of the second fiber segment 422 lying without the second base 411.
In preferred embodiments, the fiber end faces lie in parallel planes. The apparatus can further include means for limiting movement of the second base 411 with respect to the first base 402.
Desirably, the overall apparatus 401 is housed within a suitable housing means 423 for enclosing the first base 402, the second base 411, the first fiber segment 421, the second fiber segment 422 and the means for limiting movement.
The housing 423 serves a desired purpose of protecting loose fibers, protection against dirt, and protection from the environment. The embodiment depicted in FIG. 4 is preferred as it is believed to be relatively easy to manufacture. Hence, it should be apparent to those skilled in the art that various modifications can be performed without departing from the spirit and scope of the invention.
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A fully-reversing 2×2 electromechanical optical switch apparatus is set forth. Input optical signals, carried on input optical fibers, are selectively transmitted to output optical fibers in a binary relationship. The invention utilizes a pair of supports which reciprocate with respect to one another, in which one or more of the supports carry one or more loops of optical fiber for switching the path of optical data carried on a fiber.
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This Application is a continuation-in-part of U.S. application Ser. No. 11/050,976 of RICHARD COPPOLA filed Feb. 4, 2005 for TELESCOPING UNDERWATER GUIDE, the contents of which are herein incorporated by reference. U.S. application Ser. No. 11/050,976 claims the benefit of U.S. Application Ser. No. 60/547,442 of RICHARD COPPOLA filed Feb. 26, 2004 for TELESCOPING UNDERWATER GUIDE.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an independently segmental, multi-segmental, and sectional telescoping device for guiding elongated rigid and flexible objects such as directional, variable angle drill, bore and such machine and other stems, rods, piping, tubing, hoses, cables, lines and other similar elongated structures through atmospheric, vacuum, partial vacuum, semi-submerged, and completely submerged underwater environments operating through the atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials and without environmental impact.
More specifically, it relates to a means for guiding directional, variable angle drill, bore, and such machine, equipment and rigid and flexible material stems, rods, piping, tubing, hoses, cables, lines and other similar structures underwater through varying water column depths at variable longitudinal lengths and angles by creating an infinitely adjustable independently segmented and telescoping, dynamic and lockable telescoping guide segments thereby infinitely adjusting in static, dynamic and hybrid functions to the distance between fixed, variable elevation, floating, or submerged work surfaces, and surface machinery, equipment and materials and the waterway bottom and other materials. Its installation and operational length and operational angle is infinitely adjustable. Its optionally incorporated integrated floatation and buoyancy in water is infinitely adjustable per segment or over its entire length. Its structural width is adjustable per segment or over its entire length thereby permitting the handling and installation of various dimension drill, bore, machine, stems, rods, piping, tubing, hoses, cables, lines and other similar structures in semi-submerged and submerged underwater applications into and through waterway bottom and other materials without environmental impact.
2. Description of Related Art
Variable angle bore, drill stems and other type pipe, rod and elongated objects are limited and prevented from penetration and installation through the atmosphere, vacuum, fluid, and water columns into and through waterway and other bottom materials due to absence of a segmented and telescoping underwater guide providing infinitely adjustable dynamic and static longitudinal adjustment functions and operation while providing variable structural width and lateral support for bore, drills, stems rods, piping, tubing, hoses, cables, lines and other elongated objects and similar structures in semi-submerged and submerged underwater applications and absence of adjustability to accommodate varying water column depths between the water surface and waterway bottom and other material elevation(s), as well as other clear dimensional applications and absence of the ability to sectionally and telescopically adjust the guide length statically, dynamically and in hybrid mode in single, and multi-sectional length, sectional width, and its angle to the waterway bed and other material elevations and absence of a system and method of handling and installing various dimension drill, bore, machine, stems, rods, piping, tubing, hoses, cables, lines and other similar structures in semi-submerged and submerged underwater applications while eliminating environmental impact. For these reasons, there is a need in the art for a new system to permit penetrations through varying water column depths, into and through waterway bed and other materials at various angles in atmospheric, submerged, semi-submerged and other applications which overcomes the above disadvantages and limitations described.
SUMMARY OF THE INVENTION
According to an aspect of the present invention, there is a method for drilling in an environment having a fluid and a bed. The method comprises positioning a platform such that the fluid is between the platform and the bed; assembling a guide, the assembled guide being straight; placing the guide such that the guide is supported by the platform, and a major length of the guide and a normal to the bed defines an angle, the angle being greater than 0; and sending a variable angle drill inside the guide, from the platform into the bed.
According to another aspect of the present invention, there is a method for drilling in an environment having a fluid and a bed. The method comprises positioning a support such that the fluid is between the support and the bed; assembling a guide, the assembled guide being straight; placing the guide such that the guide is supported by the support, and a major length of the guide and a normal to the bed defines an angle; changing the angle; and sending a variable angle drill inside the guide, from the support into the bed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general illustration matrix of the rigid segment, and telescoping underwater guide segment assembly.
FIG. 2 is a general illustration matrix of different length rigid guide segment.
FIG. 3 is a detailed plan view (lower left) and elevation view (upper view) of the optionally used binding block.
FIG. 4 is a general illustration matrix of the telescoping guide segments.
FIG. 5 is a general illustration matrix of the telescoping guide segments.
FIG. 6 is a general illustration matrix of the telescoping guide segments.
FIG. 7 is a general illustration matrix of the telescoping guide segments.
FIG. 8 is a profile view of a variant work surface.
FIG. 9 is a profile view of a variant work surface.
FIG. 10 is a profile view of a variant work surface.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
In the absence of prior art and in order to eliminate prior restrictions and limitations, the exemplary embodiment has been devised for guiding, orienting, directing and installing elongated structures such as directional and variable angle machine, bore, drill, equipment, materials, stems, rods, piping, tubing, hoses, cables, lines and other elongated structures being not submerged, semi-submerged and/or fully submerged underwater and through varying air and water column distances in atmospheric, vacuum, partial vacuum, lakes, streams, rivers, coastal waters, oceans and through waterway bottom and other materials. The exemplary embodiment has been devised as a means for inserting, guiding and installing directional, variable angle drill, bore, and such machine, equipment and material stems, rods, piping, tubing, hoses, cables, lines and other elongated structures at variable angles by creating a segmented, incremental, infinitely adjustable and telescoping, lockable, static, and telescoping guide being infinitely adjustable in static, dynamic and hybrid states in length, dimension, and angle between stationary, fixed, moving, variable elevation, floating work surfaces, machinery, equipment, materials to and through waterway and marine bottom and other materials. Its longitudinal length and operational angle is infinitely adjustable. Its optionally attached integrated floatation and buoyancy vessels are either segmentally fixed or infinitely adjustable per segment and over the guide assembly's entire length. Its structural width is adjustable per segment or over its entire length thereby permitting the handling and installation of various dimension drill, bore, machine, stems, rods, piping, tubing, hoses, cables, lines and other similar elongated structures being not submerged, semi-submerged and/or fully submerged underwater and through varying air and water column distances in atmospheric, vacuum, partial vacuum, lakes, streams, rivers, coastal waters, oceans and through waterway bottom and other materials without environmental impact.
FIG. 1 is a general illustration matrix of the rigid segment, and telescoping underwater guide segment assembly. One or more segments may be used as shown. FIG. 1 includes three profile views of two rigid guide segments coupled together in three different configurations thereby providing structural and lateral support for the elongated objects placed within the guide to be installed, and if desired, the inner-friction/spacer sleeve ( 5 ). The illustration to the left shows one rigid guide segment ( 1 ) and one telescoping guide segment ( 1 , 2 ) comprised of one rigid guide segment and a telescoping element ( 2 ) slidable with infinite adjustment, incremented, or selected locking points. Also shown is an angled, flare, or cone end ( 4 ) optionally installed at the end of the telescoping segment.
The illustration at center shows two rigid guide segments ( 1 ) oriented as coupled with an optionally installed angled, flare, or cone end ( 4 ) secured directly to the end of the rigid segment. The illustration to the right shows two rigid guide segments ( 1 ) oriented as coupled without the telescoping guide segment or angled, flare, or cone end installed.
Referring to FIG. 1 , there is a general illustration matrix of the rigid segment, and telescoping underwater guide segment assembly. One or more segments may be used as shown. FIG. 1 includes three profile views of two rigid guide segments coupled together in three different configurations thereby providing structural and lateral support for the elongated objects placed within the guide to be installed, and if desired, the inner-friction/spacer sleeve ( 5 ). The illustration to the left shows one rigid guide segment ( 1 ) and one telescoping guide segment ( 1 , 2 ) comprised of one rigid guide segment and a telescoping element ( 2 ) slidable with infinite adjustment, incremented, or selected locking points. Also shown is an angled, flare, or cone end ( 4 ) optionally installed at the end of the telescoping segment. The illustration at center shows two rigid guide segments ( 1 ) oriented as coupled with an optionally installed angled, flare, or cone end ( 4 ) secured directly to the end of the rigid segment. The illustration to the right shows two rigid guide segments ( 1 ) oriented as coupled without the telescoping guide segment or angled, flare, or cone end installed.
FIG. 2 is a general illustration matrix of different length rigid guide segment, ( 1 ) end flanges ( 6 ) and an optionally installed base plate ( 9 ) with mounting brackets ( 10 ) for securing hardware and machinery to the base plate. Connecting hardware ( 11 ) comprised of bolting, pinning, banding, clipping and such methods for securing and coupling guide segments is shown. The lower section is a profile view of a rigid guide segment showing the binding block ( 7 ) which is secured to the rigid guide segment for the locking of the telescoping element in a fixed position or adjusted to permit dynamic extension and retraction of the telescoping segment and the underwater guide assembly.
Referring to FIG. 2 , there is a general illustration matrix of different length rigid guide segment, ( 1 ) end flanges ( 6 ) and an optionally installed base plate ( 9 ) with mounting brackets ( 10 ) for securing hardware and machinery to the base plate. Connecting hardware ( 11 ) comprised of bolting, pinning, banding, clipping and such methods for securing and coupling guide segments is shown. The lower section is a profile view of a rigid guide segment showing the binding block ( 7 ) which is secured to the rigid guide segment for the locking of the telescoping element in a fixed position or adjusted to permit dynamic extension and retraction of the telescoping segment and the underwater guide assembly.
FIG. 3 is a detailed plan view (lower left) and elevation view (upper view) of the optionally used binding block ( 7 ) components comprising of the threaded block body ( 7 ), and binding hardware consisting of set screws thereby locking or dynamically controlling the telescoping guide segment ( 2 ).
FIG. 4 is a general illustration matrix of the telescoping guide segments. The illustration at left is a telescoping segment without flanges ( 3 ) installed for coupling an angled, flare, or cone end ( 4 ) which may optionally be used as an intermediate telescoping segment within the underwater guide assemble shown in FIG. 9 The illustration at center left is a telescoping section with a flange installed for mounting an angled, flare, or cone end ( 4 ) as oriented for connection as shown. The illustration at center right is a telescoping segment ( 2 ) with the angled, flare, cone end ( 4 ) installed. The illustration at right is a telescoping segment ( 2 ) with the angled, flare, cone end ( 4 ) installed with an optionally installed inner-friction/spacer sleeve ( 5 ).
Referring to FIG. 4 , the illustration at left is a telescoping section without flanges ( 3 ) installed for coupling an angled, flare, or cone end ( 4 ) which may optionally be used as an intermediate telescoping segment within the underwater guide assemble shown in FIG. 9 The illustration at center left is a telescoping section with a flange installed for mounting an angled, flare, or cone end ( 4 ) as oriented for connection as shown. The illustration at center right is a telescoping segment ( 2 ) with the angled, flare, cone end ( 4 ) installed. The illustration at right is a telescoping segment ( 2 ) with the angled, flare, cone end ( 4 ) installed.
FIG. 5 is a general illustration matrix of the telescoping guide segments. The top illustration is a profile view of the optionally installed external floatation vessel ( 12 ) composed of rigid, solid, semisolid, hollow, static, flexible, or inflatable vessel materials for in-water floating assembly of the underwater guide assembly. The external floatation vessel is secured to the underwater guide segments by rigid connecting hardware, straps, clips, braces, ties, and such securing devices. Inflation, deflation, and over pressure relief valves for deployment, recovery, pneumatic control, and positioning of independent and multiple guide segments are optionally attached to the external floatation vessel. The top center illustration is a profile view of a rigid guide segment. ( 1 ) The bottom center illustration is a profile view of a rigid guide segment ( 1 ) with an external floatation vessel ( 12 ) attached. The bottom illustration is a profile view of a variant of a rigid guide segment whereby the rigid guide segment or segments are of open configuration where elongated objects inserted into the guide assembly are predominantly exposed and visible being secured to the rigid guide segment or segments by guide bolts, pins, clamps, straps and such anchoring devices.
Referring to FIG. 5 , the top illustration is a profile view of the optionally installed external floatation vessel ( 12 ) composed of rigid, solid, semisolid, hollow, static, flexible, or inflatable vessel materials for in-water floating assembly of the underwater guide assembly. The external floatation vessel is secured to the underwater guide segments by rigid connecting hardware, straps, clips, braces, ties, and such securing devices. Inflation, deflation, and over pressure relief valves for deployment, recovery, pneumatic control, and positioning of independent and multiple guide segments are optionally attached to the external floatation vessel. The top center illustration is a profile view of a rigid guide segment. ( 1 ) The bottom center illustration is a profile view of a rigid guide segment ( 1 ) with an external floatation vessel ( 12 ) attached. The bottom illustration is a profile view of a variant of a rigid guide segment whereby the rigid guide segment or segments are of open configuration where elongated objects inserted into the guide assembly are predominantly exposed and visible being secured to the rigid guide segment or segments by guide bolts, pins, clamps, straps and such anchoring devices.
FIG. 6 is a general illustration matrix of the telescoping guide segments. The top left illustration is a plan view of a removable end flange plate ( 13 ) for a variant type of rigid guide segment whereby solid or slotted support rails ( 17 ), hollow support rails ( 18 ), and other rigid structural supports are connected to the end flange plates forming a rigid guide assembly. The top right illustration is a plan view of a removable end flange plate ( 14 ) for a variant type of an adjustable width rigid guide segment where adjustment in size is made by securing the support rails to alternate mounting holes or other slot positions and whereby solid or slotted support rails ( 17 ), hollow support rails ( 18 ), and other rigid structural supports are connected to the end flange plates forming a rigid guide assembly. The bottom left illustration is an end view of a variant open guide segment with a fixed, removable, or adjustable optionally installed end plate ( 15 ) for joining a plurality of segments together, and securing hardware ( 16 ) comprised of connecting containment hardware comprised of either straight, curved, or formed plates, bars, bolts, pins, straps, and such rigid and flexible materials used in conjunction with an open type variant of the rigid guide segment or segments. The bottom right illustration is an end view of a variant open guide segment ( 15 ) with the connecting containment hardware ( 16 ) secured.
Referring to FIG. 6 , the top left illustration is a plan view of a removable end flange plate ( 13 ) for a variant type of rigid guide segment whereby solid or slotted support rails ( 17 ), hollow support rails ( 18 ), and other rigid structural supports are connected to the end flange plates forming a rigid guide assembly. The top right illustration is a plan view of a removable end flange plate ( 14 ) for a variant type of an adjustable width rigid guide segment where adjustment in size is made by securing the support rails to alternate mounting holes or other slot positions and whereby solid or slotted support rails ( 17 ), hollow support rails ( 18 ), and other rigid structural supports are connected to the end flange plates forming a rigid guide assembly. The bottom left illustration is an end view of a variant open guide segment with a fixed, removable, or adjustable optionally installed end plate ( 15 ) for joining a plurality of segments together, and securing hardware ( 16 ) comprised of connecting containment hardware comprised of either straight, curved, or formed plates, bars, bolts, pins, straps, and such rigid and flexible materials used in conjunction with an open type variant of the rigid guide segment or segments. The bottom right illustration is an end view of a variant open guide segment ( 15 ) with the connecting containment hardware ( 16 ) secured.
FIG. 7 is a general illustration matrix of the telescoping guide segments. The top and center illustrations are profile and end views of variant type rigid guide segments whereby a plurality of solid, slotted, or hollow support rails ( 17 ) and ( 18 ), and other rigid structural supports are connected to end flange plates ( 13 ) and ( 14 ) forming a rigid guide assembly. The bottom illustration is a profile and end view of an assembled variant guide segment with a plurality of removable support rails ( 17 ) and ( 18 ) and end flange plates ( 13 ) and ( 14 ) with an optionally installed inner-friction/spacer sleeve ( 5 ). The guide segments and variants thereof functions with or without the inner-friction/spacer sleeve ( 5 ).
Referring to FIG. 7 , the top and center illustrations are profile and end views of variant type rigid guide segments whereby a plurality of solid, slotted, or hollow support rails ( 17 ) and ( 18 ), and other rigid structural supports are connected to end flange plates ( 13 ) and ( 14 ) forming a rigid guide assembly. The bottom illustration is a profile and end view of an assembled variant guide segment with a plurality of removable support rails ( 17 ) and ( 18 ) and end flange plates ( 13 ) and ( 14 ) with an optionally installed inner-friction/spacer sleeve ( 5 ). The guide segments and variants thereof functions with or without the inner-friction/spacer sleeve ( 5 ) with an optionally installed inner-friction/spacer sleeve ( 5 ).
FIG. 8 is a profile view of one variant work surface being a marine barge ( 20 ) as shown and a matrix of underwater guide assembly options. The illustration at the left shows the guide secured to the work surface or machinery. The guide configuration is comprised of three short length rigid guide segments, ( 1 ) one longer length rigid guide segment, ( 1 ) and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration. The illustration at left center shows the guide configuration comprised of three short length rigid guide segments, two longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) and an angled, flare, cone end ( 4 ) attached to the end of the lower rigid guide segment ( 1 ) ( 15 ) ( 19 ) in a fixed length guide configuration resting on the bottom ( 21 ) of the body of water. The illustration at right center shows the guide configuration comprised of three short length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) and two longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration. The illustration at the right shows the guide configuration comprised of one longer length rigid guide segment, ( 1 ) ( 15 ) ( 19 ) resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration.
Referring to FIG. 8 , the guide configuration is comprised of three short length rigid guide segments, ( 1 ) one longer length rigid guide segment, ( 1 ) and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration. The illustration at left center shows the guide configuration comprised of three short length rigid guide segments, two longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) and an angled, flare, cone end ( 4 ) attached to the end of the lower rigid guide segment ( 1 ) ( 15 ) ( 19 ) in a fixed length guide configuration resting on the bottom ( 21 ) of the body of water. The illustration at right center shows the guide configuration comprised of three short length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) and two longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration. The illustration at the right shows the guide configuration comprised of one longer length rigid guide segment, ( 1 ) ( 15 ) ( 19 ) resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration.
In the configuration of FIG. 8 , the guide is positioned at a 55 degree angle, with respect to the surface of the bed. In other words, the guide and a normal to bed define an angle of 35 degrees. The guide in FIG. 8 has a length of 34′ and, because of the angle, a 16′ lateral reach.
Winch 25 acts to change the angle position of the guide.
FIG. 9 is a profile view of one variant work surface being a marine barge ( 20 ) as shown and a matrix of underwater guide assembly options. The illustration at the left shows the guide secured to the work surface or machinery. The guide configuration is comprised of five short length rigid guide segments, ( 1 ) one longer length rigid guide segment, ( 1 ) one flangeless telescoping section ( 3 ) for optional intermediate or end extension of rigid guide segments, and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration. The illustration at right shows a variant of the guide configuration comprised of two open frame half section longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) whereby the rigid guide segment or segments and optionally attached angled, flare, cone end ( 4 ) are of open configuration where elongated objects inserted into the guide assembly are predominantly exposed and visible, resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration.
Referring to FIG. 9 , the guide configuration is comprised of five short length rigid guide segments, ( 1 ) one longer length rigid guide segment, ( 1 ) one flangeless telescoping section ( 3 ) for optional intermediate or end extension of rigid guide segments, and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration. The illustration at right shows a variant of the guide configuration comprised of two open frame half section longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) whereby the rigid guide segment or segments and optionally attached angled, flare, cone end ( 4 ) are of open configuration where elongated objects inserted into the guide assembly are predominantly exposed and visible, resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration.
In the configuration of FIG. 9 , the guide is positioned at a 35 degree angle, with respect to the surface of the bed. In other words, the guide and a normal to bed define an angle of 55 degrees. The guide in FIG. 9 has a length of 44′ and, because of the angle, a 40′ lateral reach.
FIG. 10 is a profile view of one variant work surface being a marine barge ( 20 ) as shown and a matrix of underwater guide assembly options. The illustration shows the guide secured to the work surface or machinery. The guide configuration is comprised of three short length rigid guide segments, ( 1 ) four longer length rigid guide segments, and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration.
Referring to FIG. 10 , the guide configuration is comprised of three short length rigid guide segments, ( 1 ) four longer length rigid guide segments, and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration.
In the configuration of FIG. 10 , the guide is positioned at a 20 degree angle, with respect to the surface of the bed. In other words, the guide and a normal to bed define an angle of 70 degrees. The guide in FIG. 10 has a length of 72′ and, because of the angle, a 60′ lateral reach.
The above-described embodiments provide for an underwater guiding apparatus comprising independent rigid segments and independent telescoping segments assembly of one or more sectional segments wherein one or more tubing, open frame segments are static and one or more segments are movable being of different dimension than the static segments with a means for coupling the segments wherein the means permits the segmental extension and retraction of the telescoping segment assembly and a means for varying the length of the underwater guiding apparatus by adding and removing rigid or telescoping segments thereby extending and retracting the assembly with a combination of rigid segments and telescoping segments for guiding, containment, direction, penetration, placement, and installation, of elongated structures such as directional, variable angle machine, bore, drill, equipment, materials and such elongated structures such as stems, rods, piping, tubing, hoses, cables, lines and other similar structures through the atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials and without environmental impact, and other applications with the following distinct features and advantages.
1. It provides for guiding, direction, penetration, placement, and installation, of elongated structures such as directional, variable angle machine, bore, drill, equipment, material and such elongated structures such as stems, rods, piping, tubing, hoses, cables, lines and other similar structures through the atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials and without environmental impact at variable segmented and assembly lengths and angles by creating an infinitely adjustable angle, length, diameter, dimension, width, dynamic and statically controlling segmental and telescoping guide segments thereby adjusting its length and angle from end to end.
2. It is infinitely adjustable in length. It can be adjusted to any length within its operational limits for use in atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials.
3. It is infinitely adjustable in orientation and angle of installation. It can be adjusted to any angle within its operational limits for use in atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials.
4. It can be incrementally sized in segmented or overall diameter, dimension, and width to accommodate a variety of elongated structures and guide components for various directional, variable angle machine, bore, drill, stems, rods, piping, tubing, hoses, cables, lines equipment, materials and other such elongated structures.
5. It permits variable configuration of primary and supportive guide components such as tubes, brackets, rails, beams, frames, clamps, through hole plates, trusses, and standoffs.
6. It permits variable configuration of the guide support rails and longitudinal support members such as number, shape, and configuration of rails along with a variety of rail materials such as solid, angular, box, and tubular materials which can be drilled, slotted, and machined to accommodate various features, options, equipment, capabilities and attachment points.
7. It permits independent and combined sectional and telescoping guide configuration using solid wall tubing, drilled or slotted tubing, rings, beams, support rails, trusses, frames and angular or box materials.
8. It permits variable configuration of the telescoping segments such as locking, sectional, and telescoping extension and retraction mechanisms such as dynamic friction and static lock down screws, pressure screws, travel limitation screws, springs, bolts, pins, bolts, and control linkage.
9. It permits variable mounting and attachment of individual and multi-segment end segments such as angled, flare, bell, and cone ends by bolting, sliding, clamping, clipping, machine fitting or being fixed as well as variable configurations in angle, length, diameter, curved, solid wall, slotted, banded, caged, rigid or flexible.
10. Once installed, it can function statically thereby fixing its overall length.
11. Once installed, it can function dynamically thereby self adjusting its length for varying distances in atmosphere, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and dynamic changes in end to end clear dimension due to movement including but not limited to such movements from wind, wave action, tides, changes in work surface elevation, external mechanical, natural forces and other factors.
12. Once installed, it can function both statically and dynamically thereby partially and segmentally fixing its overall length while partially and segmentally adjusting its length for varying water column depths and changes in end to end clear dimension due to movement including but not limited to such movements from wind, wave action, tides, changes in work surface elevation, external mechanical, natural forces and other factors.
13. It is self deploying. Attaching support equipment and machinery to base plate(s) secured anywhere along its length such as equipment to assist in handling, setup, deployment, adding and removing segments, extension, retraction, recovery, breakdown, and storage of the guide components as well as support equipment and machinery for handling, manipulation and recovery of elongated structures.
14. Each guide segment is rigid thereby providing lateral support for elongated structures while reducing overall deflection using single or multiple guide segments.
15. It can be manufactured from a variety of materials such as aluminum, steel, alloys, composites, and plastics.
16. It can be universally mounted to a variety of fixed, land based, suspended, marine, aerospace, and movable construction, mechanical, and scientific type equipment.
17. It is dynamic and can be used from fixed or movable locations of varying water column depths and changes in end to end clear dimension due to movement including but not limited to such movements from wind, wave action, tides, changes in work surface elevation, external mechanical, natural forces and other factors.
18. It is fully adjustable and expandable in length, diameter, width, dimension, and operational capabilities by adding and removing guide segments and components to increase its scope and range of operation.
19. It is simple. It has no mechanical moving parts.
20. It is portable. Each rigid guide segment can be sized in as desired in length, width, and dimension and can be completely or partially dismantled, and easily transported in a small vehicle, and operates with no moving parts.
21. It is light weight. Each of its accordingly sized segments, components can be lifted and transported by hand, and operates with no moving parts.
22. The exemplary embodiment provides a professional and aesthetic appearance with functional performance. The optionally drilled and slotted support rails and beams reduce overall deflection, reduce weight and provide numerous connection points along their full length. The optional external box support rails provide lateral support for the inner guide components while providing internal integrated floatation control for individual and multiple guide segments.
23. Guide components can be easily assembled, used, and dissembled in-water close to the water surface using the externally or integrated floatation vessels providing floatation control for individual and multiple guide segments.
24. The segment end components such as angled, bell, flair, cone assists in self alignment, docking and recovery of installed elongated structures and associated installation machinery and equipment.
25. The optionally installed floatation vessels permits infinite operational floatation and buoyancy adjustment and control for individual and multiple guide segments.
26. The guide segments and assembly provides a means for guiding, handling, direction, penetration, placement, and installation, of elongated structures through the atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials without environmental impact.
27. The above advantages and uses may be employed in any area of application limited only by the imagination of the user. For example, in underwater applications, the method of the exemplary embodiment may be employed in the following environments and applications.
1. Underwater, Above Water, Fluids.
2. Semi-submerged.
3. Aerospace.
4. Containment Vessels, Tanks, and Containers.
5. Disposal Facilities
6. Installation of power and other cables and lines.
7. Installation of fiber optic and other type communications cables.
8. Installation of utility and other lines and conduits.
9. Installation of pipelines.
10. Installation of navigation lighting and related systems.
11. Installation of anchoring cables and similar structures.
12. Bottom and sub-bottom material sampling.
13. Probing, Remote testing.
14. Installation of sub-bottom sensors.
15. Installation of sub-bottom instrumentation.
In summary, The exemplary embodiment is an underwater guiding apparatus comprising independent rigid segments and independent telescoping segments assembly of one or more sectional segments wherein one or more tubing, open frame segments are static and one or more segments are movable being of different dimension than the static segments with a means for coupling the segments wherein the means permits the segmental extension and retraction of the telescoping segment assembly and a means for varying the length of the underwater guiding apparatus by adding and removing rigid or telescoping segments thereby extending and retracting the assembly with a combination of rigid segments and telescoping segments.
The underwater guiding apparatus comprises a means for locking the telescoping assembly in fixed length configurations and further comprises a means for adjusting the angle of the guiding apparatus.
The underwater guiding apparatus comprises a segment for anchoring and securing the underwater guiding apparatus to a fixed or variable elevation work surface, mechanical equipment and machinery. The underwater guiding apparatus comprises rigid fixed length segments and telescoping segment or segments in an assembly wherein the telescoping segment assembly comprises an outer segment, an inner extension segment, and an angular, flare, cone end, wherein the inner extension segment is slidably engaged with the outer segment to permit extension and retraction of the inner extension segment, the end being secured to one end of the inner extension segment.
The underwater guiding apparatus wherein the telescoping segment assembly further comprises one or more binding blocks with set screws and pins for locking the inner extension segment in a fixed position. The underwater guiding apparatus wherein one or more telescoping segment assemblies comprises an inner extension segment of differing dimension being positioned between the rigid outer receiver segments to permit both segmental extension and extension and retraction of the telescoping segment assembly.
The underwater guiding apparatus wherein the angled, flare, cone end is secured to the end of a rigid segment or end of an inner telescoping segment of the telescoping assembly being temporarily secured by connecting hardware or permanently secured by welding the end section to the inner telescoping segment assembly.
The underwater guiding apparatus wherein one or more of the segments of the telescoping segments are comprised of a plurality of bars, connecting hardware, or guides in a cylindrical or angular pattern and a friction sleeve positioned within and secured by the bars connecting hardware, or guides.
The underwater guiding apparatus bars are constructed containing airtight cavities thereby enabling the pipe to function as a floatation vessel. The underwater guiding apparatus wherein one or more of the components of the telescoping assembly further comprise integrated or attached flotation vessels.
The underwater guiding apparatus is constructed containing a completely or partially enclosed containment cavity or channel and a single or plurality of lateral containment tubes, channels, pins, and connecting hardware thereby providing the elongated objects such as directional, variable angle drill, bore and such machine and other stems, rods, piping, tubing, hoses, cables, lines and other similar elongated rigid and flexible structures with lateral support.
The underwater guiding apparatus wherein one or more of the components of the fixed length segments and telescoping segments further comprise integrated or attached flotation vessels.
The underwater guiding apparatus enables a method of guiding underwater submerged elongated structures through varying water column depths comprising the steps of: selecting a single or plurality of rigid fixed length segments and installing the assembly at a desired work angle and if desired, connecting one or a plurality of telescopic segments to the fixed length segment or segments and positioning the underwater guiding apparatus in the area and location where the elongated structures are to be guided and orienting the assembly to the desired angle and extension length.
The method for guiding underwater submerged elongated structures wherein the elongated rigid and flexible structures are one or more of stems, rods, piping, tubing, hoses, cables, and lines. The method for guiding underwater submerged elongated structures wherein the guiding is performed for the placement and installation of both rigid and flexible elongated structures. The method for guiding underwater submerged elongated structures further comprises the step of securing the assembly to a fixed or variable elevation work surface, machinery and equipment.
In other words, there is a system for positioning elongated structures such as piping, hoses, cables, wires, tubing, and such elongated structures on or below the bottom of the water columns, bodies of water such as lakes, streams, rivers, coastal waters, oceans, and fluids comprising; an underwater guiding apparatus; the underwater guiding apparatus comprising an assembly of a single and/or plurality of elongated fixed, telescopic, or combination of fixed and telescopic segments with no moving parts; each of the segments to contain, enclose, and guide the piping, hoses, cables, wires, tubing, and such elongated structures within each single or plurality of the segments; at least one of the segments individually or connected to at least one other adjacent segment by static, telescoping, or combination of static and telescoping coupling means; each the coupling means configured to permit static, and/or telescopic extension, or retraction of the adjacent segments; one or a plurality of the segments configured to be independent and/or permit the addition of one or more segments in static, telescoping, or combination of segmented fixed and telescoping relationship; at least one of the segments configured for removal from the plurality of remaining segments;
The underwater guiding apparatus further comprises means for securing and/or locking the assembly of a single or plurality of segments in a fixed, telescopic, and/or combination of fixed and telescopic segments; a work surface positioned on, above, or adjacent to a body of water and/or atmosphere; the underwater guiding apparatus secured to the work surface proximate a first end of the underwater apparatus; the underwater guiding apparatus longitudinally and angularly adjustable relative to the work surface; and at least a portion of the underwater guiding apparatus located below the surface of the water or fluid proximate a second end, in a position to guide the drills, stems, rods, piping, tubing, hoses, cables, lines equipment, materials and other such elongated structures through the guiding apparatus onto and/or under the bottom of the body of water and/or other surface atmospheric surface materials.
The guiding apparatus further comprises a means for securing or locking the fixed length segments and telescoping segments and assembly in a fixed length configuration.
The guiding apparatus further comprises a means for adjusting the angle of the fixed length segments, telescoping segments and assembly.
The guiding apparatus further comprises a segment for securing or anchoring the guiding apparatus to a fixed, movable, or variable elevation work surface.
According to an alternate embodiment, a guiding apparatus comprises: a segmented and optionally telescoping assembly; not limited to two segments for guiding elongated structures through the apparatus wherein the segmented assembly comprises a single or plurality of rigid independent segments optionally incorporating a telescoping segment within the assembly which comprises a rigid guide segment, telescoping extension segment, and an angled, flare, cone end, wherein the telescoping segment is slidably engaged with receiver segment to permit extension and retraction of the telescoping segment and guide assembly.
The alternate guiding apparatus further comprises an optionally installed base plate or plurality of base plates attached to rigid or telescoping segments for securing hardware and machinery.
The alternate guiding apparatus further comprises a rigid segment to the telescoping assembly for attaching the guiding apparatus to a fixed, movable, or variable elevation work surface, machinery or equipment.
In the alternate guiding apparatus, the sectional assembly further comprises an independent rigid segment coupled to additional rigid segments or to the telescoping segment of the sectional or telescoping assembly.
In the alternate guiding apparatus, the telescoping segment and assembly further comprises one or more binding blocks with securing hardware for locking the telescoping segment and assembly in a fixed position.
In the alternate guiding apparatus, the telescoping assembly further comprises one or more additional telescoping segments of differing dimension than the rigid guide segment positioned between the rigid guide segment the angled, flare, cone end to permit increased extension length.
In the alternate guiding apparatus, the angled, flare, cone end is secured to the fixed guide segment, telescoping segment, and assembly by being bolted, clipped, pinned or welded on to the end of a fixed guide segment or telescoping segment.
The alternate guiding apparatus further comprises a means for adjusting the angle of the fixed length or telescoping assembly. The means for adjusting the angle of may be by hand, floatation vessels, or by attached equipment or machinery.
In the alternate guiding apparatus, one or more of the segments of the rigid and telescoping assembly are comprised of a single or plurality of solid, enclosed, openly constrained, and/or hollow lateral supports in a substantially cylindrical and/or angular pattern and an optional inner-friction or spacer sleeve contained and positioned within the guide segments.
In the alternate guiding apparatus, the securing hardware are constructed containing cavities thereby enabling the guide segment lateral supports to function as a floatation vessel for the guide segments.
In the alternate guiding apparatus, one or more of the components of the guide segments and telescoping assembly further comprise externally attached or integrated flotation vessels with no moving parts.
There is an exemplary process and method for guiding elongated structures such as drills, stems, rods, piping, hoses, cables, wires, tubing, and such elongated structures through water columns, man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans, and the atmosphere with no moving parts comprising the steps of: providing a guiding apparatus; the guiding apparatus an assembly of a plurality of elongated segments; each of the segments to contain, enclose, and guide the stems, piping, hoses, cables, wires, tubing, and such elongated structures within the segments without moving parts; at least one of the segments individually or connected to at least one other adjacent segment by static, telescoping, or combination of static and telescoping coupling means without moving parts; each the coupling means configured to permit fixed, telescopic, and/or combination of fixed and telescopic extension and/or retraction of the adjacent segments; at least one or more of the segments configured to permit addition of one or more segments in fixed, telescopic, or a combination of fixed and telescopic relationship with no moving parts; at least one of the segments configured for removal from the remaining segments; the guiding apparatus further comprising means for securing and/or locking the assembly of one or more segments in a fixed, telescopic, or combination fixed and telescopic relationship; securing one or more segments to a fixed, movable, or variable elevation work surface, so that the assembly of a plurality of segments is longitudinally and angularly adjustable; orienting the assembly of a plurality of segments to a desired angle, overall length, or an extension and retraction range; positioning at least part of the guiding apparatus through water columns, man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans, and the atmosphere; and positioning and moving the elongated structures such as piping, hoses, cables, wires, tubing, and such elongated structures through a segment or plurality of segments into position on or below the bottom of the water columns, bodies of water such as lakes, streams, rivers, coastal waters, oceans, and fluids.
In the exemplary method, the elongated structure is one of stems, rods, piping, tubing, hoses, cables, and lines without moving parts.
In the exemplary method, the guiding is performed for the placement and installation of the elongated structures without moving parts.
The method for guiding elongated structures further comprises the step of securing a guide segment to a fixed, movable, or variable elevation work surface, machinery or equipment without moving parts.
Thus, an underwater guiding device includes one or combination of a plurality of rigid guide segments, and/or telescoping guide segments where one or plurality of segments are of fixed length and one or plurality of segments are telescoping permitting use of either a single segment, a plurality of rigid guide segments for incremental extension of the assembly, and a combination of rigid guide segments and a telescoping guide segment or segments for sectional, infinitely adjusted, and dynamic extension and retraction of the guide assembly. The assembly can be secured to a stationary or moving work surface with static or dynamic control of individual segments, multiple guide segments, and assembly. The guide can be adjusted to any length and for any angle of operation. The guide is a method for guiding underwater submerged elongated structures through the water column into and through marine and other bottom surface, and subsurface materials.
Benefits, other advantages, and solutions to problems have been described above with regard to specific examples. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not critical, required, or essential feature or element of any of the claims.
Additional advantages and modifications will readily occur to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or the scope of Applicants' general inventive concept. The invention is defined in the following claims. In general, the words “first,” “second,” etc., employed in the claims do not necessarily denote an order.
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Disclosed are systems and methods for drilling in an environment having a fluid and a bed. The method includes positioning a platform such that the fluid is between the platform and the bed; and assembling a guide, the assembled guide being straight. The method subsequently acts to place the guide such that the guide is supported by the platform, and a major length of the guide and a normal to the bed defines an angle, the angle being substantially greater than 0. Thus, the positioned guide allows for sending a variable angle drill inside the guide, from the platform into the bed.
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FIELD OF THE INVENTION
[0001] This invention relates to the mechanisms for adjusting the tilt of an automobile vehicle seat, the vehicle seats equipped with such mechanisms, and the manufacturing methods of such mechanisms.
BACKGROUND
[0002] More particularly, the invention concerns a mechanism for adjusting the tilt of an automobile vehicle seat comprising:
a first flange entirely obtained from a shaped metallic element, comprising a front face, an internal face that is at least partially cylindrical around a pivot axis, and a retaining face, a second flange comprising a central part and a peripheral part featuring a front face that is opposite the front face of the first flange, an external face at least partially cylindrical around the pivot axis, and a rear face.
[0005] The document FR 2 578 601 describes an example of such a tilting adjustment mechanism. In this document, a ring is used, attached to one of the flanges, and crimped onto the other, to hold the two flanges together to prevent a relative movement thereof along the pivot direction.
[0006] However, it is still sought to improve such systems, and in particular to simplify them whilst maintaining their operational functions intact.
SUMMARY
[0007] Consequently, a mechanism of the type in question is characterised in that the internal face of the first flange is opposite the external face of the second flange to guide a relative rotational movement of the first and second flanges around the pivot axis,
and in that the retaining face is opposite the rear face of the second flange, to retain the second flange in the first flange along the pivot axis.
[0009] Thanks to these measures, the additional ring is no longer required, which reduces the supply and logistics problems for the parts, and reduces the number of assembly operations.
[0010] In certain embodiments, the following measures may also possibly be used:
the mechanism further comprises a grain borne by the first flange, wherein said grain comprises a first locking surface, the second flange comprises an internal face that is at least partially cylindrical around the pivot axis, and which is opposite the external face of the second flange, wherein said internal face of the second flange comprises a second locking surface, said grain is fitted so that it is mobile on the first flange between
an active position in which the first and second locking surfaces engage so as to prevent any relative rotation of the first and second flanges around the pivot axis, and an inactive position in which the first and second locking surfaces do not engage, to allow said rotation;
the first flange is fitted with a plurality of retaining portions, distributed around the pivot axis, and each comprising a said retaining face; retaining face and internal face of the first flange are angularly offset with respect to one another around the pivot axis; the mechanism further comprises a radial opening between the retaining face and the internal face of the first flange; the first flange comprises:
a central plate featuring the front face, and a peripheral crown around the pivot axis, extending from the central plate, wherein said peripheral crown comprises an internal face forming said internal face of the first flange, and at least one retaining element, which protrudes with respect to said internal face, wherein said protrusion bears said retaining face.
[0022] According to another aspect, the invention concerns an automobile vehicle seat comprising a first element, a second element, and such a mechanism, wherein the first flange is fixed to the first element and the second flange is fixed to the second element.
[0023] According to another aspect, the invention concerns a manufacturing method for a mechanism for adjusting the tilt of an automobile vehicle seat in which:
(a) a first flange is entirely obtained from a shaped metallic element to comprise a front face, an internal face that is at least partially cylindrical around a pivot axis, and a retaining face, (b) a second flange is provided comprising a central part and a peripheral part featuring a front face designed to be opposite the front face of the first flange, an external face that is at least partially cylindrical around the pivot axis, and a rear face, (c) the first and second flanges are placed such that the front face of the first flange is opposite the front face of the second flange and the internal face of the first flange is opposite the external face of the second flange to guide a relative rotational movement of the first and second flanges around the pivot axis, (d) the first flange is deformed such that the retaining face is opposite the rear face of the second flange, to retain the second flange in the first flange along the pivot axis.
[0028] In certain embodiments, it may be necessary to use one and/or the other of the following measures:
in step (d), a retaining portion of the first flange is deformed radially toward the pivot axis, and longitudinally toward the front face of the first flange, to press a retaining face of the retaining portion onto the rear face of the second flange; in step (a), a first flange is obtained comprising a radial opening between the front face and a retaining portion featuring the retaining face.
[0031] Other features and advantages of the invention will become clearer in the following description of one of its embodiments, provided by way of non-restrictive example, in reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] In the drawings:
[0033] FIG. 1 is a diagrammatical side view of an automobile vehicle seat,
[0034] FIG. 2 is an exploded perspective view of an adjustment mechanism,
[0035] FIG. 3 is a partial view of two flanges of an adjustment mechanism, according to two different perspectives,
[0036] FIG. 4 is a view which corresponds to FIG. 3 for one of the two flanges at an intermediate step of the manufacturing method,
[0037] FIGS. 5 a and 5 b are two identical plane views at two successive steps of an assembly method, and
[0038] FIGS. 6 a and 6 b are two cross sectional views according to the VI-VI line respectively in FIG. 5 a and FIG. 5 b.
[0039] In the different figures, the same references are used to designate identical or similar elements.
DETAILED DESCRIPTION
[0040] As shown diagrammatically in FIG. 1 , the invention concerns a seat 1 of a vehicle which features a seat chair 2 mounted on a vehicle floor 3 and a seat back 4 mounted so that it pivots on the seat chair 2 by at least one articulated mechanism 5 , around a main articulation axis Y which extends transversally and substantially horizontally.
[0041] The articulation mechanism 5 has for example a single level and may be commanded for example by means of a handle 6 which may be actuated in the direction 6 a to release the pivoting of the seat back 4 around the main axis of rotation Y.
[0042] As illustrated in FIGS. 2 to 6 b , the articulation mechanism 5 essentially comprises a first flange 10 , a second flange 20 , three locking elements 11 , 12 , 13 , or “grains”, a movement transfer element 30 , or “cam”, and a command rod (not shown), which passes through the central opening of the cam and each of the flanges.
[0043] The general form of the first flange 10 is a rigid disc, formed by stamping, which is fixed for example to the chair 2 of the seat. It features a bore extending along the main axis of rotation Y and forms a passage 18 for the command rod, and is connected to the handle 6 .
[0044] It further comprises three circular shaped guiding elements 14 , 15 , 16 which are identical and are distributed on the periphery around the main axis of rotation, for example at 120°.
[0045] The first flange 10 further features three additional retaining elements 34 , 35 , 36 which are each respectively positioned circumferentially between two grains 11 , 12 , 13 . These three elements are for example identical, only the element 34 will be described below: it features a first surface opposite a complementary surface of the grain 11 and a second surface opposite a complementary surface of the grain 12 (all cylindrical with a generating line parallel to the Y axis).
[0046] The first flange 10 thus has a central plate 50 that is substantially flat normal to the Y axis, featuring a front face 39 and a rear face 51 opposite. The guiding elements 14 , 15 , 16 and the retaining elements 34 , 35 , 36 are formed by stamping, so that they protrude with respect to the plane of the front face 39 . Similarly, holding patterns may be formed, either protruding or depressed, in the rear face 51 , for example to help attach the flange on an element frame of an automobile vehicle seat.
[0047] The first flange 10 also features a peripheral crown 9 featuring a cylindrical internal face 52 revolving around the Y axis, orientated towards this axis, and an opposite cylindrical external face 53 revolving around the Y axis, orientated opposite to this axis, and positioned further away from the axis than the internal face 52 .
[0048] The peripheral crown 9 also features a front face 54 parallel to the front face 39 of the central plate 50 , and which joins the inside 52 and external 53 faces.
[0049] As may be seen in FIG. 3 , the peripheral crown 9 is equipped, in a distal region (i.e. distant from the central plate) with longitudinal retaining elements 42 , which protrude radially inwards with respect to the cylindrical revolution internal surface 52 . These retaining elements 42 may be for example distributed circumferentially around the Y axis, for example uniformly. There is a plurality of distinct elements. In the example provided, there are five of them. They each have a front face 56 that continues from the front face 54 , and a rear face (or retention face) 57 , opposite to the front face, substantially normal to the Y direction, which is most visible in FIG. 6 b.
[0050] In the example presented, a through opening 58 is provided in a proximal region of the crown (i.e. close to the central plate). It extends radially in the crown 9 , and is positioned longitudinally between the retaining element 42 and the central plate 50 . Consequently, in certain angular sectors of the flange, the crown features an internal face that is purely cylindrical in the proximal and distal regions. In other angular sectors, they feature an opening in the proximal region then a retaining element in the distal region, positioned one after the other in the longitudinal direction when moving from the central plate to the front face.
[0051] However, such openings are not essential to the implementation of the invention.
[0052] The second flange 20 has the general form of a rigid disc, formed by stamping, which is fixed in this case to the seat back 4 . It comprises a central plate 59 extending substantially in a plane that is normal to the Y axis, and which has a front face 60 and a rear face 61 opposite. The latter may feature attachment patterns, for example formed by stamping, to attach it to the seat back 4 .
[0053] The second flange also features a peripheral crown 22 comprising an internal face 62 that is globally circumferential around the Y axis, and has a toothed segment equipped with teeth 24 . An external face 63 is opposite the internal face, and has a smooth cylindrical geometry revolving around the Y axis, and with a radius that is substantially equal, slightly less than that of the internal face 52 of the crown 9 of the first flange. A front face 64 joins the internal 62 and external 63 faces, and extends for example normally to the Y axis.
[0054] The second flange also features a cylindrical bore with a circular section extending along the main axis of rotation Y and forming a passage 28 for the command rod.
[0055] The retaining elements 42 of the peripheral crown 9 of the first flange 10 , which protrude radially towards the centre, retain the second flange 20 in the first flange 10 , preventing relative translation of these two flanges along the Y axis whilst permitting their relative rotation around this axis.
[0056] In the assembled position, the front face 64 of the crown 22 of the second flange 20 is opposite the front face 50 of the first flange. The peripheral part of the rear face 61 of the second flange is opposite the retaining face 57 of the first flange 10 . They are consequently situated directly opposite one another, with no intermediate parts or elements between them. The external face 63 of the crown 22 of the second flange 20 is opposite the internal face 52 and, where applicable, the openings 58 of the crown 9 of the first flange 10 .
[0057] The actuation transfer element 30 , or “cam”, has three hooks 31 , 32 , 33 and three actuation surfaces designed to engage with each of the respective locking elements 11 , 12 , 13 . Each hook 31 , 32 , 33 , is provided to release the grains.
[0058] The cam 30 is stationary to the rod and mobile in rotation around the main axis of rotation Y between a locked position and an unlocked position.
[0059] The cam 30 engages with the locking elements 11 , 12 , 13 in a plane extending perpendicularly to the main axis of rotation Y, such that the cam 30 does not extend in the direction of the main axis of rotation Y between the locking element 11 , 12 , 13 and the first flange 10 , nor between the locking elements 11 , 12 , 13 and the second flange 20 , but engages radially to the main axis of rotation Y with the locking elements 11 , 12 , 13 .
[0060] A spring 7 tends to bring the cam 30 back to the locked position.
[0061] The locking elements 11 , 12 , 13 are positioned regularly (at 120°) in the first flange 10 . They each comprise a toothed segment 11 a , 12 a, 13 a, a guide portion 11 b , 12 b, 13 b, a release pin 11 c, 12 c, 13 c, and an actuation portion 11 d, 12 d, 13 d.
[0062] Each guide portion features a guide surface that is complementary to an external face of the respective guide element 14 , 15 , 16 .
[0063] In the active position, the cam presses against the actuation surface 11 d, 12 d , 13 d of each of the locking elements 11 , 12 , 13 , via the thrust surfaces, in order to maintain the locking elements in the active position.
[0064] In the active position of the locking elements, the toothed segments 11 a, 12 a , 13 a engage with the teeth 24 of the toothed crown 22 , in order to prevent the rotation between the first flange 10 and the second flange 20 around the main axis of rotation Y.
[0065] The engagement between the guide portions 11 b , 12 b, 13 b and the guiding elements 14 , 15 , 16 enables a movement of the locking elements 11 , 12 , 13 in a plane that is normal to the Y axis between an active position and an inactive position. The faces of the locking elements 11 , 12 , 13 which are normal to the Y direction are in contact and slide on parallel front faces of the first and second flanges (Front face 39 of the first flange 10 and front face 60 of the second flange 12 as may be seen in FIG. 3 ). In the inactive position of the locking elements, the toothed segments 11 a , 12 a, 13 a are distant from the teeth 24 of the crown 22 , which enables free rotation between the first flange 10 and the second flange 20 around the main axis of rotation Y.
[0066] When the cam pivots from its locked position to its unlocked position from the action of the command rod (from the action of a user wishing to unlock the mechanism to adjust the relative orientation of the two flanges), the actuation surfaces disengage from the respective actuation surfaces 11 d, 12 d, 13 d of the grains. Each of the retaining surfaces of the hooks 31 , 32 , 33 engage with the pin 11 c, 12 c , 13 c of a respective grain 11 , 12 , 13 to bring said respective grain to the inactive position progressively as the pin is inserted 11 c, 12 c, 13 c inside the hook.
[0067] When the user releases the handle, thus releasing the command rod 8 , the spring 7 moves the cam 30 towards its active position. The hooks 31 , 32 , 33 of the cam disengage again from the pins 11 c, 12 c, 13 c of the respective grains, then the actuation surface of the cam solicits the respective grains from their inactive position to their active position previously described. During this movement, the grains are guided by the engagement of the guide surfaces, until they reach the locked position previously described.
[0068] Even though this embodiment has been described in the context of a discontinuous adjustment mechanism with rotary grains, other embodiments may be envisaged by a person skilled in the art, provided that the two flanges are retained with one another in the Y direction, and are free to turn around this Y direction. For example, discontinuous mechanisms with sliding grains, or even continuous mechanisms with epicycloidal trains.
[0069] One example of an embodiment of a manufacturing method will now be provided in references to FIGS. 4 to 6 b . A second flange, as described above, is obtained for example by stamping. As may be seen in FIG. 4 , a first flange 10 is provided, substantially as described above, except that the parties 66 designed to form the retaining elements 42 do not protrude radially towards the centre with respect to the internal face 52 of the crown 9 . For example, the crown 9 is provided as a perfectly hollowed cylinder, featuring the openings 58 mentioned previously. Such a creation may be made by stamping sheet metal, then making the openings 58 . If required, the openings may be made before stamping, in the suitable positions on the original metal sheet.
[0070] Next, the two flanges are placed opposite one another, the front face 62 of the crown of the second flange 20 is opposite the front face 39 of the central plate of the first flange, and the external face 63 of the crown 22 of the second flange 20 is opposite the internal face 52 . The insertion of the second flange in the first one is possible due to the fact that the retaining elements at this stage do not protrude. Beforehand, care has been taken to place all of the active elements of the system (cam, grains, spring, and others where applicable) between the flanges.
[0071] Next, as shown by the arrow A in FIG. 6 b , the retaining elements are deformed, to move them radially inwards, in the direction of the Y axis, so that their rear retaining face 57 is opposite the rear face 61 of the second flange. This deformation is facilitated by the presence of the opening 58 .
[0072] Where applicable, a deformation is made as shown by the arrow B in FIG. 6 b , longitudinally along the Y axis in the direction of the front face 39 of the first flange to clamp the second flange with the retaining element, and reduce the longitudinal clearance.
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The mechanism for adjusting the tilt of an automobile vehicle seat comprising a first flange entirely obtained from a shaped metallic element, a second flange comprising a central part and a peripheral part is disclosed. The internal face of the first flange is opposite the external face of the second flange to guide a rotational movement of the flanges. The retaining face of the first flange is opposite the rear face of the second flange, to retain the second flange in the first flange along the pivot axis.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to a cable operated disc brake for a bicycle. More specifically, the present invention relates to a cable operated disc brake with cam members for moving a friction member.
2. Background Information
Bicycling is becoming an increasingly popular form of recreation as well as a means of transportation. Moreover, bicycling has become a very popular competitive sport. Whether the bicycle is used for recreation, transportation or competition, the bicycle industry is constantly improving their components. One particular component of the bicycle, which has been extensively redesigned over the past years, is the braking systems of bicycles. In particular, the braking power of the braking systems is constantly being increased.
There are several types of bicycle brake devices, which are currently available on the market. Examples of some types of common bicycle brake devices include rim brakes, caliper brakes and disc brakes. If a rider wants a very high performance brake system, then the rider typically wants a disc brake system. Disc brake systems provide a substantial braking power in relationship to the amount of braking force applied to the brake lever. Moreover, disc brake systems typically provide a high level of consistency in all types of weather and riding conditions. Of course, riders constantly desire better performance from disc braking systems, i.e., disc brake systems that have more braking power.
Conventionally, a disc brake is composed of a pair of brake pads that are movably mounted to a caliper housing. The brake pads are pressed against a disc or rotor that is fixed to the wheel to halt the rotation of the disc and thus the wheel. The brake pads are moved toward the disc hydraulically or mechanically such as by a cam mechanism. The hydraulic disc brake systems are typically complicated in construction and expensive to manufacture. Moreover, hydraulic disc brake systems are often quite heavy in construction.
The mechanical disc brake system includes a caliper housing with one brake pad that is fixed to the caliper housing and one brake pad that is movably mounted to the caliper housing by a cam mechanism. A swinging arm is coupled to the cam mechanism to move the movable pad by a cam action. Typically, a conventional brake cable is coupled to a brake lever to move the swinging arm, and thus, operate the cam mechanism. While mechanical disc brake systems are typically less expensive and lighter than hydraulic disc brake systems, mechanical disc brake systems can still be complicated in construction and require many parts resulting in expensive manufacturing costs, as with a hydraulic disc brake system. Another drawback of many mechanical disc brake systems is that the cam mechanism often has a loss of efficiency during a movement of the cam mechanism under high pressure.
In view of the above, there exists a need for a disc brake, which overcomes the problems of prior art disc brakes. This invention addresses this need in the prior art as well as other needs, which will become apparent to those skilled in the art from this disclosure.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a cable disc brake that prevents loss of efficiency during a movement of the cam mechanism under high pressure.
Another object of the present invention is to provide a cable disc brake that is relatively compact and lightweight in relation to the amount of braking power.
Another object of the present invention is to provide a cable disc brake that is relatively inexpensive to manufacture.
The foregoing objects can be basically attained by providing a cable disc brake comprising a caliper housing, a first friction member, a second friction member and an actuated mechanism. The first friction member is movably coupled to the caliper housing between a release position and a braking position. The second friction member is coupled to the caliper housing and arranged substantially parallel to the first friction member to form a rotor receiving slot therebetween. The actuated mechanism is movably coupled to the caliper housing to move the first friction member from the release position towards the second friction member to the braking position. The actuated mechanism has first and second cam members movably arranged between an axially retracted position and an axially extended position with a guide member interconnecting the first and second cam members during movement between the axially retracted position and the axially extended position.
These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the attached drawings which form a part of this original disclosure:
FIG. 1 is a side elevational view of a bicycle with a pair of cable disc brakes coupled thereto in accordance with one embodiment of the present invention;
FIG. 2 is a side elevational view of a front portion of a bicycle with a front cable disc brake coupled thereto in accordance with one embodiment of the present invention;
FIG. 3 is a side elevational view of a rear portion of a bicycle with a rear cable disc brake coupled thereto in accordance with one embodiment of the present invention;
FIG. 4 is an enlarged, partial side elevational view of the front cable disc brake in accordance with the embodiment of the present invention illustrated in FIG. 2 ;
FIG. 5 is a longitudinal cross-sectional view of the front cable disc brake, as viewed along section lines 5 - 5 of FIG. 4 ;
FIG. 6 is an exploded elevational view of the front cable disc brake illustrated in FIGS. 2 , 4 and 5 ;
FIG. 7 is a front elevational view of a left caliper portion of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 8 is a bottom plan view of the left caliper portion of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 9 is a rear elevational view of the left caliper portion illustrated in FIGS. 7 and 8 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 10 is a left side elevational view of the left caliper portion illustrated in FIGS. 7-9 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 11 is a right side elevational view of the left caliper portion illustrated in FIGS. 7-10 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 12 is a cross-sectional view of the front left caliper portion illustrated in FIGS. 7-11 , as viewed along section lines 12 - 12 of FIG. 7 ;
FIG. 13 is a side elevational view of the cable adjusting bolt for the adjusting unit of the front cable disc brake illustrated in FIGS. 2 and 4 - 5 ;
FIG. 14 is an end elevational view of the cable adjusting bolt illustrated in FIG. 13 for the cable adjusting unit of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 15 is a partial, longitudinal cross-sectional view of the cable adjusting bolt illustrated in FIGS. 13 and 14 for the cable adjusting unit of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 16 is a side elevational view of the cable adjusting nut for the cable adjusting unit of the front cable disc brake illustrated in FIGS. 2 and 4 - 5 ;
FIG. 17 is an end elevational view of the cable adjusting nut for the cable adjusting unit of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 18 is an inside elevational view of the right caliper portion of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 19 is a side elevational view of the right caliper portion of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 20 is a bottom plan view of the right caliper portion illustrated in FIGS. 18 and 19 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 21 is a side elevational view of one of the brake pads for the front cable disc brake illustrated FIGS. 2 and 4 - 6 ;
FIG. 22 is an edge elevational view of the brake pad illustrated in FIG. 21 for the front cable disc break illustrated in FIGS. 2 and 4 - 6 ;
FIG. 23 is a side elevational view of the pad axle for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 24 is an end elevational view of the pad axle illustrated in FIG. 23 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 25 is an elevational view of the pad spring prior to bending for the front cable disc brake illustrated FIGS. 2 and 4 - 6 ;
FIG. 26 is a side elevational view of the pad spring illustrated in FIG. 25 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 27 is a top plan view of the pad spring illustrated in FIGS. 25 and 26 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 28 is an end elevational view of the pad spring illustrated in FIGS. 25-27 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 29 is a side elevational view of the input cam for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 30 is an end elevational view of the input cam illustrated in FIG. 29 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 31 is an end elevational view of the input cam illustrated in FIGS. 29 and 30 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 32 is a partial, cross-sectional view of the input cam illustrated in FIGS. 29-31 as viewed along section lines 32 - 32 of FIG. 31 ;
FIG. 33 is a partial, longitudinal cross-sectional view of the input cam illustrated in FIGS. 29-32 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 34 is a side elevational view of the output cam for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 35 is an end elevational view of the output cam illustrated in FIG. 34 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 36 is an end elevational view of the output cam illustrated in FIGS. 34 and 35 for the front disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 37 is a partial cross-sectional view of the output cam illustrated in FIGS. 34-36 as viewed along section lines 37 - 37 of FIG. 35 ;
FIG. 38 is a partial, longitudinal cross-sectional view of the output cam illustrated in FIGS. 34-37 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 39 is an end elevational view of the output cain rotation stopper for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 40 is a side edge elevational view of the output cam rotation stopper illustrated in FIG. 39 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 41 is a transverse cross-sectional view of the output cam rotation stopper illustrated in FIGS. 39 and 40 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 , as viewed along section lines 41 - 41 of FIG. 39 ;
FIG. 42 is an output cam return spring for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 43 is an end elevational view of the output cam return spring illustrated in FIG. 42 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 44 is an end elevational view of the actuating arm for the front cable disc brake illustrate FIGS. 2 and 4 - 6 ;
FIG. 45 is a side edge elevational view of the actuating arm illustrated in FIG. 44 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 46 is a bottom plan view of the actuating arm for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 47 is a cross-sectional view of the actuating arm illustrated in FIGS. 44-46 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 , as viewed along section line 47 - 47 of FIG. 44 ;
FIG. 48 is an inside end elevational view of the actuating arm illustrated in FIGS. 44-47 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 49 is an end elevational view of the return spring for the actuating assembly of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 50 is a side elevational view of the return spring illustrated in FIG. 49 for the actuating assembly of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 51 is an end elevational view of the return spring illustrated in FIGS. 49 and 50 for the actuating assembly of the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ;
FIG. 52 is an end elevational view of the cover of the actuating assembly for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 ; and
FIG. 53 is a side elevational view of the front cover illustrated in FIG. 52 for the front cable disc brake illustrated in FIGS. 2 and 4 - 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1-3 , front and rear portions of a bicycle 10 are illustrated with a pair of cable disc brakes 12 a and 12 b coupled thereto in accordance with one embodiment of the present invention. Bicycles such as bicycle 10 are well known in the art, and thus, bicycle 10 and its various components will not be discussed or illustrated in detail herein. It will be apparent to those skilled in the art that bicycle 10 can be any type of bicycle, e.g., mountain bike, a hybrid bike or a road bike. Bicycle 10 is a conventional bicycle, which basically includes a bicycle frame 13 with a handlebar 14 front and rear forks 15 a and 15 b, front and rear wheels 16 a and 16 b and a drive train 17 .
As seen in FIGS. 2 and 3 , the front and rear cable disc brakes 12 a and 12 b are identical to each other, except for their connections to the bicycle 10 and their respective brake operating mechanisms 18 a and 18 b. Specifically, the front cable disc brake 12 a is mounted to the front fork 15 a and operatively coupled to the front brake operating mechanism 18 a via a front brake cable 19 a. The rear cable disc brake 12 b, on the other hand, is coupled to the rear fork 15 b and the rear brake operating mechanism 18 b via a rear brake cable 19 b. The front and rear brake operating mechanisms 18 a and 18 b are well known in the art, and thus, they will not be discussed or illustrated in detail herein.
Basically, the front brake operating mechanism 18 a is designed to actuate the front disc brake 12 a to stop rotation of front wheel 16 a. More specifically, the front brake operating mechanism 18 a is operatively coupled to the front disc brake 12 a by front brake cable 19 a to apply a forcible gripping action on a front disc brake rotor 20 a that is fixedly coupled to the front wheel 16 a. Likewise, the rear brake operating mechanism 18 b is designed to actuate the rear disc brake 12 b to stop rotation of rear wheel 16 b. More specifically, the rear brake operating mechanism 18 b operatively coupled to the rear disc brake 12 b by rear brake cable 19 b to apply a forcible gripping action on a rear disc brake rotor 20 b that is fixedly coupled to the rear wheel 16 b.
Preferably, the brake operating mechanisms 18 a and 18 b are mounted on handlebar 14 . In particular, as seen in FIG. 2 , the brake operating mechanism 18 a has a brake lever 21 a that includes a mounting portion 22 a and a lever portion 23 a. Mounting portion 22 a is designed to be clamped onto handlebar 14 in a conventional manner. Lever portion 23 a is pivotally coupled to mounting portion 22 a for movement between a release position and a braking position. Normally, the lever portion 23 a is maintained in a release position in a conventional manner, e.g. by a return spring (not shown). Likewise, as seen in FIG. 3 , the rear brake operating mechanism 18 b has a brake lever 21 b that includes a mounting portion 22 b and a lever portion 23 b. Mounting portion 22 b is designed to be clamped onto handlebar 14 in a conventional manner. Lever portion 23 b is pivotally coupled to mounting portion 22 b for movement between a release position and a braking position. Normally, the lever portion 23 b is maintained in a release position in a conventional manner, e.g. by a return spring (not shown).
The front and rear brake cables 19 a and 19 b are well known in the art, and thus, they will not be discussed or illustrated in detail herein. Basically, the front brake cable 19 a has an outer casing 24 a and an inner wire 25 a. The outer casing 24 a extends between the mounting portion 22 a of the brake lever 21 a and an adjusting unit 26 a that is mounted on the front cable disc brake 12 a. The inner wire 25 a is fixedly coupled to the lever portion 23 a of the brake lever 21 a and a portion of the front cable disc brake 12 a as discussed below. Similarly, the rear brake cable 19 b has an outer casing 24 b and an inner wire 25 b. The outer casing 24 b extends between the mounting portion 22 b of the brake lever 21 b and an adjusting unit 26 b that is mounted on the rear cable disc brake 12 b. The inner wire 25 b is fixedly coupled to the lever portion 23 b of the brake lever 21 b and a portion of the rear cable disc brake 12 b in the same manner as in the front cable disc brake 12 a discussed below.
Still referring to FIGS. 2 and 3 , the front cable disc brake 12 a is coupled to the front fork 15 a via a mounting bracket 28 a and four bolts 29 a. Similarly, the rear cable disc brake 12 b is coupled to the rear fork 15 b via a mounting bracket 28 b and four bolts 29 b. Of course, it will be apparent to those skilled in the art from this disclosure that various other types of mounting mechanisms or assemblies can be utilized as needed and/or desired. Since cable brake discs 12 a and 12 b are identical to each other, only cable disc brake 12 a will be discussed and illustrated in detail herein.
Basically, as seen in FIGS. 5 and 6 , the cable disc brake 12 a includes a caliper housing 30 , a pair of brake pads or friction members 32 , a cam assembly 34 and an actuating assembly 36 . The cam assembly 34 and the actuating assembly 36 together form a cable actuated mechanism that moves the brake pads between a release position and a braking position. The caliper housing 30 is mounted to the frame 13 of the bicycle 10 via the bracket 28 a and bolts 29 a. The brake pads 32 are movably coupled to the caliper housing 30 to move between the release position and the braking position via the cam assembly 34 and the actuating assembly 36 (cable actuated mechanism). In the release position, the pads 32 are spaced from the disc brake rotor 20 a to allow free rotation thereof. In the braking position, the brake pads 32 are pressed against the sides of the disc brake rotor 20 a to stop rotation of the bicycle wheel 16 a and the disc brake rotor 20 a.
Turning to FIGS. 4-6 , the caliper housing 30 basically includes a left caliper portion 38 and a right caliper portion 40 that are fixedly coupled together by a pair of bolts 41 . When the left and right caliper housings 38 and 40 are coupled together, an internal cavity is formed for movably supporting the brake pads 32 and the cam assembly 34 , as discussed below. The left and right caliper housings 38 and 40 are preferably constructed of a hard, rigid material, such as a metallic material. Of course, other suitable materials can be utilized for the left and right caliper housings 38 and 40 .
As seen in FIGS. 7-12 , the left caliper portion 38 basically has a body portion 42 a pair of mounting flanges 43 and a cable support flange 44 . The body portion 42 has a pad support bore 45 extending in a longitudinal direction and an axially extending internal bore 46 that extends longitudinally between a first open end 48 and a second open end 50 of the left caliper portion 38 . The pad support bore 45 is utilized to support the brake pads 32 on the caliper housing 30 as discussed below.
Basically, the internal bore 46 can be divided into three sections 51 , 52 and 53 for supporting a part of the cam assembly 34 , as discussed below. The first section 51 of the internal bore 46 is a cylindrical bore with the smallest diameter. The first section 51 of the internal bore 46 is located at a first end 48 of the left caliper portion 38 . The first end 48 of the left caliper portion 38 has the actuating assembly 36 coupled thereto, as discussed below. Preferably, end surface of the first end 48 of the left caliper portion 38 has an annular step to form a pair of annular end surfaces 54 and 55 that lie in different planes. The inner end surface 55 adjacent the first section 51 of the internal bore 46 is preferably provided with three through bores 56 that are adapted to receive a part of the actuating assembly 36 , as discussed below. Preferably, the centers of these bores 56 are spaced approximately twenty degrees apart in a circumferential direction. These bores 56 allow for adjustment of the actuating assembly 36 , as discussed below. The middle one of the bores 56 is preferably spaced approximately four degrees in a circumferential direction from the center plane P 1 of the disc brake device 12 a.
The second section 52 of the internal bore 46 is also a cylindrical bore that is located between the first section 51 and the third section 53 . The second section 52 of the internal bore 46 has a larger diameter than the first section 51 of the internal bore 46 . Thus, an internal abutment surface or end wall 64 is formed radially between the first and second sections 51 and 52 of the internal bore 46 .
The third section 53 of the internal bore 46 is also cylindrical, but is a discontinuous cylinder. Specifically, the third section 53 of the internal bore 46 has a pair of longitudinal slots 65 and an annular groove 66 formed therein. The slots 65 that are spaced 180° apart and divide the annular groove 66 into two sections.
The second end 50 of the left caliper portion 38 is provided with a pair of threaded bores 69 for receiving the bolts 41 to secure the left and right caliper housings 38 and 40 together. The second end 50 of the left caliper portion 38 has a brake pad mounting recess 67 that is substantially identical to the outer periphery of the brake pads 32 . The bottom of the brake pad mounting recess 67 is open and the sides of the second end 50 of the caliper housing 38 has a pair of cutouts 68 for accommodating a portion of the disc brake rotor 20 a therein.
The mounting flanges 43 of the left caliper portion 38 preferably have slots 70 to allow axial adjustment to and from the disc brake rotor 20 a. The slots 70 receive the mounting bolts 29 a therethrough to fasten the left caliper portion 38 to the front bracket 28 a.
As seen in FIGS. 2 , 4 , 7 and 8 , the cable support member or flange 44 extends outwardly from the body portion 42 in a direction that is substantially tangent to an imaginary circle with its center located at the center axis of the internal bore 46 . The free end of the cable support flange 44 has a threaded hole 72 therein for receiving a cable adjusting bolt 73 of the cable adjusting unit 26 a as seen in FIGS. 2 and 4 . The cable adjusting unit 26 a adjusts the relative tension between the outer casing 24 a and the inner wire 25 a. Specifically, as seen in FIGS. 13-15 , the cable adjusting bolt 73 has a head portion 73 a and a threaded shaft portion 73 b with an axially extending bore 73 c extending through both the head portion 73 a and the threaded shaft portion 73 b.The bore 73 c is step-shaped for accommodating outer casing 24 a and inner wire 25 a in a conventional manner. The head portion 73 a is a tubular member with a textured outer surface.
The threaded shaft portion 73 b has threads on its outer surface that threadedly engaged the internal threads of the threaded hole 72 . Accordingly, rotation of the cable adjusting bolt 73 causes the cable adjusting bolt 73 to move axially relative to the cable support flange 44 . As seen in FIGS. 2 and 4 , the cable adjusting bolt 73 has a cable adjusting nut 74 located on the threaded shaft portion 73 b. The cable adjusting bolt 73 ( FIGS. 13-15 ) and the cable adjusting nut 74 ( FIGS. 16 and 17 ) form the cable adjusting unit 26 a for controlling the tension within the brake cable 19 a.
Turning now to FIGS. 6 and 18 - 20 , the right caliper portion 40 is fixedly coupled to the second end 50 of the left caliper portion 38 by the bolts 41 . The right caliper portion 40 substantially closes off the open end of the second end 50 of the left caliper portion 38 , except for a slot for accommodating the disc brake rotor 20 a. Accordingly, the right caliper portion 40 has a pair of through bores 75 for receiving the bolts 41 therein. Preferably, these through bores 75 are step-shaped so that the heads of the bolts 75 are recessed from the outer surface of the right caliper portion 40 .
Also, the right caliper portion 40 has a threaded bore 76 for receiving the pad axle 77 therein. Preferably, as seen in FIGS. 23 and 24 , the pad axle 77 is a threaded bolt having a head portion 77 a and a shaft portion 77 b extending outwardly from the head portion 77 a. The section of the shaft portion 77 b adjacent the head portion 77 a is provided with threads 77 c that threadedly engage the threaded bore 76 of the right caliper portion 40 . The free end of the shaft portion 77 b is preferably provided with an annular recess 77 d for receiving a retaining clip 78 .
The inner surface of the right caliper portion 40 has a brake pad mounting recess 80 that has the shape of the periphery of the brake pad 32 , such that the right brake pad 32 is securely retained against the inner surface of the right caliper portion 40 . This brake pad mounting recess 80 should be sized and shaped such that the right brake pad 32 does not rotate or move. The side edges of the right caliper portion 40 has a pair of cutout portions 82 for forming a half of the disc brake rotor slot.
As seen in FIGS. 5 and 6 , the left and right brake pads 32 are substantially identical to each other and can preferably be interchanged with each other. As seen in FIGS. 21 and 22 , the right and left brake pads 32 each include a rigid support plate 83 and an arcuate portion of friction material 84 attached to the support plate 83 for engaging the brake rotor 20 a. The rigid support plate 83 having a mounting tab 85 with a bore 86 therein for receiving the pad axle 77 ( FIGS. 6 , 23 and 24 ) therethrough. When the brake pads 32 are mounted on the pad axle 77 , the brake pads 32 can move axially on the pad axle 77 , but cannot rotate due to the structure of the brake pad mounting recesses 67 and 80 of the left and right caliper housings 38 and 40 .
As seen in FIGS. 6 and 25 - 28 , a pad spring 87 is provided between the left and right brake pads 32 to bias them apart. The pad spring 87 is preferably constructed of a thin resilient material, such as a spring steel. The pad spring 87 has a central connecting portion 87 a and a pair of biasing portions 87 b extending outwardly from opposite ends of the connecting portion 87 a. The connecting portion 87 a is preferably an inverted U-shaped member with a pair of axially aligned holes 87 c that receive the pad axle 77 . The biasing portions 87 b are also inverted U-shaped members that diverge outwardly to their free ends relative to a center line bisecting the connecting portion 87 a.
Turning again to FIGS. 5 and 6 , the cam assembly 34 basically includes an input cam 90 , an output cam 91 , a set of rolling members 92 , a return spring 93 , an output cam rotation stopper 94 , a retainer 95 and a bushing 96 . Basically, the cam assembly 34 is located in the internal bore 46 of the left caliper portion 38 and is adapted to expand in an axial direction by movement of the actuating assembly 36 via the brake operating mechanism 18 a. In particular, rotation of the input cam 90 by the actuating assembly 36 causes the output cam 91 to move in an axial direction against the force of the return spring 93 and the pad spring 87 to compress the left and right brake pads 32 together against the disc brake rotor 20 a.
As seen in FIGS. 29-33 , the input cam 90 has a cam member 90 a with an operating shaft 90 b extending from one end and a guide pin 90 c extending outwardly from the other end. The cam member 90 a has an axially facing camming surface 90 d with three camming slots 90 e that receive the three roller members 92 (balls). These camming slots 90 e are preferably arcuate slots that curve about the center rotational axis of the input cam 90 . These camming slots 90 e are ramp-shaped and have an angled bottom surface that is preferably sloped approximately 17° relative to a plane passing perpendicularly through the axis of rotation of the input cam 90 . Accordingly, when the input cam 90 is rotated, the rolling members 92 will move in a circumferential direction within the camming slots 90 e, such that all of the rolling members 92 are located at the same position within the camming slots 90 e to axially move the output cam 91 .
The operating shaft 90 b is preferably a step-shaped shaft having a first cylindrical section 90 f, a second non-cylindrical section 90 g and a third cylindrical section 90 h. The first cylindrical section 90 f is sized to be received in the first section 51 of the internal bore 46 of the left caliper portion 38 . Preferably, the bushing 96 is located around the first cylindrical section 90 f as seen in FIG. 5 . The second non-cylindrical section 90 g of the operating shaft 90 b is adapted to non-rotatably support a portion of the actuating assembly 36 , as discussed below. The third cylindrical section 90 h of the operating shaft 90 b is preferably threaded for receiving a nut 97 to secure the actuating assembly 36 thereto.
The guide pin 90 c is preferably a short pin that is located on the longitudinal axis of the input cam 90 and engages the output cam 91 to ensure smooth movement of the output cam 91 relative to the input cam 90 .
Referring now to FIGS. 34-38 , the output cam 91 basically includes a camming member 91 a and a thrust shaft 91 b. The camming member 91 a is preferably a cylindrical member having a camming surface 91 c facing the camming surface 90 d of the input cam 90 . The camming surface 91 c is preferably provided with three camming slots 91 d that are substantially identical to the camming slots 90 e of the input cam 90 and are adapted to engage the rolling members 92 to move the output cam 91 axially in response to rotational movement of the input cam 90 .
As seen in FIGS. 5 , 34 and 38 , the camming surface 91 c of the output cam 91 is also provided with a centrally located blind bore 91 e that is adapted to receive the guide pin 90 c therein. Preferably, the lengths of the guide pin 90 c and the blind bore 91 e are such that they do not disengage at any time during the axial movement of the output cam 91 relative to the input cam 90 . The thrust shaft 91 b of the output cam 91 is preferably a non-circular member that engages the output cam rotation stopper 94 , which in turn engages the left caliper portion 38 so that the output cam 91 cannot rotate relative to the left caliper portion 38 .
In particular, the rotation stopper 94 , as seen in FIGS. 39-41 , has an annular center section 94 a with a non-circular hole 94 b that is adapted to receive the thrust shaft 91 b of the output cam 91 therein such that there is no relative rotation therebetween. A pair of tabs 94 c are located 180° apart and extend radially outwardly from the center section 94 a of the rotation stopper 94 . These tabs 94 c are received in the slots 65 of the left caliper portion 38 such that the rotation stopper 94 cannot rotate relative to the left caliper portion 38 . Thus, since the rotation stopper 94 cannot rotate, the output cam 91 cannot rotate. The rotation stopper 94 is secured on the thrust shaft 91 b of the output cam 91 by the retainer 95 . The retainer 95 is preferably a C-shaped snap ring. This C-shaped snap ring or retainer 95 is received in the annular groove 66 formed in the internal bore 46 of the left caliper portion 38 .
As seen in FIG. 5 , the return spring 93 for the output cam 91 is located between the output cam 91 and the output cam rotation stopper 94 . Preferably, the return spring 93 is a conically-shaped compression spring (as seen in FIGS. 42 and 43 ) that has an inner diameter at its small end 93 a that is substantially equal to the outer width of the thrust shaft 91 b of the output cam 91 , and an outer diameter at its large end 93 b that is substantially equal to or slightly smaller than the inner diameter of the second section 52 of the left caliper portion 38 . When the cable disc brake 12 a is assembled, the return spring 93 should not be compressed, or only under a slight amount of compression. However, this compression should not be such that it has a biasing force of the return spring 93 that is greater than the biasing force of the pad spring 87 . In other words, the biasing force of the output cam return spring 93 , relative to the biasing force of the pad spring 87 in its normal rest position, should not compress the pad spring 87 .
The actuating assembly 36 basically includes an actuating arm 98 , a return spring 99 and a cover 100 that are secured on the first end 48 of the left caliper portion 38 via the nut 97 . The actuating assembly 36 basically includes an actuating arm 98 that is fixedly secured to the third section 90 h of the operating shaft 90 b of the input cam 90 .
As seen in FIGS. 44-48 , the actuating arm 98 has a cylindrical main portion 98 a with an outwardly extending cable mounting portion 98 b. The central mounting portion 98 a has a step-shaped bore 98 c extending therethrough with a first cylindrical section 98 d and a second non-cylindrical section 98 e. An abutment surface 98 f is formed between the first cylindrical section 98 d and the second non-cylindrical section 98 e. This abutment surface 98 f has three bores 102 for mounting the return spring 99 thereto. Preferably, the centers of the bores 56 are spaced approximately twenty-five degrees apart in a circumferential direction.
As seen in FIGS. 2 and 4 , the cable mounting portion 98 b has a threaded bore 98 g at its free end for receiving a clamping bolt 103 with a clamping plate 104 to secure the end of the inner wire 25 a of the cable 19 a thereto. Preferably, the cable mounting portion 98 b also has a recess 98 h around the threaded bore 98 g for receiving the clamping plate 104 , and to prevent relative rotation of the clamping plate 104 . A projection 98 i is formed at the free end in the direction of the inner wire 25 a of the cable 19 a. This projection 98 i has a curved surface for supporting the inner wire 25 a of the cable 19 a during rotation of the actuating arm 98 .
As seen in FIGS. 5 , 6 and 49 - 51 , the return spring 99 is preferably a torsion spring having a coil portion 99 a with first and second ends 99 b and 99 c extending in opposite axial directions from the coil portion 99 b. The first end 99 c is received in one of the bores 56 of the left caliper portion 38 , while the second end 99 c of the return spring 99 is received in one of the bores 102 of the actuating arm 98 . The first and second ends 99 b and 99 c are preferably longitudinally aligned with each other in the rest position.
The bores 56 and 102 form an adjustment mechanism for controlling the biasing force of the return spring 99 on the actuating arm 98 . The biasing force between the caliper housing 30 and the actuating arm 98 can be adjusted by selecting various combinations of the bores 56 and 102 . If both the first and second ends 99 b and 99 c of the return spring 99 are moved one hole in the same direction, then a 5° adjustment can be attained. For example, if the first and second ends 99 b and 99 c are located in the center bores 56 and 102 , then either direction will result in a ±5° change in the biasing or urging force of the return spring 99 . Of course, the first and second ends 99 b and 99 c can be adjusted independently for greater adjustment.
Moreover, it will be apparent to those skilled in the art from this disclosure that additional hole bores 56 and 102 can be provided for additional adjustment. Moreover, the angular spacing of the bores 56 and 102 can be changed as needed and/or desired. In any event, the angular spacing between the bores 56 and the angular spacing between bores 102 are preferably different from each other to provide for a small incremental adjustment of the return spring 99 . As seen in FIG. 4 , only five of the bores 56 and 102 are illustrated since one of the bores 56 is axially aligned with one of the bores 102 .
When the cable disc brake 12 a is in the assembled position, the return spring 99 normally biases the input cam 90 and the actuating arm 98 to a brake releasing position. When the rider squeezes the brake lever 21 a, the inner wire 25 a of the cable 19 a moves relative to the outer casing 24 a of the cable 19 a to cause the actuating arm 98 and the input cam 90 to rotate together. This rotation causes the rolling members 92 to move from the deep ends of the camming slots 90 e and 91 d to the shallow ends of the camming slots 90 e and 91 d. As the rolling members 92 move within the camming slots 90 e and 91 d, the output cam 91 is moved in an axial direction against the biasing force of the output cam return spring 93 . This axial movement of the output cam 91 causes the left brake pad 32 to move against the urging force of the pad spring 87 to engage the rotor 20 a, which is then pressed against the right brake pad 32 . This engagement of the brake pads 32 with the disc brake rotor 20 a causes the braking action of the cable disc brake 12 a.
Referring now to FIGS. 5 , 52 and 53 , a cover 100 is located between the actuating arm 98 and the first end 48 of the left caliper portion 38 . Preferably, this cover 100 fits on the outer annular end surface 54 of the first end 48 of the left caliper portion 38 so as to seal the space between the actuating arm 98 and the left caliper portion 38 .
While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. Furthermore, the foregoing description of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
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A bicycle cable disc brake is provided with a cam assembly that has improved efficiency during movement under high pressure. Basically, the cable disc brake has a cable housing, a pair of friction members and an actuated mechanism. The first friction member is movably coupled to the caliper housing between a release position and a braking position. The second caliper is also coupled to the caliper housing and arranged substantially parallel to the first friction member to form a rotor receiving slot therebetween. The actuated mechanism is movably coupled to the caliper housing to move the first friction member from the release position towards the second friction member to the braking position. The actuated mechanism has a pair of cam members movably arranged between an axially retracted position and an axially extended position with a guide member interconnecting the cam members during movement between the axial retracted position and the axially extended position. In the preferred embodiment, the guide member is a guide pin that extends from one of the cam members and is received in a bore of the other cam member.
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BACKGROUND OF THE INVENTION
This invention relates to improving the heat distortion temperature (HDT) and tensile strength of: glass fiber reinforced (GFR) poly(vinyl chloride) (PVC) without vitiating other physical properties of the GFR PVC. More specifically, this invention relates to the improvement of the foregoing properties, inter alia, by blending the PVC with a particular copolymer, reinforcing it with specifically sized glass fiber, and incorporating these components with a unique mixing procedure.
It is known that, with an aminosilane coupling agent and the correct choice of sizing agent, glass fibers may be so strongly bonded to the PVC that a GFR PVC composite formed therewith fails in cohesive failure. By "cohesive failure" we refer to failure of a sample of GFR VC resin due to tearing of resin from resin, rather than tearing of resin from the glass surface ("adhesive failure"). Thus, cohesive failure is predicated upon the resin's properties rather than upon the bond between resin and glass.
Details of the mechanism of the reaction thought to be responsible for the improved physical properties of the aforementioned GFR PVC composite are taught in U.S. Patent No. 4,536,360 to Rahrig, D., the disclosure of which is incorporated by reference thereto as if fully set forth herein. However, the utilization of the Rahrig GFR PVC in applications requiring operation of an article at relatively high temperature under load, is restricted by the limitation of the relatively low HDT of the GFR PVC. Though the HDT of PVC is improved by the presence of the glass, this improvement of HDT in the range from about 10% by weight (wt) to about 30% by wt of glass, based on the total wt of the GFR PVC, is only marginal. For example, the HDT of GFR commercial grade Geon R 86 PVC, reinforced with 10% glass is about 165° F. (74° C.), and with 30% glass is about 170° F. (76.7° C.).
An improvement was subsequently made relating to a wider choice of film formers to catalyze the thermal dehydrohalogenation of the VC homopolymer at the fiber-resin interface so as to generate allylic Cl moieties in chains of the homopolymer, which moieties react with the amine groups of the aminosilane. Details of this improvement are taught in copending U.S. patent application Ser. No. 897,437 filed Aug. 18, 198, now U.S. Pat. No. 4,801,627 the disclosure of which is incorporated by reference thereto as if fully set forth herein. However, a wide spectrum of film formers fell far short of providing a noticeable improvement in HDT, or resulted in a noticeable loss in tensile strength, degradation of spiral flow, etc. and failed to fill the need for an inexpensive, durable and rugged GFR PVC composite with relatively higher HDT, at least equivalent tensile strength, excellent wet strength and only a small loss in impact strength, compared to the aforementioned prior art composites. By "equivalent tensile strength" we mean that the measured tensile strength is not less than 90% of that of a similar prior art composite.
By relatively higher HDT we refer to a HDT of at least 80° C. (176° F.) which is about 3° C. (5.4° F.) higher ed according to the '360 patent. The HDT of general purpose grade injection molding PVC resin is about 74° C. (165° F.), and by reinforcing it with 30% glass fibers sized as in the '360 patent, the HDT is about 76.7° C. (170° F.). It must be borne in mind that such GFR PVC having a HDT of less than 170° F. has inadequate tensile strength and creep resistance under load for general purpose applications where the GFR article is exposed to harsh environmental conditions which may reach to about 180° F.. Such a temperature is reached in a closed automobile left in the sun on a summer day in the southern U.S., in northern Africa, or in southeast Asia, temperatures in the range from 76.7°-79.4° C. (170°-175° F.) being more common than those in the range 2° C. (175°-180° F.). Thus, every degree of improvement in HDT resulted in being able to assure the usefulness of a shaped article made from the GFR PVC blend at a higher temperature than prior art materials, without any substantial loss in desirable physical properties. In particular, it was essential that the tensile strength of the Rahrig composites at least be matched, if not improved. Since there is a need for GFR PVC articles which will withstand each progressive incremental degree above 170° F. for such harsh environmental exposure, the subject matter of this invention derived from a deliberate and concerted effort to fill that need.
Since the improvement sought primarily related to maintaining the chemistry at the surface of the glass fiber, which chemistry was known to be effective, it was logical to search for a copolymer which was miscible with PVC. Since the improvement also sought to improve HDT it was logical to seek a copolymer which contributed high HDT to a blend in which it was a component. But the presence of the copolymer could not adversely affect the bonding of the PVC to the glass fibers.
From the foregoing related disclosures it was known that effective bonding relied upon there being a sufficient number of runs of 10 or more C atoms in VC chains to generate an allylic chlorine (Cl) moiety in the VC chain, represented thus:
--CH.sub.2 --CHCl--CH═CH--CH.sub.2 --CHCl--CH.sub.2 --CHCl under
under thermoforming conditions. But it was not known what effect the presence of a blended copolymer would have in this regard, though it was evident that its structure and the relative number of copolymer chains present, would be determinative.
Therefore the choice of the copolymer to be blended with the PVC required that the copolymer not interfere with the ability of the PVC to generate the necessary allylic Cl moiety.
From the foregoing related disclosures it was also known that the enhanced properties of the improved composite (relative to GFR PVC composites which failed in adhesive failure) required the use of an aminosilane coupling (or keying) agent (sometimes referred to as `finish`) which is essential, in combination with certain polymeric film formers used in the production of glass fibers, most preferably from E glass.
Therefore the choice of the copolymer to be blended with the PVC required that the copolymer not interfere with the ability of the aminosilane to provide the necessary chemistry to perform its designated task.
From the foregoing related disclosures it was also known that the enhanced properties of the improved composite (relative to GFR PVC composites which failed in adhesive failure) required the use of a particular "size", namely one which has sufficient basicity as evidenced by a Cl(2p)/C(1s) peak ratio of at least 0.91.
Therefore the choice of the copolymer to be blended with the PVC required that the copolymer not interfere with the basicity of the film former used to provide the necessary chemistry to perform its designated task.
Since the chemistry occurring at the surface of the glass fiber was critical to the successful reinforcement of any blend, the question which presented itself was not whether, but how, that chemistry would be affected by the presence of any copolymer known to provide high HDT at the elevated processing temperature necessary to thermoform, and specifically extrude, or injection mold, PVC resin composites, not to mention that any effect on this chemistry would further be complicated by the presence of a stabilizer without which a PVC resin cannot be effectively thermoformed.
Finally, assuming the "correct" polymer was found for producing the desired GFR PVC blend with improved HDT, one had to recognize that there may be a decrease in tensile strength, spiral flow and impact strength, rather than an overall improvement in any one property, particularly tensile strength.
In view of the foregoing, it seemed logical to search for a suitable copolymer first among those known to be miscible with PVC, and it was convenient to search among these copolymers for those which could be prepared from readily available monomers, and those which were commercially available. In this framework it was not long before the commercially available PVC blends with copolymers disclosed in U.S. Pat. No. 3,053,800 to Grabowski et al claimed our attention. What received even more of our attention was that, despite the clear teaching that the excellent HDT and impact strength of their blends were most useful for rigid shaped articles for use under conditions where high environmental stability was required, there was a singular lack of any suggestion that the blend may be reinforced with any reinforcement of any kind, in any way. This lack of what should have been an opportunity to explore technology known at the time to provide reinforcement of polymers generally, to make an improvement directly in line with the purpose for which the blend was found most useful, led us to believe that the reinforcement of such blends was seriously circumscribed.
Further inspection of the '800 patent for assistance indicates that in the three-component blend of (i) PVC with (ii) the copolymer of alpha-methyl styrene ("AMS"), styrene ("S") and acrylonitrile ("AN") (the copolymer is referred to as alpha-SAN, for brevity), and (iii) the graft copolymer of the polybutadiene latex (rubbery phase), the alpha-SAN and rubbery phases are each critical for the formation of the blend with PVC. Since the rubbery phase of graft copolymer (of AN and S grafted to a PBD latex) is known to exist as a discontinuous rubbery phase in PVC, it was concluded that in a blend of the three components, alpha-SAN provided the continuous phase while PVC and the graft copolymer existed as the discontinuous phases. It seemed highly improbable that a relatively small amount of alpha-SAN copolymer by itself (that is, without the graft copolymer) blended with a major amount of PVC might provide an essentially single phase having a significantly improved HDT, that is, at least 80° C. (176° F.).
It was in the foregoing framework that we discovered that a GFR blend of PVC and alpha-SAN copolymer would provide a substantially single phase which could be reinforced with a particularly sized glass fiber to provide a GFR composite of the blend having a HDT of at least 80° C. (176° F.). In such a composite, the PVC preferentially wets the glass to produce desirable cohesive bonding resulting in improved tensile strength, only if the amount of alpha-SAN copolymer in the blend was maintained in the narrowly defined range of from 15 to about 40 phr (parts by weight (wt) per 100 parts of blended resin). An amount less than 15 phr produces no substantial improvement of HDT, and an amount greater than 40 parts produces a brittle composite with unacceptably low impact strength.
Though impact modification of PVC by using a specific combination of impact modifiers, namely the ABS graft copolymer and the alpha-SAN copolymer, was the sole thrust of the '800 patent, our invention provides a PVC blend with excellent HDT and tensile, in addition to good spiral flow and retention of tensile and impact strength after long exposure to water. These properties, namely tensile and resistance to water, derive from the cohesive bonding we obtain, which only Rahrig suggested.
Having thus arrived at a composition of a GFR PVC blend which would meet the criteria for use under harsh environmental conditions when injection molded or compression molded without an impact modifier, it became evident that an extrusion grade blend would require a compatible impact modifier. Since it was known that the acrylonitrile, butadiene, styrene graft copolymer of the '800 patent provided the impact performance in that blend because there was good "wetting" of the non-rubbery phase it seemed that it would lend itself particularly well as a suitable impact modifier. However, we found that the wetting was not good enough to provide the desired morphology and chemical reactions required to produce reliable and reproducible cohesive failure in a composite. Hence it became necessary to provide a more suitable impact modifier, which we have done.
SUMMARY OF THE INVENTION
It has been discovered that a resin blend comprising from 60 to 85 parts by weight (wt) of PVC with no more than 40 parts by wt of a copolymer of alpha-methyl styrene ("AMS"), styrene ("S") and acrylonitrile ("AN"), and less than 20 parts by wt additives including stabilizers, antioxidants, lubricants, and processing aids, may be thermoformed with particularly sized glass fibers at an elevated processing temperature to provide a reinforced composite in which the PVC is covalently bonded to the glass fiber so as to have a substantially higher HDT and substantially equivalent tensile strength compared to that of a similarly reinforced unblended PVC composite, without sacrificing other desirable physical properties of the novel composite.
It is therefore a general object of this invention to provide a GFR PVC composite consisting essentially of a PVC blend with an alpha-SAN copolymer, the blend containing a stabilizer against degradation during thermoforming, in which composite the glass fibers are sized with (i) an aminosilane coupling agent, and (ii) a basic film former, more basic than poly(vinyl acetate) ("PVA"), present in an amount sufficient to catalyze the thermal dehydrohalogenation of the PVC homopolymer at the fiber-resin interface so as to generate allylic Cl moieties in chains of the homopolymer, which moieties react with the amine groups of the aminosilane. The size is most conveniently coated on the fibers from a sizing solution, dispersion or emulsion containing the coupling agent and film former.
It is also a general object of this invention to provide a surprisingly effective sequence of mixing for preparing a GFR blend of a major amount of PVC and a minor amount of a copolymer of AMS, S and AN, reinforced with from 10 to 30 parts by wt of glass fiber sized with an aminosilane coupling agent, and, a polymer film former selected from the group consisting of (i) a polymer with a nitrogen-containing repeating unit such as an amine, amide, ureido, or urethane group, and (ii) a dispersible or emulsifiable epoxide polymer, which composite, upon extraction with THF, and a subsequent XPS examination, yields a Cl(2p)/C(1s) ratio of at least 0.91, and more preferably of at least 1.13, the sequence requiring that the PVC and copolymer be homogeneously blended into a single phase, then substantially homogeneously dispersing the glass fibers in the blend.
It is still another object of this invention to provide pellets of the foregoing GFR PVC homopolymer which may be thermoformed into a shaped article which is characterized by a HDT of at least 80° C. (176° F.), excellent dry strength, and also excellent wet strength after 168 hr (hours) of exposure to 50° C. (122° F.) water; which fails in cohesive failure; and, which has a higher tensile strength, and at least substantially equivalent HDT compared to that of an identical GFR PVC composite prepared with a different mixing sequence.
Other objects and advantages of the invention will be evident to one skilled in the art from the following detailed description of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the most preferred embodiment of the invention the PVC homopolymer used in the PVC-copolymer resin blend is obtained by either the mass or suspension polymerization techniques, in the form of porous solid macrogranules. By "copolymer" I refer hereinafter to alpha-SAN. Macrogranules of PVC typically have an average diameter in excess of 20 microns, with a preponderance of particles in excess of 50 microns in diameter. Suspension polymerized PVC desirably has a porosity in the range from about 0.1 to about 0.35 cc/g, a surface area in the range from about 0.6 m 2 /g to about 3 m 2 /g, and an inherent viscosity in the range from about 0.46 to about 1.2, that is, having a relatively high molecular weight. The mol wt may be related to its inherent viscosity which is determined as taught in U.S. Pat. No. 4,412,898. The most commonly used PVC resins have an inherent viscosity in the range from about 0.53 to about 1.1, or slightly higher, and are referred to as "rigid PVC". Such a resin is commercially available from The B. F. Goodrich Company under the Geon R 86 or 110X377 designations.
It is well known that the key to providing satisfactory strength in a GFR PVC composite is the proper choice of "size" or "sizing" on the glass fibers which are coated with an aqueous sizing solution, suspension, or emulsion consisting essentially of water in which is dispersed a coupling agent, film former, lubricant, surface Z5 active agent, "antistat", plasticizer and the like, sometimes with a water-soluble colloid to provide the necessary stability for the dispersed polymeric film former. It is most important to use the correct combination of coupling agent and film former in the "size".
Glass fibers sized for use in our invention may be used in strands, rovings, tow or yarns, which are treated specifically for use in a GFR thermoplastic resin. Unsized glass fibers are also referred to as untreated, pristine, or bare glass glass.
Glass fibers for use in this invention are conventionally sized with known aminosilane coupling agents and film formers, surfactants, lubricants and the like, but the fibers have unexpectedly shown an improvement in HDT, tensile strength, and spiral flow of a thermoplastic PVC-alpha-SAN copolymer blend shaped into an article of arbitrary shape reinforced with the fibers. When such a composite containing 30 wt % glass is molded from a typical GeonR injection molding PVC-alpha SAN blend without an impact modifier, the composite has a HDT (ASTM D 648) of at least 80° C., a minimum tensile strength (ASTM D 638) of about 12,000 psi, and an notched Izod impact at room temperature (ASTM D 256) of about 1.0 ft.lb/in 2 . Such strength was never before deliberately or reproducibly attained, except in the aforesaid '360 Rahrig patent, but the annealed HDT of the composite was only as high as 76.7° C. (170° F.).
All references to HDT herein refer to annealed HDT, to minimize differences due to residual stresses such as remain in an injection molded, extruded, compression molded, or otherwise thermoformed composite sample tested. All samples were annealed at 70° C. for 24 hr.
Though the type of glass, and the diameter of the fibers is not critical, relatively soda-free lime-aluminum borosilicate glass, such as "E" and "S" glass is preferred, drawn into filaments having a diameter less than 20 microns, preferably from 10 to about 16 microns.
The length of the filaments, and whether they are bundled into fibers and the fibers bundled, in turn, into yarns, ropes or rovings, or woven into mats, and the like, are not critical to the invention, but it is most convenient to use filamentous glass in the form of chopped strands from about 1 mm to about 27 mm long, preferably less than 10 mm long. In the composition most preferably used for producing pellets in the size range from about 3 mm to about 8 mm in equivalent diameter, which pellets are used to mold shaped articles, even shorter glass fiber lengths, generally less than 1 mm will be encountered because, during compounding, considerable fragmentation will occur, some fibers being as short as 100 microns.
The best properties of the thermoformed composites are obtained when the glass fibers are present in an amount in the range from about 5% to about 50% by wt, based on the wt of combined glass fibers and resin; and the fibers are in the range from about 500 microns to about 1 mm long. It will be appreciated that less than 5% by wt fibers has little reinforcing value, and more than about an equal part by wt of glass fibers, relative to the amount of PVC resin, results in a mixture which cannot be satisfactorily processed.
The most widely used size for glass fibers used in GFR composites for general purpose reinforcing of resins contains a suspension of poly(vinyl acetate) particles in an aqueous medium. Polyesters, epoxides, poly(methyl methacrylate) and polystyrene are also used as film-formers sometimes on their own, sometimes as separate additives to the size, and sometimes as a copolymer with poly(vinyl acetate). No film former was considered to have a reactive or catalytic function in the composite.
The essential qualification of a size found satisfactorily to fulfil the strengthening function of glass fiber in PVC resin is its (the size's) ability to generate allylic chlorine (Cl) moieties in a zone adjacent the surface of each glass fiber ("fiber-resin interface") where the moieties can react with the primary amine moiety of the coupling agent. This concept is taught and illustrated in the aforementioned Rahrig patent. The specific effective combination disclosed therein for a PVC resin is (a) an aminosilane coupling agent, and, (b) a polymer film former of a ring-opened lower alkylene oxide containing 1 to 4 carbon atoms as an essential component in a repeating unit, for example poly(ethylene oxide:propylene glycol) ("PEO"), optionally containing another copolymerizable component.
The reaction of aminosilane coupling agents with PVC resin occurs between aminosilane and PVC during mixing, and this reaction involves the C═C bonds present in the PVC. Whether these bonds are generated in a sufficient quantity at or near the interface of glass surface and VC resin, to strengthen the reinforcing effect of the glass fibers appreciably, depends on the basicity of the film former and the characteristics of the repeating units in its generic structure.
Any aminosilane coupling agent in which the silanol end couples to the glass leaving an amino-functional end for coupling the PVC, may be used. In addition to the specific ones represented by the formula (I) hereinabove, these may be represented by the general formula
A--Si--B.sub.3
wherein A represents an amino-functional radical which bonds with the PVC resin, and,
B represents a hydrolyzable radical which leads to bonding of the silane silicon atom to the glass surface through oxane bonds such as --SiOSi--, or --AlOSi-- bonds.
In the above formula (II), A typically represents an aminoalkyl radical such as H 2 NCH 2 CH 2 CH 2 --or H 2 NCH 2 CH 2 NH--CH 2 CH 2 CH 2 Numerous commercially available aminosilanes represented by formula (I) are disclosed in the Rahrig '30 patent, and the polyaminosilanes such as the diaminosilanes and triaminosilanes are most preferred.
The aminosilane is generally liquid and, because the amount to be deposited on the fibers is relatively small, unhydrolyzed aminosilane is applied to the fibers from a solution, dispersion or emulsion, usually in water, of preselected concentration.
Evaluation of the adhesion of glass fiber to PVC resin in a composite was done by measuring the composite tensile strengths and the Izod impact strengths, both notched and unnotched. In addition, the scanning electron microscopy was used to examine the fracture surfaces of composite specimens to determine when failure was not cohesive failure.
The GFR PVC thermoplastic resin composition in the best mode of this invention consists essentially of from about 60 to about 85 parts, preferably from 65 to 75 parts by wt of PVC resin; from 15 to about 40 parts, preferably from 20 to 30 parts by wt of copolymer; and from 10% to about 35% by wt of glass fibers coated with from 0.2% to about 0.6% by wt of a specified aminosilane, and from 0.2% to about 0.6% by wt of a specified film former. If the amounts of each of the foregoing is substantially outside the specified ranges, the HDT may be relatively high, but the moldability and processability of the glass fibers and resin is reduced, the composite fails in adhesive failure, and both the dry strength and wet strength are vitiated.
The PVC-copolymer blend is typically stabilized with a metallo-organic salt or soap, or an organometallic compound having a carbon-to-metal bond, specifically to counter the thermal dehydrohalogenation of the VC resin during thermoforming, and such a stabilizer is essential in our composition. The stabilizer does not negate the same reaction catalyzed by the film former and/or aminosilane coupling agent. The stabilizer is generally present in an amount less than about 5 phr.
Evidence for the catalytic action of the film former is provided by the rate and extent of HCl evolution when the film former and PVC resin are blended. Addition of the copolymer does not appear to diminish the catalystic action sufficiently to diminish the physical properties obtained without the copolymer.
The generic structure of the film former is not narrowly critical provided it is more basic than PVA which itself is basic. The essential criterion for desirable tensile strength of at least 12,000 psi, is provided by sufficient basicity, as evidenced by a Cl(2p)/C(1s) peak ratio of at least 0.91. Any film former of polyester, polyamine, polypyrrolidone, polysulfide, polyalkylene sulfide, or polymer with aromatic or olefin groups, which film former is sufficiently basic to yield the minimum Cl(2p)/C(1s) ratio, will provide an improvement in tensile strength. More preferred are those which produce at least double the tensile of an unreinforced PVC-copolymer blend, that is, without glass fibers.
Most preferred are film formers which are soluble in an aqueous sizing solution, but the method of coating the glass is not critical provided a sufficient amount of film former is deposited to catalyze a reaction in which allylic Cl moieties in the VC resin chain are covalently bonded to an aminosilane. Less preferred are non-aqueous solutions, because of difficulty dealing with an organic solvent economically, and aqueous dispersions which are binary colloid systems in which particles of polymer are dispersed in a continuous phase (water). More preferred because of better stability are emulsions which are colloidal mixtures of two immiscible fluids, one being dispersed in the other in the form of fine droplets, the one preferably being water.
The alpha-SAN copolymer employed in the production of the PVC blend is prepared by the copolymerization of a minor proportion of vinyl cyanide or a vinyl cyanide type compound, and a major proportion of an asymmetrical alkyl, aryl substituted ethylene. Particularly suitable copolymers of his nature are obtained if the greater part of the total monomer mixture comprises a relatively large quantity of alpha-methyl styrene together with a small quantity of styrene and the lesser part of the total monomer mixture comprises acrylonitrile (AN). The AN preferably comprises from about 20% to about 30% by weight (wt) of the total monomer mixture employed in forming the blending resin. The vinyl aromatic hydrocarbon and/or asym. alkyl, aryl substituted ethylene comprise, correspondingly, from 80% to 70% by wt of the reaction mixture and, as mentioned previously, may consist of alpha-methyl styrene (AMS) exclusively or advantageously may be a mixture of AMS and S in a ratio of from about 50:50 to say 90:10 or higher.
The copolymer is formed as described in the Grabowski '800 patent, the disclosure of which is incorporated by reference thereto as if fully set forth herein. It is advantageous to employ a S-AMS mixture in order to accelerate the emulsion polymerization. Referring only to the binary S-AMS mixture, preferably this contains not more than about 7% to 15% styrene.
As used herein, the term "consists essentially of" means that the named ingredients are essential, though other ingredients which do not vitiate the advantages of the invention can also be included. Such ingredients may include conventional additives such as fillers like talc, mica, clay and the like, light stabilizers, heat stabilizers, antioxidants, pigments and dyes, lubricants and processing aids, as may be required for a particular purpose, it being recognized that the amount of the additive(s) used will affect the physical properties of the thermoformed composite. The combined amount of such additives is generally in the range from about 5 to about 20 phr, preferably from 5 to 10 phr, and are chosen from additives known to be compatible with commercially available general purpose PVC resin. For example, a typical stabilizer is Thermolite 31, a lubricant is Synpro 128 calcium stearate, and a processing aid is Acryloid K-120N, used in amount together totalling about 10 phr.
In addition, there may be included an impact modifier in an amount in the range from 0 to 25 phr, particularly for an extrusion grade PVC. Preferred impact modifiers are those which are graft copolymers of (i) a lower C 1 -C 3 alkyl ester of vinyl cyanide, or of an assymmetrical cyano, alkyl substituted ethylene compound such as methylmethacrylate, and (ii) a vinyl aromatic hydrocarbon or an asymmetrical alkyl, aryl substituted ethylene such as styrene, with (iii) a conjugated diolefin polymer latex, such as polybutadiene latex. Such impact modifiers are preferred because the non-rubber portion of the graft copolymer has better miscibility in the PVC-alpha-SAN copolymer phase than a comparable graft copolymer in which the acrylate is substituted with acrylonitrile, methacrylonitrile, or the like. The latter graft copolymers with acrylonitrile have undesirable immiscibility which adversely affects the desirable properties of the blend particularly with respect to obtaining impact resistance.
The composition of this invention is preferably formed in a multiple ported Buss Kneader having downstream and upstream ports into which latter ports the PVC resin, copolymer and other compounding ingredients are fed. The chopped glass roving is added in the downstream port. The discharge from the Buss kneader may be comminuted into pellets. The pellets may then be extruded or injection molded under essentially the same conditions as those conventionally used for the extrusion or injection molding of PVC.
Alternatively, sections of glass mat, or other shaped glass mat, for example U-shaped channel, or chair seats, may be impregnated with a powder mix of the blend ingredients, and then thermoformed under sufficient heat and pressure to melt the mix and bond the glass mat. Typically, for such impregnation, whether continuous or batch, the PVC, thermal stabilizer and alpha-SAN, optionally with impact modifier and additives, are first dry-mixed to form a homogeneous powder. If the glass mat is to be impregnated with an impact modified blend, the impact modifier is typically added as a powder and dry-mixed with the other ingredients and does not interfere with formation of the single phase of PVC and alpha-SAN.
Glass mat is then `dusted` or `filled` with the desired amount of powder mix, generally so that there is from about 30% to about 60% mix evenly spread through the
and the dusted mat is then molded under from 100-1000 psi pressure and from 170°-190° C. temperature to form shaped GFR article of PVC blend.
Glass mat, or other shaped glass fiber stock may also be impregnated with a melt of the blend ingredients, such as in pultrusion. Typically, there is about an equal weight of resin and glass fibers in each sheet. Several such sheets cut to a predetermined configuration may be stacked in a mold and conventionally molded at a temperature of 160°-200° C. and a pressure of about 1000 psi (about 30,000 lbf) to form a thick-walled shaped article.
The blend of PVC, copolymer and glass fibers must be prepared in a particular sequence of addition to get the maximum improvement in physical properties of the composite. We found that forming a single phase blend of the PVC and copolymer before adding the glass fibers yielded optimum physical properties. This essential order of mixing, namely adding the glass fibers after formation of the single phase, is demonstrated by the following three experimental runs in which 70 parts of PVC, 30 parts copolymer, and 10 percent by wt glass fibers were blended, each in a different sequence, at 150° C., to yield, when molded, test specimens each having a density of 1.32 gm/cc:
Run 1: PVC and glass fibers are mixed for just long enough to obtain a substantially homogeneous dispersion of the fibers in the PVC, as described in the Rahrig patent. The dispersion was then pelletized, and the pellets were blended with the copolymer before it was extruded. This sequence of mixing would be expected to allow the PVC to coat the glass fibers without interference of the copolymer. The amount of the copolymer coating the glass fibers would be expected to be proportional to the amount of copolymer present. Whatever the surface area of glass coated by the copolymer, its effect would be expected to diminish the bonding of the blend. Reinforcement of copolymer alone with the glass fibers shows poor physical properties. Therefore, coating the glass thoroughly with the PVC, before adding the copolymer would appear to be advantageous.
Run 2: The PVC and copolymer were blended until a single phase is formed and the glass fibers are then mixed in. The time and temperature of blending is the same as that for blending the PVC and glass in Run 1. Since the copolymer is miscible in the PVC the resulting blend is a single phase.
Run 3: The copolymer and glass fibers were first blended until a substantially homogeneous dispersion of the fibers is obtained. The PVC was then added to the mixture. The time and temperature of mixing is the same as that used in Run 1, but the copolymer and glass fibers are mixed first.
In each case, the same weight of pellets was molded into test specimens on a 40 ton Arburg molding press, and the specimens tested under standard ASTM test conditions.
The averaged physical properties of each of seven test specimens are listed in Table I herebelow:
TABLE I______________________________________Physical Property Run 1 Run 2 Run 3______________________________________Tensile strength (psi) 10,068 10,829 8,938Tensile Modulus (psi) 730,000 768,000 657,000Elongation at yield (%) 2.5 2.4 2.5Yield Work (ft-lbs/cu.in.) 14.2 14.1 12.6Flexural Strength (psi) 16,606 17,436 14,896Flexural Modulus (psi) 644,000 682,000 598,000Notched Izod (ft-lb/in) 0.7 0.8 0.6Unnotched Izod (ft-lb/in) 3.9 3.7 3.3Annealed HDT (°C.) 80 80 78Spiral flow (in) 32.7 33.3 32.8______________________________________
As is readily evident, the tensile strength of the samples of Run 2 is better than those of samples from runs 1 and 3, and though it is not much better, the difference is both significant and substantial. The same is true for the spiral flow. HDT of all samples is at least 4° C. (7° F.), and generally about 10° C. (18° F.) higher than that of a Rahrig composite containing the same amount of glass fibers (10% by wt) with the same size, and using the same PVC and combination of stabilizer, lubricants, etc.
In the following Table II is a comparison of the physical properties of the composites of this invention with those of the Rahrig '360 patent, and it is seen that the excellent properties of the prior art composites are substantially preserved. The values listed are the averaged physical properties of composite samples prepared from typical commercially available Geon R PVC (70 parts) blended with the alpha-SAN copolymer (30 parts) free of impact modifier, for use in injection molding applications in which the recommended melt temperature is the same for all samples, namely in the range from 196°-204° C. (385°-400° F.).
TABLE II______________________________________ Glass content of blend, % by wt Rahrig '360 This invention 10 20 30 10 20 30______________________________________Tensile strength, psi × 10.sup.3 10.5 12.8 13.9 10. 11.1 12.2Tensile modulus, psi × 10.sup.4 56. 96. 129. 66. 90. 122.5Elongation, % 6.0 2.7 2.0 3.3 2.4 1.5Flexural strength, 64. 97. 119. 65. 96. 120.psi × 10.sup.4Izod, notched, ft-lb/in 0.8 1.0 1.1 0.8 1.0 1.0@ - 40° C. 0.7 0.8 0.9 0.8 1.0 1.0Specific gravity 1.43 1.5 1.57 1.31 1.40 1.49HDT (annealed) 264 167 167 169 185 185 185psi, °F.Coeff of Therm Exp*, 2.0 1.3 1.2 2.2 1.7 1.2× 10.sup.-5Relative Spiral Flow, in. 32 28 25 32 28 25*in/in °F.______________________________________
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A high temperature PVC resin blend is made by blending from 60 to 85 parts PVC with no more than 40 parts of a ("alpha-SAN") copolymer of alpha-methyl styrene ("AMS"), styrene ("S") and acrylonitrile ("AN") and less than 20 parts by wt additives including stabilizers, antioxidants, lubricants, and processing aids. In addition, an impact modifier may be added. The blend with particularly sized glass fibers, may be thermoformed at an elevated processing temperature and pressure, to provide a reinforced composite in which the PVC is covalently bonded to the glass fiber. The composite has a substantially higher HDT and equivalent tensile strength, compared to that of a similarly reinforced, unblended PVC composite, without sacrificing the novel composite's other desirable physical properties. The glass is sized with an aminosilane coupling agent, and, a polymer film former selected from the group consisting of (i) a polymer with a nitrogen-containing repeating unit such as an amine, amide, ureido, or urethane group, and (ii) a dispersible or emulsifiable epoxide polymer, which composite, upon extraction with THF, and a subsequent XPS examination, yields a Cl(2p)/C(1s) ratio of at least 0.91, and more preferably of at least 1.13. Glass fibers, thus sized, provide cohesive bonding of the resin, so the composite fails in cohesive failure. A unique sequence of mixing the blend ingredients with glass fiber provides optimum properties in the composite. The sequence requires formation of a single phase of PVC and alpha-SAN copolymer before dispersing the glass fibers in the blend.
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This application is a Continuation of PCT/AU2006/001122, filed 8 Aug. 2006, which claims benefit of Serial No. 2006903269, filed 16 Jun. 2006 in Australia and which applications are incorporated herein by reference. To the extent appropriate, a claim of priority is made to each of the above disclosed applications.
FIELD OF THE INVENTION
This invention relates to underground boring and more particularly to an improved microtunnelling system and apparatus.
In this document “microtunnelling” is considered to comprise trenchless horizontal boring of a bore of the order of 600 millimeters and less.
BACKGROUND OF THE INVENTION
Modern installation techniques provide for underground installation of services required for community infrastructure. Sewage, water, electricity, gas and telecommunication services are increasingly being placed underground for improved safety and to create more visually pleasing surroundings that are not cluttered with open services.
Currently, the most utilised method for underground works is to excavate an open cut trench. This is where a trench is cut from the top surface and after insertion of piping or optical cable is then back-filled. This method is reasonably practical in areas of new construction where the lack of buildings, roads and infrastructure does not provide an obstacle to this method. However, in areas supporting existing construction, an open cut trench provides obvious disadvantages, major disruptions to roadways and high possibility of destruction of existing infrastructure (i.e. previously buried utilities). Also, when an open cut trench is completed and backfilled the resultant shift in the ground structure rarely results in a satisfactory end result as the trench site often sinks. Open trenches are also unsafe to pedestrians and workers.
Another concept employed for underground works is that of boring a horizontal underground hole. Several methods employ this philosophy as it generally overcomes the issues of disruption to roads and infrastructure as described for open cut trenches however even these methods have their inherent problems.
One method is horizontal directional drilling (HDD). In this method a boring device is situated on the ground surface and drills a hole into the ground at an oblique angle with respect to the ground surface. A drilling fluid is typically flowed through the drill string, over the boring tool, and back up the borehole in order to remove cuttings and dirt. After the boring tool reaches a desired depth, the tool is then directed along a substantially horizontal path to create a horizontal borehole. After the desired length of borehole has been obtained, the tool is then directed upwards to break through to the surface. A reamer is then attached to the drill string, which is pulled back through the borehole, thus reaming out the borehole to a larger diameter. It is common to attach a utility line or other conduit to the reaming tool so that it is dragged through the borehole along with the reamer. A major problem with this method is that the steering mechanism is extremely inaccurate and unsuitable for applications on grade. The stop and start action utilised by the operator results in a bore that is not completely straight. The operator has no way of knowing exactly where the hole goes which can result in damage to existing utilities. This could pose a safety threat particularly if the services in the area are of a volatile nature.
Another method is the pilot displacement method. This method uses a drill string pushed into the ground and rotated by a jacking frame. A theodolite is focused along the drill string as a point of reference to keep the line on grade. This system is not accurately steered. The slant on the nose is pointed in the direction of intended steering. The position of the head is monitored through a total station with a grade and line set and measuring this point against a target mounted in the head of the pilot string. If the ground conditions are homogenous and the conditions absolutely perfect, it will produce a satisfactory bore. Unfortunately this is rarely the case. Ground conditions are generally variable the pilot tube will tend to steer towards whichever ground offers the least resistance irrespective of the direction in which you are the steering. As the drill strings are generally short, the time to drill is often slow with repeated connections making the process tedious. Once the bore reaches the reception shaft augers are attached and pulled back along the bore to displace the spoil into the reception shaft. This then has to be manually removed which is time consuming.
Slurry style microtunnelling utilises slurry reticulation to transport spoil removal throughout the installation process. Two lines are fed via a starting shaft along the bore. The pipes are jacked via a hydraulic jacking frame into the hole. Water is forced along the feed pipe to the cutting face where the spoil slurry of rock and mud is forced back along the return pipe. Whilst enjoying a good degree of accuracy, this system requires a structural shaft that needs a massive amount of force to push the pipes. This results in a large, expensive jacking shaft pit that is time consuming to build. The sheer weight and size of the components make them slow to connect and cumbersome to use, If the unit becomes damaged or stuck in the bore, the only method available to retrieve the unit would be to dig down onto the drill head location.
In one form of boring machine shown by U.S. Patent Application No. U.S. 2004/0108139 to Davies and corresponding to Australian Patent 2003262292 there is disclosed a micro tunnelling machine having a tunnelling head with a boring bit which is forced in a horizontal direction by an hydraulic thruster. The direction of the head is laser guided. The beam strikes a target in the head and a camera relays an image of the target to an operator located at the tunnel entrance. The operator adjusts the direction by admitting water and draining water from a pair of rams inside the head, which move the boring bit up and down or left and right. A semi automatic version is disclosed in which a microprocessor adjusts the direction until the operator assumes control. In particular the invention is claimed to be a guidance system for the boring head of a micro-tunnelling machine of the type which bores in a selected direction and inclination using laser beam guidance having the endmost part of the drive to the boring bit adjustable in two directions at 90°, wherein, the endmost part of the drive has a target for the laser beam, means to convey an image of the target and the laser strike position thereon to an operator situated remotely from the boring head and input means for the operator to adjust the direction of the endmost part of the drive.
The major approach of the directional control of the disclosed apparatus of U.S. Patent Application No. U.S. 2004/0108139 to Davies is to have the drive shaft connected at its end distal to the cutting edge in a manner that allows the drive shaft to move as required and to allow the cutting element to be redirected to correct position as determined by the laser controlled directional system. However this form of apparatus places all the strain on an elongated movable drive shaft retained by cylinders and therefore readily increases the risk of breakage. There is clearly a need to provide an improved system to decrease chance of breakage of the drill head components.
It can be appreciated that present methods of underground tunnelling are cumbersome, inaccurate; and require repeated halting of boring operations due to waste removal and heating effects. Moreover, there is an inherent delay resulting from replacement of parts of conventional boring systems since it usually requires the boring tool to be recovered from the site and returned to the assembly factory. Recovery in itself can be cumbersome and expensive particularly if a new vertical access hole is required to recover the tool. This could damage the road or services under which the bored tunnel is extending. Further present systems are unable to accurately remain on fixed boring direction, which are often needed when a buried obstruction is detected or changing soil conditions are encountered.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided an apparatus and method for underground boring on grade more particularly to an improved microtunnelling system and apparatus.
In this document “microtunnelling” is considered to comprise trenchless horizontal boring of a bore of the order of 600 millimeters and less. This is particularly relevant to the insurgence of pipes of the order of around 300 millimeters.
The drawbacks of current microtunnelling technology are significant and have been overcome or are at least ameliorated by the current invention including one or more of the following improvements and other improvements as will be understood from the description.
A first fundamental improvement is the use of an external casing with flow channels therein and the drive rod mounted therein and allows for all cabling and hosing to be mounted in an external cavity, which thereby allows for continuous cabling over a plurality of encased intermediate drill rods.
A second fundamental improvement is the incorporation of the driveline within the vacuum chamber. Incorporating the rotation within the vacuum achieves multiple goals. Firstly, the vacuum area can be dramatically increased and so maximize the machines ability to remove spoil and in such increased productivity. Secondly, the rotation component of the drill rod generates heat. The removal of this heat from the laser area is critical to laser accuracy. By combining the rotation into the vacuum area, any heat generated is immediately removed and the laser therefore is unaffected.
A third fundamental improvement is the steering mechanism of the encased drill rod using radially protrusions engaging steering shell to direct the drill head and prevent any undue force on the drill head centrally mounted within the casing.
A fourth fundamental improvement is the modular structure of the drill head by a plurality of disc like modules that can be created by direct external etching, drilling or casting or the like and be combined in cylindrical shells to form a readily assembled drill head.
A fifth fundamental improvement is the modular components of the drive means that allows for differing rotational units to be used with a thrust unit that provides linear pull as well as push capabilities. This allows matching of rotational units to material being bored and size of pipe being inserted and further allows for reverse reaming to a larger diameter after initial bore has been accurately drilled.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention is more readily understood an embodiment will be described by way of illustration only with reference to the drawings wherein:
FIG. 1 is a perspective view of a drive means of a microtunnelling system and apparatus in accordance with the invention including a thrust module and rotation module mounted on a rack system and further including a vacuum for assisting return slurry;
FIG. 2 is a perspective exploded view of a drill head able to be driven by the drive means of FIG. 1 for use in the microtunnelling system and apparatus in accordance with the invention;
FIG. 3 is a front view of an enclosed drill head with front cutting means able to be driven by the drive means of FIG. 1 for use in the microtunnelling system and apparatus in accordance with the invention;
FIG. 4 is a cross sectional view of the enclosed drill head with front cutting means of FIG. 3 through section A-A;
FIG. 5 is a cross sectional view of the enclosed drill head with front cutting means of FIG. 3 through section B-B;
FIG. 6 is a cross sectional view of the enclosed drill head with front cutting means of FIG. 3 through section C-C;
FIGS. 7A and 7B show front and rear perspective views of the steering module of the drill head of FIG. 2 ;
FIG. 8A is a side view of the of the steering module of FIGS. 7A and 7B ; FIG. 8B is a cross sectional view through section line 8 B- 8 B of FIG. 8A ;
FIGS. 9A and 9B show front and rear perspective views of the bearing module of the drill head of FIG. 2 ;
FIG. 10A is a side view of a drill shaft;
FIG. 10B is a perspective view of the drill shaft of FIG. 10A ;
FIG. 10C is an end view of the drill shaft of FIG. 10A :
FIG. 10D is a cross sectional view taken alone section line 10 D- 10 D of FIG. 10C .
FIGS. 11A and 11B show front and rear perspective views of the front bearing bush of the drill head of FIG. 2 ;
FIG. 12A is an end view of the front bearing bush of FIGS. 11A and 11B ; FIG. 12B is a cross sectional view through section line 12 B- 12 B of FIG. 12A ;
FIG. 13 is a cross sectional view of the enclosed drill head showing the pressure fluid path through the modules to the bearing module and the front bearing bush supporting the front cutting arm;
FIG. 14 is a perspective view of a drive rod for extending between the drive means of FIG. 1 and the drill head of FIG. 2
FIG. 15 is a perspective reverse view of the drive rod of FIG. 6 ;
FIGS. 16A and 16B are respectively female and male end views of the drive rod of FIGS. 14 and 15 ; and
FIG. 17 is a perspective detailed view of the drill rod of FIGS. 14 and 15 showing the toggle locking mechanism.
FIG. 18 is a rear perspective view of a vacuum assisted precision reamer showing the connection means to the drill rod and rearward facing cutting face.
FIG. 19 is a front perspective view of a vacuum assisted precision reamer of FIG. 18 showing the connection means to the product pipe to be installed.
FIG. 20 is a rear perspective view of a vacuum assisted precision reamer of FIG. 18 .
FIG. 21 is a cross-sectional view through section A-A of FIG. 20 of a vacuum assisted precision reamer of FIG. 18 showing the internal pressure fluid passages, vacuum cavity, air channel, input drive shaft, planetary gear set, cutter hub and bearing.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings there is shown a microtunnelling apparatus and system that comprises a drive system ( 11 ), a drill head section ( 20 ) and intermediate drill rods ( 41 ) allowing extension of the boring hole created by the drill head section driven by the drive system.
The drive system ( 11 ) as shown in FIG. 1 includes a power source and a track system for allowing limited linear drive of the power source. The track system includes a rack and pinion gearing system ( 12 ) to allow maintained linear thrust pressure along the length of the track. The power source includes a hydraulic thrust module ( 13 ), which reciprocates a rotation module ( 14 ) housed in the thrust box in the launch shaft. The product pipe can be either pushed or pulled into place for pipeline completion.
To the front of the rotation module ( 14 ) is attached encased intermediate drill rods ( 41 ) such as shown in FIGS. 14 and 15 .
Attached to the distal end of the last intermediate drill rod ( 41 ) is attached a drill head ( 20 ) shown in exploded view in FIG. 2 and in cross sectional views in FIGS. 4 , 5 , and 6 . As such a drill rotor assembly ( 21 ) connected to the end of the drill shaft or drill rod ( 22 ) and connecting to intermediate drill rods ( 23 ) form a continuous drill string that is driven by the external drive means ( 11 ) comprising the hydraulic thrust module ( 13 ), reciprocating a rotation module ( 14 ) and linearly movable on the rack and pinion gearing system ( 12 ).
The casing ( 42 ) of the intermediate drill rods ( 41 ) and the casing of the drill head ( 20 ) formed by the steering shell (M 6 ) and the rear shell (M 5 ) form a continuous covering of the continuous drill string with internal defined continuous bores or channels. In particular a vacuum channel ( 51 ), as shown particularly in FIG. 16 , can be formed by a number of continuous cavities extending along the length of the intermediate drill rods ( 41 ) to the drill head ( 20 ). This vacuum channel ( 51 ) has vacuum seals at connecting female end ( 46 ) to maintain vacuum between longitudinally engaged and aligned intermediate drill rods. Within this vacuum channel 51 is located the connecting intermediate drill rods ( 41 ). A separate air channel ( 52 ) is formed by a separate number of continuous cavities extending along the length of the intermediate drill rods ( 41 ) to the drill head ( 20 ). This forms a linear channel within which the controlling laser can penetrate to the drill head ( 20 ). By the separation of the heat generating drill rod ( 22 ) to the linear laser channel and the cooling effect of the return slurry along the vacuum channel ( 51 ) creates a highly effective and accurate steering mechanism.
The microtunnelling system and apparatus further includes:
a) drill head with fluid bearing bush and modular construction b) enclosed drill rods with internal cooling system c) pullback extraction reamer d) rack and pinion thrust module with rotation unit e) rod loading system f) microprocessor control system.
In use upon excavation of a launching shaft, the base of the shaft would be prepared for the installation of the drilling machine. The shaft would typically have a pipe invert start point already marked and a line surveyed. A laser would be set up in the shaft at the extreme rear on line and grade. Thick boards are typically placed along the base of the shaft horizontally on grade. The microtunnelling drive means ( 11 ) including thrust module ( 13 ) and rotation unit ( 14 ) is lowered into the shaft and set up on line and grade.
The drill head ( 20 ) is lowered into the shaft and data, hydraulic and pressure fluid lines ( 44 ) are attached to the drill head ( 20 ). The drill head size and ground conditions are entered into the control panel which selects appropriate parameters for drill thrust speed and force, drill rotation speed and torque, vacuum flow and pressure, and pressure fluid flow. The drill head is attached to the vacuum thrust adaptor mounted on the rotation unit. Once set in launch mode, the vacuum unit is started and the pressurised drill fluid is actuated to eject at the drill face. The drill head is launched into the earth face.
The hole is cut via a combination of rotating cutting tooling and assisted by ejecting pressurised fluid. This pressurised fluid flow, which also acts as a fluid bearing, is shown in bold in FIG. 13 . Whilst drilling, the drill head ( 20 ) is thrust into the ground with the slurry/spoil being vacuumed up back into vacuum pipe ( 15 ) into a waste tank for removal. Once the drill head is completely in the ground the thrust, rotation, vacuum and pressure fluid is stopped. The drill head is detached from the vacuum thrust adaptor, and the thrust trolley with rotation unit return to the starting position.
Once in the start position an intermediate drill rod ( 41 ) is loaded either manually with a crane or via the use of the automated rod loader. Once the drill rod is sitting in the bed of the thrust module the thrust trolley and rotation unit are started at low speed, low thrust and low torque respectively to engage the drill rod. The rod engagement is automatic in that the drill rod has self-aligning pins ( 48 ) that accurately aligns the rod to both the drill head and the drill machine. Upon full alignment and further forward travel, the self-locking toggles (shown in detail in FIG. 17 ) engage behind the locking pins to affect a solid connection. Control hoses and cables ( 44 ) are inserted into the concave cavity ( 43 ) of the outer cover or casing ( 42 ) encasing the drill rod ( 23 ). Vacuum and pressure fluid resume with the drilling process reverting to preset drilling speed, thrust and torque. This process is continued until the final bore end point is reached.
Operation of the microtunnelling machine is performed remotely via a control box, which displays all the current pressure and speed settings. The control box is computerised and integrates the control of the steering, thrust module, rotation unit, vacuum unit and the pressure fluid. The operator can adjust any of the parametric settings to perfectly suit the current ground conditions. Both the drilling process and the steering process can be automated via the use of integrated computer software and can also be manually controlled. Throughout the drilling process the drill position is monitored via the laser hitting a target positioned in the drill head ( 20 ) and viewed through the use of closed circuit television (CCTV) so that the operator or software package constantly steers the drill head to keep the laser in the centre of the target.
Once the bore is complete there are three options; progress the drill rods into the reception shaft whilst inserting jacking pipes, pull back to the launching shaft whilst trailing a pipe directly behind it, or remove the drill rods prior to pipe insertion.
Currently, the microtunnelling industry only allows for forward excavation. The current invention is the only system of microtunnelling that incorporates precision back reaming. As shown in FIGS. 18 to 21 there is provision for the drill head ( 20 ) to be replaced by a back reamer ( 60 ) that is similarly connected to the intermediate drill rod ( 41 ) and driven by the drill string and external drive means. However instead of forward facing drill rotor assembly ( 21 ) of similar diameter to the drill head ( 20 ), instead there is a rearward facing reaming assembly ( 61 ) of larger diameter to the intermediate casing ( 42 ). The pipe can be installed by back reaming and attaching pipe to open cylindrical end housing ( 65 ) mounted at the very end of the back reamer ( 60 ). Thereby as the back reamer ( 60 ) is drawn back by the drive means ( 11 ) while undertaking rotational drilling with rearward facing reaming assembly ( 61 ) of larger diameter, a pipe of same or smaller diameter is drawn along and laid in the enlarged bore.
Back reaming allows use of low cost reamers to open the hole for different pipe size installations. Back reaming also utilises one size drill head and drill rod for each thrust module which in turn simplifies the rod loading process and reduces overall equipment cost.
Looking at the apparatus in further detail the system includes:
Guidance system with a laser striking a target, which is monitored to constantly maintain an accurate position. Vacuum: Use of vacuum allows for clean operation, fast extraction minimising regrind and Vacuum also reduces volume area occupied by extraction unit Pressure Fluid: Allows for enhanced cutter life whilst creating greater option via the use of drill fluid when dealing with different drill conditions. Drill rods: providing the ability to push or pull means that we can cut in both directions. This allows the machine to essentially drill a pilot hole accurately on the thrusting forward of the line and then cut back or open the hole as you pull back. As the line and grade of the hole is already determined the tooling required is simplistic and inexpensive which allows the machine to be more versatile through a large range of hole sizes at minimal cost. Pulling back in microtunnelling is unique. By only using one sized drill rod for each unit the jacking frame can be customised to automate the loading and unloading of the drill rods. With automated loading and unloading of drill rods the system reduced the need for man entry whilst operating. This enhances safety on the worksite.
The thrust module, which is installed in the launching shaft, can provide 300 kN force for thrust and pullback of 2.5 meter stroke within a longitudinal space of 3.0 meters. The thrust module uses rack and pinion gearing for increased stroke to retracted length ratio. It provides a high load capability with positive force. Pressure, force and speed are fully adjustable for both thrust and pull back and have a programmable stroke with adjustable limit stops for the trolley assembly. Overall the thrust module allows fast drop in boxes for the rotation unit.
A variety of rotation modules can be selectively utilised with the one thrust module according to the requirements. Rotation modules ideally cater for one drill diameter, by maximising available hydraulic power, rotating at ideal speeds (rpm) by maintaining optimum cutting face surface speeds (m/min) to best utilise working range of tungsten and carbide cutting inserts, and by maintaining the most desirable cut face/vacuum area ratio. Other sizes of rotation modules can also be used but with less efficiency.
Each rotation module comprises its own hydraulic motor (low speed/high torque, high speed/low torque, two-speed automatic selective unit, or other) coupled through a drive train assembly (chain and sprockets, simple gear box, planetary gearbox, or other) to rotate a drive shaft with a hexagonal end, which is to be coupled to the drill string inside the drill rods.
Each rotation module also includes a Vacuum thrust adaptor for connection with drill rods. This vacuum thrust adaptor incorporates the features suited to each drill rod, being vacuum sealing method, drill rod alignment, drill string torque transmission connection, thrust face and pullback connection. The Vacuum thrust adaptor also houses any hydraulic clamping and disconnection mechanisms for drill rods.
The microtunnelling machine targets extremely precise small diameter trenchless pipe installations particularly <600 mm and more particularly <300 mm. This is achieved by tracking a laser striking a target in the drill head, which is monitored via CCTV in the drill head and then steered accordingly to maintain line and grade. A unique fluid bush assembly transmits water and thrust to the rotating cutting face, where the pressure water and subsequent cutting spoil are mixed to a slurry for removal by vacuum extraction.
The drill head utilises a unique radial steering system capable of directly variable directional changes to continually and precisely cut the bore hole. The drill head is progressed through the ground by connecting subsequent drill rods between the drill head and thrust module until final bore length is achieved. These drill rods are either encased or open and combine rotation shaft/drill string, vacuum, air and control channels providing mechanical and control workings. Hydraulics, water and data is remotely controlled and utilised by the operator at the remote control panel and conveyed by cables and pressure hoses.
The front cutting rotor assembly consists of tungsten, carbide or other sintered hard metal inserts housed both axially and radially on a variety of face styles. The shape of the front cutting face varies remarkably with ground conditions, and can be flat, piloted or conical in shape and is built to suit.
All front cutting rotors are designed so that cuttings large enough to potentially block drill head vacuum cavity are kept ahead of cutters for further processing (mixing, cutting, grinding or shattering). Once cuttings are small enough, they are permitted past the cutter face for vacuum extraction.
A clay cutting face will have a multitude of spokes (range from 3 to 6) possibly connected together again to an outer rim. The main consideration is the clay consistency, as the openings through the cutting face are calculated to restrict cut spoil ahead of the cutter until small enough to be able to fit through the vacuum chamber of the drill head. When clay is soft it is easy to drill, but builds on itself and can cause blockages if the correct cutter is not chosen.
A shale cutting face will be similar to the clay version, but face openings are modified to allow for front regrind of large chipped material prior to vacuum extraction.
A rock cutting face generally comprises a cutter face with three, six or nine conical roller assemblies with peripheral openings (usually three) for cutting spoil extraction. Utilising multiple small diameter conical rollers, each set of three are staggered in distance and angle from the front face. The inner set of three cones being most forward, the intermediate set radially skewed from the inner at 60 degrees and setback by 25-100% of the cut diameter, and the final set again radially skewed from the intermediate at 60 degrees to bring the inner conical portion back in line with the radial centre-lines of the inner set of cones, and setback from the intermediate face by another 25-100% of the cut diameter. Roller cutter face then has the benefit of continual steering capability, increased stability in non-homogenous ground conditions, and increased chip rate resulting in less regrind time prior to vacuum extraction of spoil.
Downhole drilling technology has been using “tri-cone” rollers to cut rock for decades. They are available in a variety of grades—soft, medium and hard formation. A tri-cone roller utilises three conical rollers, equispaced at 120 degrees, fitted with hard metal inserts each rotating about their own bearing shaft. The conical shape of each roller, tapered into the centre of the cutting face, rotating about an axis skewed 60 degrees forward in towards the centre of the cutter results in a full flat face cut diameter. The resultant large flat cutting face is very difficult to maintain stability in non-homogenous ground, and due to the size of three rollers required to obtain the full cut diameter, the axial distance traveled prior to any steering response is often half the cut diameter.
All front cutting rotors 100 are shown including cutting bars 99 having front and rear sides 101 a , 101 b that respectively define front and rear pressure fluid ports 102 a , 102 b (i.e., fluid discharge ports, see FIG. 13 ). Holes (i.e., fluid passages 104 ) are drilled radially to the centre of the cutter to coincide with the porting on the drill shaft 114 . Additional holes are drilled axially from both the front and rear faces of the cutter. These holes are sized approx 2 mm diameter to allow extreme pressure at face for best cutting and mixing qualities with minimal pressure fluid usage. An internal chamfer on front ports 102 a to increase surface area at opening only to allow for blockage ejection. Rear ports 102 b are directed back towards drill head to aid in clearing any residues from air channel and vacuum cavity. Outer ends of the cutting bars 99 include angled relief surfaces 97 .
All front cutting rotors 100 have a central cavity 108 for connection with the drill shaft 114 in the drill head. This cavity 108 is either threaded with a trapezoidal or acme thread taking up onto a shoulder on the shaft, or a hollow hexagon (i.e., a hexagon having flats 110 ) for the quick connection arrangement used in conjunction with a front threaded cone (i.e., a front retainer 112 ) and lock bolt. Both styles accommodate for through shaft and cutter pressure fluid transmission. The cutting bars 99 project outwardly from a hub 106 of the front rotor 100 . The cutting bars 99 have lengths L (see FIGS. 3 and 4 ), widths W (see FIG. 3 ) and depths d (see FIG. 4 ).
The cutting bars 99 project outwardly from a hub 106 of the front rotor 100 . The cutting bars 99 have lengths L (see FIGS. 3 and 4 ), widths W (see FIG. 3 ), and depths d (see FIG. 4 ). The depths d extend in a front to back orientation along an axis of rotation 501 of the front cutting rotor 100 .
The drill head drives the front cutting rotor 100 by way of the drill shaft 114 . The front of the shaft 114 is a male hexagonal drive having flats 116 (see FIGS. 10A-10D ), with 75-100% of across flats dimension of the hexagon in length, with a front threaded extension 118 generally 50-75% of the across flats dimension of the hexagon in diameter, and 75-100% of the thread diameter in length.
The drill rod is radially drilled (eg 3×5 mm diameter holes at 120 degrees) through the faces of the hexagonal final drive through to a central larger axial port (i.e., a fluid passage 120 ) (eg 8 mm-12 mm diameter). This axial port is drilled as a blind hole into the drill shaft, to the length corresponding to the position of the front fluid bush. Here, another series of smaller radial holes are drilled through to meet with the axial port (eg 3×5 mm diameter holes at 120 degrees). These holes are peened (eg 8-10 mm concave diameter) to eliminate any seal degradation from the rotating shaft.
The front fluid bearing bush encapsulates this mid-front section of the drill rod and provides a centralized bearing location capable of high radial and thrust forces combined. The peened radial holes of the drill rod are longitudinally aligned with the internal radial pressure fluid distribution groove of the fluid bearing bush.
This groove is in turn fed pressure fluid from radial drill holes (eg 6×5 mm diameter holes equispaced at 60 degrees). Fluid cannot escape to the rear of the fluid bush due to an energising U-cup seal placed at the rear of M 1 bearing module. Pressure fluid is proportionally distributed—to the drill shaft axial port through to the front cutting rotor, creating back pressure to distribute to the annulus area between the outside diameter of the drill rod and the inside diameter of the fluid bush. This is achieved by high helix angle, low depth multi-start grooves machined on the inside of the fluid bush from the front edge of the distribution groove to the front face of the fluid bush (eg triple-start, 20 mm pitch 0.5 mm deep grooves with 1.5 mm concave radius). This pressure fluid is then channeled to a helical spiral groove on the front face of the bush (eg single 10 mm pitch continuously decreasing right-hand 0.5 mm deep face groove with 1.5 mm concave radius). This channeling effect essentially hydrostatically separates the shaft from the bush both radially and axially, to counteract steering and thrust face forces. The relationship is linearly proportional in that the higher the load, the harder the faces act against one another, providing a greater hydrostatic seal, which in turn acts to repel the two components. Hence we have a bearing, which mechanically transfers load, provides a pressure fluid swivel, and continually lubricates and cools itself. This method allows a very strong shaft construction with minimal stress riser points, and excellent pressure fluid conveyance.
The drill head functions to drive the front cutting rotor by means of a drill rod. The bore hole position is monitored within the drill head by means of a laser set at the launch shaft indicating a position on a target mounted in the drill head. A camera within the drill head is directed at the target, and relays a video image to a video screen viewed by the machine operator. The operator controls any required steering direction changes. Steering is achieved by altering the position of the cutting face relative to the bore hole.
The prior art was to manufacture a cylindrical drill head, and moving the cutting face. One steering method is to pivot the front portion of the drill head vertically and horizontally. Although effective in steering, this required the laser target to be situated a considerable distance from the cutting face. The further rearward the laser target position, the further the distance is required to be drilled prior to an update of current bore face location.
Another steering method is to move the drill shaft within the drill head. This has the advantage of being able to mount the laser target further forward in the drill head, and therefore, providing a more accurate target to bore face position. However, the pivotal mounting of these steering mechanisms provides a weak steering with high failure rates and increased maintenance.
These past methods of steering are physically large and cumbersome, and due to plumbing required to each hydraulic cylinder, makes this method unsuitable to small diameter drill head design. The invention entails construction of a modular drill head for increased strength and reduced size.
The drill head is of a segmental modular design to minimise overall size while achieving maximum strength and durability. Each module is centralized and retained by the next module by male and female stepped spigots. Clamping of each module achieves angular alignment and axial clamping. Each module is designed for its particular purpose in the drill head, and all hydraulic, fluid, air and vacuum channels are interconnected by way of stepped face seals. It is this method of construction that allows the use of integrated pressure porting, reliable bearing design, maximum vacuum area, good air channel ducting, maximum forward position of laser target area and plumb indicator for visual head tilt indication.
The drill head and steering module for use in the microtunnelling system has a steering shell M 2 mounted axially on the drive rod ( 22 ) in a manner to allow radial movement and having a plurality of radially mounted pistons able to engage the inner surface of the steering shell M 6 such that the control of the protrusion of the plurality of radially mounted pistons controls the direction of the steering shell.
As shown particularly in FIGS. 8A and 8B , the plurality of radially mounted pistons is included in a circular steering module fitting around the drill rod and having radial bores from which the radially mounted pistons protrude. The circular steering module includes a spoked wheel effect with the radial bores extending at least partially along the radial extending spokes. Preferably cavities are between the spokes to allow axial pathways. The circular steering module includes ports near the radial centre and able to receive water or hydraulic fluid for driving the pistons to protrude from the radial bores and engage the inner surface of the steering shell.
As shown in FIG. 2 , the drill head includes a modular construction having a plurality of circular disc like elements for axial alignment and abutment and mounting within a cylindrical shell, wherein each of the circular disc like elements is created by direct bore construction and the axial alignment and abutment creates continuous axial and radial channels allowing fluid flow, vacuum waste return channel, and control flows.
One of the circular disc like elements forms a bearing module M 1 at the front of the drill head with flow paths for providing axially extending fluid jets to assist cutting and radially extending flow paths to assist aquaplaning bearings of the rotating cutting means.
One of the circular disc like elements forms a steering module M 2 at the front of the drill head with flow paths for providing axially extending fluid jets to control protrusion of pistons to engage the outer cylinder and alter direction of the drill head.
One of the circular disc-like elements forms a spacer module M 3 within the drill head with flow paths for providing axially extending flow paths to adjacent modules.
One of the circular disc like elements forms a mounting module M 4 at the rear of the drill head with flow paths for providing axially extending flow paths and able to form non rigid mounting of base of outer cylinder.
The drill rod ( 22 ) and connected intermediate drill rods ( 23 ) are a steel rod drive shaft, with male and female hexagonal ends to effect connection and resist torsional forces. The drill rod and connected intermediate drill rods are retained within either end of the drill rod end plates by front and rear rod bush bearings. The drill rod and connected intermediate drill rods are housed in an axially extending tubular section ( 51 ) to separate the bearings from the spoil through the vacuum section. The axially extending tubular section drill string housing is located fully within the vacuum chamber, surrounded by the vacuum channel and vacuum cavities. It is this full surround by vacuum that functions to absorb heat created by the rotating drill string, transferring it directly to the slurry and spoil cuttings and fluid returning from the drill head, and in turn to the vacuum waste tank.
The laser beam used for drill head guidance travels through the protected top air channel ( 52 ). It is the effective removal of heat and creation of a stable laser environment that minimises otherwise unavoidable hot-cold transitions at every drill rod connection. In past drill rods, these hot-cold transitions cause consecutive and culminating laser refraction, leading to an inaccurate borehole.
During connection the drill rods ( 23 , 23 ) are pushed together. The vacuum thrust adaptor has two conical combination pins ( 48 ) in the male drill rod end plate ( 47 ) about the rod's longitudinal axis and centred vertically about the drive, and offset equidistant about the horizontal plane. These combination pins have a conical taper at the front and align with two bores ( 49 ) in the female drill rod end plate ( 46 ) about the rod's longitudinal axis. As the pins are further inserted, the drill rod is aligned to a horizontal plane; the drill rod and connected hexagonal intermediate drill rods are aligned and further inserted until the two end plate faces are mating.
Consecutively during this alignment process, the toggles mounted to the female end plate are caused to pivot about the pivot bush axis, moving radially outwards from the end plate diameter, allowing the major diameter of the combination pins past the toggles. Once the Combination Pins pass the major diameter, the toggles are allowed to spring back to their original position, moving in between the combination pins and the female end plate, thus locking the connection, and allowing either thrust or pullback under load. Once the drill rod end plates are mated face to face, the vacuum and laser space are sealed due to the elastomeric seals inserted in the milled grooves of the female plate.
Referring to FIGS. 2 , 4 , and 5 the M 1 bearing module comprises of a circular disc with a central stepped bore for the location of the front fluid bearing bush. The housing is cross-drilled to divert an axial pressure fluid port originating to the side of the drill rod, connected to a radially drilled port which in turn connects to a radial groove on the inside of the central bore. Two additional smaller radial grooves—one to the rear and one to the front of the channel groove provide housing for o-ring seals which completes this cavity and directs all pressure fluid through to the radial holes drilled through the fluid bush. The radial pressure cavity also connects to a vertical radial port fitted with a jetted plug, which directs some fluid to the Annulus between the steering ring and steering shell M 6 . At the rear of the M 1 bearing module is a self-energising u-cup seal retained by a soft metal bush to complete the front seal cavity.
As shown in FIGS. 2 , 6 , 7 A, 7 B, 8 A and 8 B the M 2 steering module comprises a circular disc with a central bore through which the drill rod passes. At the top and to the sides are air channels. At the bottom is the vacuum cavity. There are four radial drillings, bores and counter bores equispaced around the circumference of the disc. Four independent oil ports drilled axially from the rear of the housing and countersunk with face sealing enter the lower portion of the radial drilling in each of the four bores. These bores house the steering pistons with high pressure seals. With pressurised hydraulic oil entering any of these cavities, the associated piston is forced radially outward providing force to move the steering shell M 6 . The piston is retained from ejection from the housing by a stepped gland ring incorporating a piston rod wiper and auxiliary seal which in turn is retained by an internal circlip within the stepped bore.
The M 6 steering shell comprises a hollow tubular section with a front end stepped return section reducing in inside diameter then tapered both internally and externally towards the front. This front stepped return is faced up against the front of M 1 bearing module, and the main inner bore has full annular clearance around the circumference of the steering ring assembly allowing the shell to move about radially in any direction. As one piston in the M 2 steering module is actuated, the M 6 steering shell is forced radially and moves with the extending piston. As the opposing side of the M 6 steering shell moves in towards the steering ring assembly, the piston radially opposed to that actuated is in turn retracted, allowing for the next steering manoeuvre. The same applies to the other set of pistons acting about an axis at 90 degrees to the first set of pistons. This actuation on 2-cylinder movement axes, either independently or together allows the drill head to alter its shaft and cutter position relative to the bored hole thus providing steering control.
The hydraulically steered drill head has a fast system for changing cutting tooling. Rock capabilities have been enhanced with the design of a rock roller system for the microtunnelling unit.
The drill head has been modified to accommodate the covered drill rod system and designed to allow for the introduction of automated steering. Drill head segmental design allows for strength and durability whilst enhancing the ability to maintain drill head positioning via hydraulic rams holding a position of one circular piece within a second circular ring providing for maximum strength in minimal space.
The drill shaft must rotate freely under high loads, and pressure fluid must be transferred to the drill face. The use of high-pressure fluids out of the drill face allows for enhanced tooling life whilst also giving the ability to flush tacky ground.
The prior art was to retain the shaft within steel bearings, either tapered roller, or ball bearings with needle thrust bearing. This solved the mechanical rotation issue, but brought with it a whole plethora of associated problems to do with sealing bearings from ingress of cutting spoil and water, both ingredients deadly to bearings. Maintenance is increased as seals and bearings have to be replaced regularly. If a bearing was to seize, it would halt the complete drilling process, drill head would have to be removed for overhaul, causing unplanned down-time and site delays.
The prior art for pressure fluid transmission is with a pressure swivel assembly, which rotates about the shaft axis. The swivel construction would be tubular in design with two pressure seals axially opposed to retain a central pressure chamber within the swivel. A threaded inlet port enters this central pressure chamber radially, flows around the axis of the cavity, through a radial hole drilled in the drill shaft, then through an axial hole in the drill shaft to the front face. This design required external retention of the swivel housing to stop it rotating with the drill shaft, causing radial side-loads on one inside face, in turn, causing seal failure and therefore leakage. The seals had to have a high preload to accommodate high pressure, and would wear grooves in the drill shaft, causing leakage. The swivel would be located behind the target position, so any water spray from leaks would upset visual sight of target. Using pipe fittings from the swivel housing with elbows to bring hose in axially beside drill shaft meant size was too large to be used in small diameter drill heads, assembly and maintenance of hose and fittings would be awkward at best.
The invention entails construction of a modular designed drill head, with integrated pressure fluid conveyance cavities. Further, the invention includes the use of a fluid bearing bush to act as a front drill rod bearing and pressure swivel in one assembly. The fluid bearing bush is retained in the M 1 bearing module by three grub screws (equispaced at 120 degrees). Pressure fluid directed to the distribution groove in the M 1 bearing module is sealed form escaping past the inside of the stepped bush bore and the outside diameter of the fluid bearing bush by means of two O-ring seals on each side of the distribution groove. This M 1 bearing module distribution groove is longitudinally aligned with radial drill holes (eg 6×5 mm diameter holes equispaced at 60 degrees) around the perimeter of the fluid bearing bush. These drill holes enter the inside diameter of the bush and are interconnected with an internal radial distribution groove within the fluid bearing bush. Fluid cannot escape to the rear of the fluid bush due to an energising U-cup seal placed at the rear of M 1 bearing module.
The fluid bearing bush encapsulates a mid-front section of the drill rod and provides a centralized bearing location capable of high radial and thrust forces combined. The peened radial holes of the drill rod are longitudinally aligned with the internal radial pressure fluid distribution groove of the fluid bearing bush.
Pressure fluid is proportionally distributed—through radial holes in the drill shaft, connecting to an axial port through to the front cutting rotor, creating back pressure to distribute to the annulus area between the outside diameter of the drill rod and the inside diameter of the fluid bush. This is achieved by high helix angle, low depth multi-start grooves machined on the inside of the fluid bush from the front edge of the distribution groove to the front face of the fluid bush (eg triple-start, 20 mm pitch 0.5 mm deep grooves with 1.5 mm concave radius).
This pressure fluid is then channeled to a helical spiral groove on the front face of the bush (eg single 10 mm pitch continuously decreasing right-hand 0.5 mm deep face groove with 1.5 mm concave radius). This channeling effect essentially hydrostatically separates the shaft from the bush both radially and axially, to counteract steering and thrust face forces. The relationship is linearly proportional in that the higher the load, the harder the faces act against one another, providing a greater hydrostatic seal, which in turn acts to repel the two components.
Hence we have a bearing, which mechanically transfers loads, provides a pressure fluid swivel, and continually lubricates and cools itself. This method allows a very strong shaft construction with minimal stress riser points, excellent radial and axial bearing loads, excellent impact resistance, excellent pressure fluid conveyance, minimal assembly and maintenance costs, and is field replaceable.
The position of the target at the extreme front of the drill head ultimately enhances the drills ability to be extremely accurate and responsive to positional changes. The use of high-pressure fluids out of the drill face allows for enhanced tooling life whilst also giving the ability to flush tacky ground. The ability to run drill fluids at the cutting face creates greater efficiencies within cutting and assists our abilities through varied ground conditions. Front bearing combination of high load axial and thrust bearing with a high-pressure fluid and integrated lubrication system.
The drill rods are inserted and connected consecutively with the thrust module to allow bore hole progression while maintaining drill string, vacuum, air channel, hydraulic, pressure and data line connection. The drill rod transmits torque from the rotation unit mounted on the thrust module to the drill head at the bore face via a drill rod and connected intermediate drill rods. The drill rod also transmits thrust from the rotation unit mounted on the thrust module to the drill head at the bore face via a vacuum tube.
The prior art was to have the vacuum tube section aligned longitudinally with the drill string, situated below it, generally to rest on the invert of the borehole. This allows cutting spoil extraction by vacuum.
The vacuum tube has bearing bushes mounted at each end along the drill rod and connected intermediate drill rods axis to retain the drill rod and connected intermediate drill rods, and male and female cleats at each end for connection by means of a manual pin inserted to two holes either vertically or horizontally aligned. The drill string is exposed, causing possible operator injury from the rotating shaft. The connection method with manual pin insertion is tedious, and pin extraction after bore completion is difficult.
The manual connection method required clearance to allow manual connection. This clearance between subsequent drill rods allows each rod to rotate slightly about its axis as a result of drill string rotational torque. This rotation, possibly only 1 degree per rod, extrapolates the error the further the borehole. Final error over a 100 m bore could be a 50-degree rotation, causing an inaccurate target position relative to the start point. This target position is then potentially out by up to 10 mm.
The borehole is not peripherally supported, causing ground collapse in certain ground conditions, thereby blocking laser and target view, and halting drilling operation. The bearings are directly under the laser position, causing hot sections at each end of the drill rod and a cooler section between the bearings. These hot-cold transitions cause consecutive and culminating laser refraction, leading to an inaccurate borehole.
The microtunnelling system uses a casing mounted on the drill rod that includes at least two axially extending cavities or bores wherein liquid is axially transported along one of said axially extending cavities or bores under pressure to the drill head to assist drilling and resulting slurry is vacuum returned along the other of said axially extending cavities or bores. However as drill rods are fully enclosed, and slightly smaller than the drill head diameter allowing the microtunnelling machine to be effective in collapsing ground conditions, under water table, soft or hard ground. The vacuum or slurry spoil extraction volume within the drill rod provides minimum restriction to increase productivity and length of lines achievable. With all moving components enclosed, the drill rod is safer to use.
Rotation within vacuum or slurry spoil eliminates heat from bearings, minimising laser distortion and wear and tear to the equipment. Enclosed laser space for stability of beam. Provides airflow to equalize temperature and humidity, more accurate operation. Automatic alignment system speeds and simplifies operation. Automatic clamping system, for positive joining, withstands full load in both forward and reverse directions. Clamping system maintains strong sealing of vacuum. Fully encapsulated hose and dataline pocket, protecting sensitive data and pressure lines.
The pullback extraction reamer is used to increase the size of a microtunnelled bore hole. This is advantageous for operators as one size microtunnelling drill head and drill rods can be used in conjunction with a pullback extraction reamer in various bore sizes, while maintaining good productivity. Once the drill head reaches the reception shaft, the drill head is removed from the end of the drill rod and replaced by the pullback extraction reamer. The product pipe to be installed can be coupled to the pipe pullback adaptor mounted on the rear. Drilling is now commenced in reverse, or pullback mode. The drill string is coupled to a drive spur gear that rotates three planetary gears fixedly mounted to the vacuum thrust plate. The spur gears are meshed inside an internal ring gear that is fixed to the cutter hub, allowing the cutter hub to rotate at a lower speed but higher torque than its input drive. The cutter hub is mounted to the pipe pullback adaptor by way of thrust and radial bearings. This embodiment allows the drill rod and pullback pipe to remain rotatably fixed and the reamer cutter hub can rotate about the longitudinal axis at a greater torque. The cutter hub is typically concave within its cutting face, so that as it is pulled back through the ground, slurry and spoil are offered to the vacuum or slurry channel entrance for evacuation.
It should be understood that the above description is of a preferred embodiment and included as illustration only. It is not limiting of the invention. Clearly a person skilled in the art without any inventiveness would understand variations of the microtunnelling system and apparatus and such variations are included within the scope of this invention as defined in the following claims.
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The present disclosure relates to a microtunnelling apparatus including a cutting apparatus adapted to be rotated by a drill shaft defining a central axis of rotation that extends along a length of the drill shaft. The cutting apparatus includes a front cutting rotor having a hub defining a shaft receiver that extends at least partially through the hub in a direction extending from a back side toward a front cutting side of the front cutting rotor. The shaft receiver is configured to receive the drill shaft. The drill shaft and the shaft receiver cooperate to define a torque transmitting mechanical interface for allowing torque to be transferred between the drill shaft and the front cutting rotor such that the drill shaft can be used to rotate the front cutting rotor about the central axis of rotation. The front cutting rotor also includes a plurality of cutting bars that project at least partially radially outwardly from the hub. The cutting apparatus further includes a front retainer that mounts at the front cutting side of the front cutting rotor for retaining the front cutting rotor on the drill shaft.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuing application, under 35 U.S.C. §120, of copending international application No. PCT/EP2013/067286, filed Aug. 20, 2013, which designated the United States and was not published in English; this application also claims the priority, under 35 U.S.C. §119, of German Patent Application Nos. 10 2012 214 867.1, filed Aug. 21, 2012, and 10 2012 215 062.5 filed on Aug. 24, 2012; the prior applications are herewith incorporated by reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
FIELD OF THE INVENTION
The present systems and methods lies in the field of cycles. The present disclosure relates to an electronically controlled suspension system for a bicycle, comprising at least one spring element that is disposed between a first part of the bicycle and a second part of the bicycle, both parts being movably interconnected, wherein at least one parameter of the spring element can be modified, and at least one actuator that acts on the spring element to modify the at least one parameter, and an electronic module serving for producing a control signal for the at least one actuator.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 6,050,583 to Bohn discloses equipping a bicycle with a suspension. The suspension is dampened by an oil bath in that the oil flows through a bore in a piston of a piston-cylinder pair of the suspension. Furthermore, this known suspension has a micromechanical acceleration sensor and an actuator to adapt the damping force to the acceleration acting on the bicycle by varying the openings. The acceleration sensor, the control electronics and the actuator are connected to one another through cable connections.
This known apparatus has a drawback in that the cable connections can corrode or tear off when riding the bicycle off-road, which limits the operational reliability of the apparatus. Although it is possible by this known apparatus to adapt the damping, it is not possible to adapt the elastic force and, therefore, an adaptation to different riding conditions is only rudimentarily possible.
Thus, a need exists to overcome the problems with the prior art systems, designs, and processes as discussed above.
SUMMARY OF THE INVENTION
The systems and methods described provide an electric chassis for a bicycle that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that provide such features with an improved operational reliability and/or offers different adjusting possibilities to enable an automated adaptation to different operating conditions.
The invention proposes an electronically controlled suspension system for a bicycle. The suspension system can be attached solely to the front wheel of a bicycle. In other embodiments of the invention, the suspension system can be disposed at both the front wheel and the rear wheel. In some embodiments of the invention, the suspension system can also be attached solely to the rear wheel. In yet another embodiment of the invention, the suspension system can be disposed in a seat post and/or in a steering tube. The suspension system, on the one hand, raises the riding comfort for the bicycle user. Moreover, the suspension system can enable an improved grip of the wheels to the ground to improve the traction and/or transmit greater steering or braking forces. This serves for positively influencing the driving safety or the off-road usability of the bicycle.
In some of the embodiments of the invention, the bicycle can be a human-powered, two-wheeled vehicle, e.g., a mountain bike, a trekking bike or a road bike. In some of the embodiments of the invention, the bicycle can have three wheels, i.e., two front wheels and one rear wheel or one front wheel and two rear wheels, for example. In some of the embodiments of the invention, the bicycle can have an electric motor that drives the bicycle either at least partially as an alternative to the human-powered pedal drive or that supports the cyclist in pedaling. As a result, the bicycle can reach a higher speed and/or a greater range and/or manage steeper climbs while the cyclist's energy input remains constant.
The inventive bicycle has at least one spring element that is disposed between a first part of the bicycle and a second part of the bicycle, both parts being movably connected to one another. For example, the first, immovable part of the bicycle can be the frame of the bicycle or the stanchion tubes of a fork or the seat post part that can be connected to the frame. The second, movable part of the bicycle can be formed by the slider tubes of a fork or by a movably mounted chainstays kinematics of a rear wheel suspension system or the seat post part that can be connected to the saddle. Both the own weight of the bicycle, the user's weight and also dynamic impacts on the wheels result in a relative movement between the first part and the second part of the bicycle. The spring element counteracts this movement.
In some of the embodiments of the invention, the spring element can contain a leaf spring or a helical spring, made of steel, for example. In other embodiments of the invention, the spring element can comprise an air suspension, i.e., a piston-cylinder pair, which encloses a self-contained air volume that is compressed on the application of external forces. Furthermore, the spring element can have a device for producing a damping force, e.g., an oil volume that flows through the openings of a piston.
As a result of a mechanical interference with components of the spring element, at least one parameter of the spring element can be modified. By modifying the spring element, the handling of the bicycle equipped with the spring element can be changed, e.g., the energy dissipation in the suspension can be reduced or the response pattern can be adapted to different grounds. The influenceable parameter of the spring element can be selected from the elastic force of the pressure stage and/or the damping force and/or the suspension travel and/or the lock-out, i.e., a fixation apparatus by which the suspension can be fully blocked. To this end, the spring element can be equipped with an operating lever and/or an adjustment wheel, which performs the mechanical interventions at the spring element in generally known manner to carry out the desired modifications. The mechanical interventions can comprise, e.g., the opening or closing of a valve or the change in the spring preload or the modification of the clear width of at least one opening or the application of an electric field or the application of a magnetic field.
According to the invention it is now proposed to actuate the operating element of the spring element through at least one actuator that influences the spring element to modify the at least one parameter.
The actuator is actuated by a control signal that can be a pulse-width modulated electric signal, for example. In other embodiments of the invention, the control signal can be an analog current or voltage signal. It can determine either the on-time or off-time of an actuator or its absolute position. The control signal is produced by an electronic module.
The electronic module produces the control signal depending on at least one input variable which can be produced with at least one control. The control can generate the input variable either depending on the cyclist's desire or in automated fashion based upon measured values that detect the respective operating condition of the bicycle.
According to the invention, it is now proposed to connect the control to the electronic module, preferably through a radio signal, and/or to connect the actuator to the electronic module through a radio signal. As a result, cabling along the frame is dispensed with, and, therefore, weight can be reduced, on the one hand, and a reliable transmission of the signals can be enabled, on the other hand, because damage to the cable is now impossible. The radio signal can be coded in digital or analog fashion. In some of the embodiments of the invention, the radio signal can be around 433 MHz in the frequency band. In other embodiments of the invention, the radio signal can be around 2.4 GHz in the frequency band. The radio signal can be encoded to avoid an impairment of different bicycles riding side by side. Furthermore, the electronically controlled chassis cannot be manipulated from the outside when the radio signal is encoded. The encoding can be made with generally known cryptographic methods, e.g., AES, WPA, WEP, or other methods. The radio signal can realize a generally known interface, e.g., WLAN or Bluetooth or near-field communication (NFC).
In some embodiments, the control can be an operating element and/or a tilt sensor and/or a position sensor and/or an acceleration sensor. The user of the bicycle can manually interfere through the operating element and, e.g., block the suspension or the damping force and/or adapt the suspension travel to a desired damping pattern. In other embodiments of the invention, the control can include a tilt sensor which, e.g., detects a lateral tilt of the bicycle when travelling on curved roads and/or identifies climbs and slopes, and, therefore, a relatively soft spring characteristic can be chosen in downhill rides and a relatively hard spring characteristic can be chosen in climbs including major pedal power to avoid or reduce an unintended shaking of the chassis. For the same purpose, it is also possible to use an optional torque sensor that detects the pedal power produced by the cyclist. In some of the embodiments of the invention, the control can alternatively or additionally contain a position sensor by which the position of the bicycle on the surface of the earth is identifiable. In some of the embodiments of the invention, the position sensor can be or contain a radio navigation system, e.g., GPS, Glonass, Compass or Galileo. To increase accuracy, the position sensor can also receive and process additional terrestrial radio signals. Additional terrestrial radio signals can be selected from differential GPS or a cellular radio signal, such as GSM, LTE or UMTS.
In some of the embodiments, the control can contain a cell phone or be a cell phone. The cell phone can be connected to the electronic module through a generally known radio connection, such as Bluetooth. In other embodiments of the invention, the cell phone can be connected to the electronic module through a cable connection, e.g., through a USB interface. The system can be feedback-controlled or controlled through the user interface of the cell phone by the user's interferences and/or the electronic module can output current configuration data through the display of the cell phone. In this connection, the cell phone can implement software that translates the user's inputs into a control signal. In some of the embodiments, the cell phone can retrieve software updates or configuration data or topographic information from an online memory through a GSM interface, through a GPRS interface, through an LTE interface or a comparable interface, and provide them to the electronic module or store a safety copy of the memory content of the electronic module on the online memory.
In some of the embodiments, the electronic module can contain a cell phone or be a cell phone. The cell phone can be connected to the actuators and/or at least one control through a generally known radio connection, such as Bluetooth. In some of the embodiments, the cell phone additionally can be used as an operating element. This serves for reducing weight because no separate electronic module and/or operating element has to be attached to the bicycle. The power supply of the electronic module and a GPS system for localization and a memory for topographic data can also be dispensed with when the cell phone is equipped with these components. The accumulator of the cell phone is charged by the user at regular intervals anyhow, and, therefore, separate charging of the electronic unit of the bicycle can be dispensed with. In other embodiments, an additional operating element can be attached to the handlebar of the bicycle, said element being connected to the cell phone, e.g., through a radio interface or a tethered interface. This embodiment has the advantage that the cell phone can be carried along while protected from impact and dust, e.g., in a backpack, while the user still has direct access to the suspension system and the user can be informed of the condition of the system.
In some of the embodiments, the electronic module can contain a map memory for receiving topographic information. The topographic information can represent a course of the road or a road surface so as to always and automatically ensure an optimum adaptation of the parameters of the spring elements from the position of the bicycle and the selected route of travel, without the cyclist having to interfere manually. For example, a relatively hard spring characteristic can be chosen ahead of a curve or it is possible to select a spring characteristic on paved roads that is harder than that on a dirt road. Likewise, the topographic information can contain height data, and, therefore, the parameter of the spring elements can correspondingly be selected based upon climb or slope.
In some of the embodiments, the suspension system can contain a speed sensor that allows the adaptation of the parameter of at least one spring element based upon the riding speed. In some of the embodiments, the speed sensor can be integrated in the position sensor, which simultaneously outputs data as to location and speed. In yet another embodiment, the control can be or contain an acceleration sensor, and, therefore, with great acceleration that applies a corresponding force to the driving wheel, the spring elements can be adjusted by the electronic module such that the applied cyclist's energy is converted as effectively as possible.
In some of the embodiments, the electronic module can contain a microprocessor or a microcontroller to convert the input variable into a control signal. To this end, it is possible to use software that implements a neural network and/or a fuzzy logic and/or a control or feedback-control method. It is thus ensured to always obtain an optimum control signal for the optimum adjustment of the spring elements from a plurality of input variables that can partially also provide vague or inconsistent information.
In some of the embodiments, the method for controlling the spring elements can have a self-learning algorithm, and, therefore, the electronic module detects the preferences of the bicycle user based upon the user's interferences and selects the corresponding parameters of the spring elements so that it is possible to reduce the number of user interferences after a prolonged use of the bicycle by the user. If the bicycle is used by several users, the electronic module can contain a plurality of memory areas, and, therefore, different parameters can be filed for different users to also adapt the riding pattern of the bicycle to several different users.
In some of the embodiments, the tilt sensor or the acceleration sensor can contain or be a micromechanical sensor. This enables a compact, reliable, and cost-effective design of the proposed suspension system, wherein, in some of the embodiments, the sensor can be integrated on a pc board together with the electronic module.
In some of the embodiments, the micromechanical sensor can be a multi-axis sensor that can detect an acceleration and/or a position in two or three axes. As a result, it is possible to detect both a straight acceleration or a deceleration of the bicycle and also a transverse acceleration that occurs in a curve ride. Finally, the system can detect whether the bicycle is accelerated towards the ground by acceleration due to gravity or a value close to the acceleration due to gravity. In such a case, the bicycle is fully off the ground, e.g., in the case of jumps, and, therefore, the characteristic of the suspension system can be adjusted to the hard impact accompanied by the landing.
In some of the embodiments, the micromechanical sensor can be a three-axis sensor that can detect an acceleration in three axes. By integration of the acceleration over time, a speed can be determined in all three spatial directions or the temporal change in the spatial position can be determined by the electronic unit. By integration of the speed over time, the spatial position of the bicycle can be determined. A plurality of riding conditions can be detected from this data using only one three-axis micromechanical sensor. When the bicycle is tilted to the rear, i.e., the front wheel is higher than the rear wheel, the cyclist goes uphill. In this case, a harder spring characteristic can be chosen or the suspension can be blocked or a height-adjustable seat post can be raised to a high position or a lowerable suspension fork in a low, sunken position. When the bicycle is tilted to the front, i.e., the front wheel is lower than the rear wheel, the cyclist goes downhill. In this case, a softer spring characteristic can be chosen or the blocked suspension can be released again or a height-adjustable seat post can be brought into a low position or a lowerable suspension fork can be raised into an upper position. When the bicycle has a lateral tilt, the cyclist drives through a curve. In this case, a harder spring characteristic can be chosen or the suspension can be blocked. When the lateral tilt changes cyclically and/or the acceleration in the direction of travel is greater than a settable limiting value, the cyclist pedals out of the saddle. In this case, a harder spring characteristic can be chosen or the suspension can be blocked.
In some of the embodiments, the operating element can be fixed to a joint attachment element together with a brake lever and/or a gearshift lever. From such a configuration, the number of clamps at the handlebar is reduced to obtain a good reachability of the operating element, on the one hand, and minimize danger of damaging the handlebar tube by clamps, on the other hand.
In some of the embodiments, the actuator can be selected from an electric motor and/or a solenoid-valve controller and/or a piezo-valve controller and/or a controller that contains or is a shape memory alloy. An electric motor can be a stepping motor that can be rotated in a controlled fashion and/or is a gear motor that, at its outer side, provides a speed smaller than that of the rotor. A gear motor can have a worm gear. It is self-locking and, therefore, a once-chosen position can be maintained without consuming any current. An electric motor has the advantage that the power consumption is only small because the electric motor must only be energized if the parameters of the spring elements are actually modified. To energize the electric motor, an H-bridge circuit can be used. A magnetic-valve controller and a piezo-valve controller have the advantage that they can modify the parameters of the spring elements very fast to enable a rapid adaptation to dynamic riding conditions.
In some of the embodiments, an actuator that contains or is of a shape memory alloy can be used to influence the closure of a valve such that a valve opening can be closed or opened or its clear cross-section can be influenced. As a result, it is possible to influence the flow-through of a fluid such as air or oil. This can influence the damping force or fully block the suspension (lock-out). In a further embodiment, a valve opening can be closed or opened by a rotary valve or the clear cross-section thereof can be influenced. The rotary valve can be driven through an electric motor or an element made of a shape memory alloy.
In some of the embodiments, the damping force of at least one spring element can be adjusted by an electrorheological liquid, the viscosity of which changes depending on an electric field. In this case, the actuator can have one or several electrodes that, according to a plate or ring capacitor, expose the oil in the damping element or the electrorheological liquid to an electric field.
In some of the embodiments, the control and/or the electronic module and/or the actuator can have at least one first operating condition and at least one second operating condition, wherein, in the second operating condition, the number of functions that can be executed is reduced and the energy consumption is lowered compared to the first operating condition. The service life of the battery in the electronic module and/or in the control can thus be extended because the full variety of functions and the full energy consumption are only available when the bicycle is actually moved. The number of functions that can be executed in the second operating condition, which can also be referred to as the energy saving condition, can be reduced to such an extent that the components only monitor the use of the bicycle and subsequently return to the first operating condition. In this way, without the user having to actively turn-on the system, a constant availability can be ensured without the batteries being discharged rapidly, e.g., overnight. The operating condition can be switched over by a micromechanical acceleration sensor that changes into the second operating condition when no acceleration is recorded during a settable time and that changes into the first operating condition when an acceleration is recorded again for the first time.
In some of the embodiments, the control and/or the electronic module can contain at least one operating condition indicator. In some of the embodiments, the operation condition indicator can contain at least one LED and/or at least one LCD display. Preferably, but not compulsorily, the operating condition indicator is disposed in an operating element that is attached to the handlebar of the bicycle or on the display of a cell phone. Due to this configuration, the operating condition indicator is in the cyclist's field of vision. The operating condition indicator can indicate, e.g., the currently existing operating condition and/or the currently chosen parameters of the spring elements. In addition, the operating condition indicator can output a warning when the battery state is low. Finally, the operating condition indicator can be adapted to indicate or support the arrangement of a radio frequency and/or a transmission protocol between the control and the electronic module.
In some of the embodiments, the spring element parameter to be modified can be selected from a spring force and/or a damping force and/or a suspension travel and/or a zero position. For example, the suspension travel on paved roads can be reduced to zero and, therefore, there is a safe handling and a direct conversion of the introduced driving output in the advance. When the roads are relatively poor, the suspension travel can be extended in one-step or multi-step fashion until the full suspension travel is available on a very uneven ground.
In some of the embodiments, the spring force can be adapted to result in a rather convenient response or a rather firm response of the spring elements.
Finally, the zero position can be adapted, i.e., the position of the spring elements, when the chassis is unloaded. For example, a suspension fork can be lowered in an up-hill ride to enable a more favorable weight distribution. The fork lowering can be eliminated again in a down-hill ride to have available the full suspension travel.
With the foregoing and other objects in view, there is provided, an electronically controlled suspension system for a bicycle including at least one spring element disposed between a first part of the bicycle and a second part of the bicycle, both parts being movably interconnected, the at least one spring element having at least one parameter that can be modified, at least one actuator operatively influencing the spring element to modify the at least one parameter, an electronic module producing at least one control signal for the at least one actuator, and at least one control device by which the control signal produced by the electronic module can be influenced, the at least one control device having at least one multi-axis micromechanical acceleration sensor.
In accordance with another feature, at least one of the at least one control device and the actuator is connected to the electronic module through a radio signal.
In accordance with a further feature, the multi-axis micromechanical acceleration sensor is adapted to determine an acceleration in three spatial directions.
In accordance with an added feature, the at least one control device comprises at least one of an operating element, a tilt sensor, a speed sensor, a torque sensor, and a position sensor.
In accordance with an additional feature, the bicycle has at least one of a brake lever and a gearshift lever and a joint attachment element disposes the operating element with one of the brake lever and the gearshift lever.
In accordance with yet another feature, the electronic module comprises a map memory to receive topographic information.
In accordance with yet a further feature, the electronic module determines at least one of a speed and a position by integration of data of the acceleration sensor over time.
In accordance with yet an added feature, that the actuator is selected from at least one of an electric motor, a magnetic-valve controller, a piezo-valve controller, a controller containing a shape memory alloy, and a controller being a shape memory alloy.
In accordance with yet an additional feature, at least one of the control device and the electronic module has at least one first operating condition and at least one second operating condition, wherein, compared to the first operating condition, in the second operating condition a number of functions that can be executed is reduced and an energy consumption is lowered.
In accordance with again another feature, at least one of the electronic module changes from the first operating condition to the second operating condition when no acceleration is detected over a settable time and the electronic module changes from the second operating condition to the first operating condition when an acceleration is detected.
In accordance with again a further feature, the position sensor contains at least one radio navigation system.
In accordance with again an added feature, at least one of the electronic module and the operating element includes or is a cell phone.
In accordance with again an additional feature, at least one of the control device and the electronic module contain at least one operating condition indicator and/or at least one of the control device and the electronic module visualize an operating condition by at least one of at least one LED and an LCD display.
In accordance with still another feature, the electronic module enables at least one manual operating condition in which the user influences the control signal produced by the electronic module and the electronic module enables at least one automatic operating condition in which the control signal produced by the electronic module is produced depending on at least one riding parameter.
In accordance with still a further feature, the at least one riding parameter is selected from at least one of a terrain topography, a longitudinal acceleration, a transverse acceleration, a tilt, a driving torque, a speed, and a road condition.
In accordance with still an added feature, the at least one parameter is selected from at least one of a spring force, a damping force, a suspension travel, a zero position, and a saddle height.
With the objects in view, there is also provided a method for controlling a suspension system for a bicycle including the steps of producing an input variable by at least one control device, the input variable representing an acceleration in at least one spatial direction, transmitting the input variable to an electronic module, producing a control signal for at least one actuator with the electronic module, and modifying at least one parameter of at least one spring element with the at least one actuator, the spring element being disposed between first and second parts of the bicycle movably interconnected.
In accordance with still an additional mode, the input variable represents at least one of a driver's desire, a tilt, a terrain topography, a speed, and a road condition.
In accordance with another mode, the at least one parameter is selected from at least one of a spring force, a damping force, a suspension travel, and a zero position.
In accordance with a further mode, the input variable is transmitted to the electronic module through a radio signal.
In accordance with an added mode, at least one of the tilt, the position, and the speed is determined by integration of the acceleration over time.
In accordance with an additional mode, there is provided the step of detecting acceleration in three spatial directions with a three-dimensional micromechanical acceleration sensor.
In accordance with yet another feature, there is provided a data carrier with data stored thereon or a signal sequence suitable for transmission through a computer network and representing data, the data representing a computer program that carries out the method when the computer program is running.
With the objects in view, there is also provided a seat post for a bicycle including a post body having a first end shaped to be connected to a bicycle frame, a second end shaped to be connected to a saddle, at least two longitudinal portions meshing with each other and slidable relative to one another along a longitudinal extension, and a fixing apparatus by which the two longitudinal portions can be fixed to one another in a settable relative position, the fixing apparatus being influenced to selectively fix and unfix by a radio signal.
In accordance with yet a further feature, the radio signal is produced by an operating element.
In accordance with yet an added feature, the radio signal is produced by an electronic module dependent upon terrain topography.
In accordance with a concomitant feature, the two longitudinal portions are connected to each other through a gas pressure spring.
Although the systems and methods are illustrated and described herein as embodied in an electronically controlled suspension system for a bicycle, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Additionally, well-known elements of exemplary embodiments will not be described in detail or will be omitted so as not to obscure the relevant details of the systems and methods.
Additional advantages and other features characteristic of the systems and methods will be set forth in the detailed description that follows and may be apparent from the detailed description or may be learned by practice of exemplary embodiments. Still other advantages of the systems and methods may be realized by any of the instrumentalities, methods, or combinations particularly pointed out in the claims.
Other features that are considered as characteristic for the systems and methods are set forth in the appended claims. As required, detailed embodiments of the systems and methods are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the systems and methods, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to variously employ the systems and methods in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the systems and methods. While the specification concludes with claims defining the systems and methods of the invention that are regarded as novel, it is believed that the systems and methods will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, which are not true to scale, and which, together with the detailed description below, are incorporated in and form part of the specification, serve to illustrate further various embodiments and to explain various principles and advantages all in accordance with the systems and methods. Advantages of embodiments of the systems and methods will be apparent from the following detailed description of the exemplary embodiments thereof, which description should be considered in conjunction with the accompanying drawings in which:
FIG. 1 is a side elevational view of an exemplary embodiment of a bicycle equipped with an electronically controlled suspension system;
FIG. 2 is a block diagram of employed electronic components of an electronically controlled suspension system for a bicycle;
FIG. 3 is a perspective view of an operating element of an electronically controlled suspension system for a bicycle;
FIG. 4 is a cross-sectional view of the operating element of FIG. 3 ;
FIG. 5 is a perspective view of one exemplary embodiment of an assembly of the operating element of FIG. 3 ;
FIG. 6 is a perspective view of another exemplary embodiment of an assembly of the operating element of FIG. 3 ;
FIG. 7 is a perspective view of the assembly of the operating element of FIG. 6 attached to part of a handlebar tube;
FIG. 8 is a perspective view of a first exemplary embodiment of a spring element;
FIG. 9 is a cross-sectional view of the spring element of FIG. 8 ;
FIG. 10 is an enlarged, cross-sectional view of a portion of the spring element of FIG. 9 ;
FIG. 11 is a perspective view of another exemplary embodiment of a spring element;
FIG. 12 is a cross-sectional view of the spring element of FIG. 11 ;
FIG. 13 is a perspective view of the spring element of FIG. 11 from a mechanical adjustment side of the spring element;
FIG. 14 is a cross-sectional view of the spring element of FIG. 11 ;
FIG. 15 is a cross-sectional view of a detail of the spring element of FIG. 11 ; and
FIG. 16 is a perspective view of an exemplary embodiment of a seat post.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments of the systems and methods are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the systems and methods, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the systems and methods in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the systems and methods. While the specification concludes with claims defining the features of the systems and methods that are regarded as novel, it is believed that the systems and methods will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.
In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.
Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the systems and methods will not be described in detail or will be omitted so as not to obscure the relevant details of the systems and methods.
Before the systems and methods are disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms “comprises,” “comprising,” or any other variation thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The terms “a” or “an”, as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The description may use the terms “embodiment” or “embodiments,” which may each refer to one or more of the same or different embodiments.
The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may mean that two or more elements are in direct physical or electrical contact (e.g., directly coupled). However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other (e.g., indirectly coupled).
For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” or in the form “at least one of A and B” means (A), (B), or (A and B), where A and B are variables indicating a particular object or attribute. When used, this phrase is intended to and is hereby defined as a choice of A or B or both A and B, which is similar to the phrase “and/or”. Where more than two variables are present in such a phrase, this phrase is hereby defined as including only one of the variables, any one of the variables, any combination of any of the variables, and all of the variables, for example, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).
Relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of disclosed embodiments. Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments; however, the order of description should not be construed to imply that these operations are order dependent.
As used herein, the term “about” or “approximately” applies to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure.
It will be appreciated that embodiments of the systems and methods described herein may be comprised of one or more conventional processors and unique stored program instructions that control the one or more processors to implement, in conjunction with certain non-processor circuits and other elements, some, most, or all of the functions of the powered injector devices described herein. The non-processor circuits may include, but are not limited to, signal drivers, clock circuits, power source circuits, and user input and output elements. Alternatively, some or all functions could be implemented by a state machine that has no stored program instructions, or in one or more application specific integrated circuits (ASICs) or field-programmable gate arrays (FPGA), in which each function or some combinations of certain of the functions are implemented as custom logic. Of course, a combination of these approaches could also be used. Thus, methods and means for these functions have been described herein.
The terms “program,” “software,” “software application,” and the like as used herein, are defined as a sequence of instructions designed for execution on a computer system. A “program,” “software,” “application,” “computer program,” or “software application” may include a subroutine, a function, a procedure, an object method, an object implementation, an executable application, an applet, a servlet, a source code, an object code, a shared library/dynamic load library and/or other sequence of instructions designed for execution on a computer system.
Herein various embodiments of the systems and methods are described. In many of the different embodiments, features are similar. Therefore, to avoid redundancy, repetitive description of these similar features may not be made in some circumstances. It shall be understood, however, that description of a first-appearing feature applies to the later described similar feature and each respective description, therefore, is to be incorporated therein without such repetition.
Described now are exemplary embodiments. Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 , there is shown a first exemplary embodiment of a bicycle. The bicycle 1 has a frame 10 that, for the purposes of the below description, represents a first, stationary part of the bicycle. The frame 10 carries in generally known manner a saddle above a seat post 16 and a foot pedal by which a user can produce a driving force. The driving force or the torque can be detected through a torque sensor 5 . The driving force is transmitted to the rear wheel 12 through a chain and an optional shifting system.
The seat post 16 can be height-adjustable and, therefore, the cyclist can adopt, uphill or in the plane, a high seat position that allows a better and ergonomic power transmission to the foot pedal. In downhill rides, the seat post can be retracted to obtain a low seat position with favorable focal point position. Height adjustment of the seat post can be made as in an office chair through a gas pressure spring or a steel spring and, therefore, the cyclist can adjust the height while riding and does not have to descend. The height adjustment can be triggered through an operating element at the handlebar, the operating element being connected to the seat post through a hydraulic system or a Bowden cable. In some of the exemplary embodiments, the height adjustment can be triggered through a radio signal. The radio signal can be transmitted, e.g., through an operating element at the handlebar and, therefore, a Bowden cable or a hydraulic line is not necessary. In other exemplary embodiments, the radio signal can be transmitted by the electronic unit depending on the riding condition and, therefore, the saddle height is also adjusted in automated fashion along with the respectively optimum adjustment of at least one spring element.
The bicycle 1 has two wheels 12 . The front wheel 12 is rotatably mounted on a suspension fork to steer the bicycle 1 . The suspension fork has stanchion tubes 11 that are connected to the frame 10 in a substantially immovable fashion and slider tubes 14 into which the stanchion tubes 11 immerse when the front wheel is deflected. The force opposite to the immersion is produced by a spring element 3 , which is described in more detail by FIGS. 11 to 15 . A handlebar tube 17 serves for steering the bicycle 1 and also carries an operating element 2 and, therefore, the user can be informed on the operating parameters of the system and/or can manually influence the parameters of the spring elements 3 and 4 .
The rear wheel 12 is attached to movable chainstays 15 . The forces transmitted to the frame 10 during the deflection or during a load are absorbed by the spring element 4 . The forces opposed in this case to the deflected rear wheel 12 are defined by the parameters of the spring element 4 , which is explained in more detail by FIGS. 8 to 10 .
Finally, an electronic module 6 is mounted on the seat post 16 and produces control signals for the actuators in the spring elements 3 and 4 . The operating element 2 , the torque sensor 5 and the spring elements 3 and 4 are connected to the electronic module 6 through a radio signal 64 . As a result, weight for cable connections or Bowden cables can be saved, on the one hand, and a high operational reliability can be ensured, on the other hand, because neither electric terminal contacts can corrode nor the cable can be damaged mechanically. In some of the exemplary embodiments, the electronic module 6 and/or the operating element 2 can be a cell phone where correspondingly adapted software is executed. As a result, a dedicated electronic module connected to the bicycle is dispensed with.
FIG. 2 shows a block diagram of the electronic module 6 and further peripheral components. The electronic module 6 contains a microprocessor CPU on which a computer program runs that calculates a control signal for the actuators from input variables of the sensors. The computer program can be filed in an EEPROM 65 or a flash memory and, therefore, the respective data is not lost even in the case of turning-off of the device or a deep discharge of the battery 61 . In addition, the flash memory can contain configuration data, e.g., user's preferences or topographic data, e.g., digitized maps with height information and/or information on the road quality. Data can be supplied to the microprocessor and the memories 65 through a serial interface GPIO or SPI and/or an analog-to-digital converter ADC. This data can contain software updates or topographic data that can be supplied through a USB interface 62 , for example. The latter can optionally also be used for charging the battery 61 . In other exemplary embodiments, a separate charging interface can be present for this purpose or the battery 61 is replaced after its discharge or charged outside the electronic module 6 . The voltage and/or the current drawn from the battery 61 can be monitored through the analog-to-digital converter ADC by the microprocessor CPU. As a result, the chassis can be taken into an emergency program when the battery 61 has been discharged. In some of the exemplary embodiments, the electronic module 6 can be equipped with the CPU, the EEPROM 65 , the memory 65 , the serial interface GPIO or SPI, the USB interface 62 and the battery 61 in the form of a cell phone or a smartphone or a tablet computer.
Finally, the electronic module 6 can contain an acceleration sensor 63 that can detect a change in the riding speed and/or a travelling on curved roads. In other exemplary embodiments, the acceleration sensor 63 can also be attached to the bicycle 1 in a separate assembly or can be part of the operating element 2 and transmit its data through a radio signal 64 . As described in analogy to the acceleration sensor 63 , the electronic module 6 can also contain a tilt sensor, a speed sensor, or a position sensor. FIG. 2 shows the position sensor 66 as a separate assembly that is connected to the electronic module 6 through a radio signal 64 . In some of the exemplary embodiments, only a multi-axis acceleration sensor can be present from the data of which a speed vector and a tilt or position vector can be calculated by integration over time. To determine a coordinate zero point, an initialization can be made by placing the bicycle upright on a level area and subsequently storing this position as a horizontal rest position. All further positions, such as lateral tilt, up-hill ride, downhill ride and the current speed follow therefrom by integration of the accelerations in all three spatial directions. Should the bicycle not be upright during the initialization, but, e.g., have a higher front or rear wheel, the cyclist can also choose a different coordinate zero point. This permits individual fine tuning.
Finally, FIG. 2 shows how to connect an operating element 2 to the electronic module 6 through the radio signal 64 . The operating element 2 as such is specified below by means of FIGS. 3 to 7 . The electronic module 6 according to FIG. 2 additionally contains an operating condition indicator 21 . In other exemplary embodiments, the operating condition indicator 21 can be a component of the operating element 2 or be integrated into a spring element 3 or 4 .
The electronic module 6 can contain an optional H-bridge for the motor control when the actuator 431 contains at least one electric motor. In other exemplary embodiments, the actuator 431 can also be a component of the spring element 3 or 4 together with the H-bridge and, therefore, these components need not be integrated into the electronic module 6 .
FIGS. 3 to 7 show an exemplary embodiment of an operating element 2 . Here, equal parts have equal reference signs and, therefore, not all the components are explained in connection with all the figures to avoid repetitions.
In the exemplary embodiment shown, the operating element 2 has a three-part housing. Here, the lower housing part 22 has a concave inner surface 221 , by which the lower housing part 22 can abut against a handlebar tube 17 . This configuration permits a safe assembly and the operating element 2 is protected from twisting, tilting, or moving out of place. The middle housing part 26 is adapted for receiving a battery cell 283 , e.g., a lithium ion battery, an alkali battery, or a zinc-air battery. Penetration of moisture between the middle housing part 26 and the lower housing part 22 is prevented by a gasket 27 . A screw connection allows easy opening and closing and, therefore, it is easy to exchange the battery 283 . The upper housing part 23 has a window 21 through which light from a light-emitting diode 284 can reach the observer. As a result, it is possible to realize an operating condition indicator when the light-emitting diode 284 emits light of different colors or intermittent light having different flashing patterns. Furthermore, the upper housing part 23 has a push button 25 by which the cyclist can transmit control signals to the electronic module 6 when standing or during a ride. To this end, the operating element 2 has a simple electronic circuit disposed on a pc board 281 and detects the pushing of the button 25 as well as carries the light-emitting diode 284 and supplies it with electric energy.
A second pc board 282 is disposed therebelow and carries a high-frequency interface to establish a radio connection to the electronic module 6 . As a result of the two-part design, the transmitting HF part of the circuit can easily be exchanged to comply with different legal provisions in different countries or to enable an adaptation to different transmitting protocols.
FIGS. 6 and 7 show the attachment of the operating element 2 to an optional clamp 222 through a screw connection 261 . As a result, the operating element 2 can be positioned at any point of a handlebar tube 17 . The operating element 2 is advantageously disposed in the vicinity of a handle 171 and, therefore, the user can reach the button 25 without taking a hand off the handlebar. This allows a safe operation of the bicycle and an adjustment of the suspension system in any riding condition.
FIG. 5 shows an alternative form of attachment to an existing attachment clamp 223 . The attachment clamp 223 can be a component of a brake and/or gearshift lever that is already attached to the handlebar tube 17 to enable the actuation of a brake or a gearshift. The operating element 2 can additionally be attached to the clamp 223 through spacer bolts 224 and a screw connection 261 and, therefore, the use of a further clamp 222 is dispensable. As a result, it is thus possible to save weight, on the one hand, and to increase the reliability, on the other hand, because there is no notch effect of a further clamp 222 on the handlebar tube 17 . Finally, all this leads to a tidy and attractive optics for the user.
An exemplary embodiment of a spring element 4 is explained by FIGS. 8 to 10 . In this case, too, equal reference signs designate equal components of the spring element 4 . As evident from FIG. 1 , the spring element 4 is provided for use at spring-suspended chainstays or a rear wheel suspension. The spring element has a base body 42 in which an air chamber 421 is disposed. A piston 41 slides in the air chamber 421 , wherein the compressed air counters the piston 41 with resistance. The base body 42 and the piston 41 can be attached to the chainstays 15 or the frame 10 by the mounting eyes 422 and 411 and, therefore, depending on the loads acting on the wheels 12 , the piston 41 is deflected in the air chamber 421 . In other exemplary embodiments, a helical spring can be used instead of the air chamber 421 , which is made of steel, for example.
In some of the exemplary embodiments, the suspension pattern and/or the damping pattern and/or the suspension travel available can be influenced by an actuation member 423 . Here, the user can adapt in a generally known manner the response pattern of the rear wheel suspension to the respective operating condition of the bicycle or completely block the suspension at times (lock-out).
The actuation member 423 can be actuated through a cam 433 of a shaft 432 . The shaft 432 is connected to an actuator 431 that acts as an actuator in the present exemplary embodiment. The control signal for the actuator 431 is produced in the electronic module 6 and transmitted through a radio connection that is provided by the HF pc board 482 . A second pc board 481 can decode the received signals and/or support an H-bridge that energizes the actuator 431 . A battery 483 is available to supply energy to the electronic controls 481 and 482 and to the actuator 431 . This battery 483 can be recharged through a charging socket, which is accessible after a screw cap 45 is removed. In some of the exemplary embodiments, the charging state of the battery 483 can be visualized through the operating condition indicator 21 at the operating element 2 .
The electronic modules 481 , 482 , the battery 483 , and the actuator 431 can be accommodated in a dust-free and splashing water-sealed fashion in a housing 43 and, therefore, they are not impaired while riding the bicycle 1 . As regards a dust-free and splashing water-sealed closure, the screw cover 45 can be provided with a gasket 451 .
Finally, FIGS. 11 to 15 describe a spring element 3 that is intended for use at a suspension fork. The spring element 3 is disposed in the stanchion tube 11 of the fork in a generally known manner and counters the immersion into the slider tube 14 by a defined resistance. The quality and quantity of this resistance force characterize the suspension pattern of the fork and can be adjusted by a mechanical adjustment system 32 in a general known manner. As a result, the spring force, the damping force, and/or the height of the fork or its unloaded zero position can be adjusted by the user. This can also be made in the present case by either the user's interference through the operating element 2 or the button 25 disposed thereon or in an automated fashion, in that the electronic module 2 selects a respectively appropriate pattern depending on the input variables of the optionally present sensors. To move the mechanical adjustment system 32 in an automated fashion, there is again provided an actuator 431 , which can be an electric motor, a piezo-valve controller, or a solenoid-valve controller, for example. Like the electronics 381 and 382 , the actuator 431 is supplied with electrical energy by a battery 383 . As described above, the electronics of the spring element 3 can contain a high-frequency part on a pc board 382 and a control logic for the actuator 431 on a further pc board 381 . In other exemplary embodiments of the invention all electronic components can, however, also be disposed on a single pc board.
After detaching a screw cap 35 , the part shown in FIG. 15 and including the actuator, the battery, and the electronic control can be removed from the fork for maintenance work to thus exchange the battery 383 , for example. In addition, a charging socket 62 is available after detaching the screw cap 35 without further disassembly work, said socket 62 serving for recharging the battery 383 in a normal operation of the bicycle. The charging condition of the battery 383 can also be monitored by the electronic module 6 and be visualized by the operating condition indicator 21 .
The exemplary embodiment of the suspension system thus offers, on the one hand, the possibility to change the response pattern of the suspension system in a formerly known manner by the user's manual interference; however, on account of lacking Bowden cables and/or cable systems, the operational reliability is increased and the weight is reduced. The electronic adjustment here offers the advantage that the suspension at the front and rear wheels can be adjusted at the same time. Furthermore, the suspension proposed herein can enable an automatic riding operation on account of the algorithms implemented in the software of the electronic module 6 , in which the front and/or rear suspension patterns and/or the response of an optional suspended seat post 16 can be adapted to the respective operating condition in fully automated fashion. The adaptation can here be made depending on the speed, the acceleration, the position, the terrain topography, the road condition, and/or the applied torque.
FIG. 16 shows an exemplary embodiment of a seat post 16 usable for a bicycle, for example. The seat post 16 has a first end 161 that can be connected to a bicycle frame 10 . The connection can be made by a clamp. Furthermore, the seat post 16 can have a second end 162 that can be connected to a saddle. To this end, a clamping bolt can be used that, in some of the exemplary embodiments, also enables an adjustment of the tilt and/or a longitudinal adjustment of the saddle. The seat post 16 has at least one upper longitudinal portion 165 and at least one lower longitudinal portion 164 that mesh with each other and are slidable relative to one another along their longitudinal extension. The more the upper longitudinal portion 165 meshes with the lower longitudinal portion 164 , the lower is the adjustment of the saddle. Furthermore, the seat post 16 has a fixing apparatus 166 by which the two longitudinal portions 164 , 165 can be fixed in a settable relative position to one another. The fixing apparatus 166 can be influenced by a radio signal 64 . To receive the radio signal, an optional antenna 167 is available, which can also have a different design in other exemplary embodiments of the invention.
The two longitudinal portions 164 and 165 are connected to each other through a gas pressure spring that is covered in the figures and thus not visible. When the fixing apparatus 166 is detached, the longitudinal portion 165 is extended and, therefore, the seat height is enlarged. The seat post 16 thus allows a simple adjustment of the saddle height during a ride and, therefore, the seat height can be adapted to the respective riding condition. When the radio signal 64 is produced by the operating element 2 , the cyclist can keep both his hands on the handlebar when he adjusts the seat height and, therefore, safe control over the bicycle is enabled. In some of the exemplary embodiments, the radio signal 64 can be produced by an electronic module 6 and, therefore, an automatic height adjustment is enabled depending on the riding condition. If the seat post 16 has a position transducer that reports the position of the seat post 16 to the electronic module 6 , the electronic module 6 can reuse this data to determine a control signal for the chassis components.
The invention is, of course, not limited to the exemplary embodiments shown in the figures. The above description should not be regarded as limiting but as explanatory. Features of different, above specified embodiments of the invention can be combined into further embodiments. The below claims should be comprehended to the effect that a feature mentioned is present in at least one embodiment of the invention. This does not exclude the presence of further features. Should the claims and the above description define “first” and “second” features, this designation serves for distinguishing two like features without determining a rank order.
It is noted that various individual features of the inventive processes and systems may be described only in one exemplary embodiment herein. The particular choice for description herein with regard to a single exemplary embodiment is not to be taken as a limitation that the particular feature is only applicable to the embodiment in which it is described. All features described herein are equally applicable to, additive, or interchangeable with any or all of the other exemplary embodiments described herein and in any combination or grouping or arrangement. In particular, use of a single reference numeral herein to illustrate, define, or describe a particular feature does not mean that the feature cannot be associated or equated to another feature in another drawing figure or description. Further, where two or more reference numerals are used in the figures or in the drawings, this should not be construed as being limited to only those embodiments or features, they are equally applicable to similar features or not a reference numeral is used or another reference numeral is omitted.
The foregoing description and accompanying drawings illustrate the principles, exemplary embodiments, and modes of operation of the systems and methods. However, the systems and methods should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art and the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the systems and methods as defined by the following claims.
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An electronically controlled suspension system for a bicycle includes at least one spring element between first and second parts the bicycle, both parts being movably interconnected. At least one parameter of the spring element is modified. At least one actuator influences the spring element to modify the at least one parameter. An electronic module produces a control signal for the at least one actuator. A control device is influenced by the control signal produced by the electronic module. The control device is connected to at least one of the electronic module and the actuator through a radio signal. A corresponding method controls the suspension system for the bicycle and a computer program executes the method.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to automotive accessories and, more specifically, to a tire scraper for removing mud from the tires of a truck.
1. Description of the Related Art
Trucks that are licensed for road travel are sometimes required to travel off-road to a particular job site, where they may experience muddy conditions. In the case of trucks having dual wheels (meaning two wheels at each end of each rear axle), these are particularly susceptible to mud build-up between the tires mounted on the dual wheels. Moreover, the outer circumference of each tire is susceptible to mud build-up, due to the fact that a deep tread may be provided o the tire.
A mud and gravel mix is frequently encountered at a construction site, and this mixture is particularly difficult to remove from the tires before the vehicle is placed back on the road.
Many state and local governments have passed ordinances that prohibit trucks from driving onto a paved road with muddy tires. It is not uncommon for these ordinances to provide stiff penalties in the way of fines for truck drivers/owners. When the truck driver is about to drive onto a paved road from a construction site, he must stop his vehicle and, using a stick, board or other suitable object, he must scrape the mud and gravel off the circumference of the tires and from between the tires of the dual wheels to avoid the penalties. This process is time consuming and ultimately not very effective.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a tire scraper which is relatively simple in construction and cost effective to produce.
Another object of the present invention is to provide a tire scraper which minimizes the amount of time required to make the tires of a vehicle clean before driving on a paved road.
Another object of the present invention is to provide a tire scrape which is capable of being stowed in an inoperative position and deployed in an operative position with a minimal amount of work for the vehicle driver.
These and other objects of the invention are met by providing a tire scraper for removing mud from a vehicle having dual tires, including scraper means for removing mud from the dual tires, a support member mounted on the vehicle adjacent the dual tires and having the scraper means mounted thereon, and an actuator for moving the support member and thus the scraper means between a first, retracted position and a second, deployed position in which the scraper means is juxtaposed the dual tires while the dual tires are rotating.
These and other features and advantages of the tire scraper of the present invention will become more apparent with reference to the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a vehicle having the tire scraper according to the present invention mounted thereon;
FIG. 2 is an enlarged vertical sectional view, showing a portion of the tire scraper according to FIG. 1;
FIG. 3 is a sectional view taken along line III--III of FIG. 2;
FIGS. 4(a) and 4(b) are side elevational views of wire brush segments which form at part of the present invention;
FIG. 5 is a rear elevational view of the tire along line 5--5 of FIG. 2 scraper showing brush assemblies attached thereto and positioned in juxtaposition to the tires;
FIG. 5(a) is a sectional view taken along line 5(a)--5(a) of FIG. 5; and
FIG. 6 is a side elevation view of the tire scraper of FIG. 5 with the brush assemblies removed for illustration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a vehicle such as a tandem rear axle dump truck 10 has a dump bed 12 to which is connected on the underside thereof a tire scraper apparatus 14 according to the present invention. The scraper apparatus 14 is illustrated in a deployed position in which a first scraper bar or element 16 is actuated downwardly to extend between a pair of dual tires by extension of a fluid pressure (hydraulic or pneumatic) cylinder 18. Similarly, for the rear-most axle, a second scraper bar or element 20 is actuated downwardly by a fluid pressure cylinder 22.
The cylinders 18 and 22 may be actuated by a compressed air source (not shown) or a hydraulic fluid source (not shown) as controlled by a panel switch or other suitable means in the cab 24 of the truck 10.
Referring now to FIG. 2, which is an enlarged, vertical sectional view taken at the rear-most axle, the dump bed 12 includes a lower frame member 26 to which are welded or otherwise suitably attached a pair of steel support bars 28 and 30, which run essentially parallel to the axis of rotation 32 of the dual tires, illustrated in FIG. 2 as the broken line 34.
As further illustrated in FIGS. 5 and 6, the rear-most support bar 30 has a pair of downwardly extending arms 36 and 38, each having a transverse bore so as to collectively define a clevis through which a pivot pin 40 is pivotally mounted. The pin carries the scraper bar 20 at a medial portion of the pin 40. The scraper bar 20 is provided with a plurality of brush segments (to be described below). The scraper bar 20 extends between the two tires 34a and 34b (as seen in FIGS. 5 and 6), while a pair of shorter, side scraper bars 42 and 44 are provided on opposite sides of the dual tire assembly.
By rotating the pin 40, the scraper bars 20, 42 and 44 can be moved from a stowed position in relative proximity to the frame member 26 of the dump bed 12 to a deployed position in which the bars move in between and juxtaposed to the tires 34a and 34b. Rotation or actuation of the pin 40 may be performed manually by the use of a crank 46 (shown in broken lines in FIG. 6) or by the cylinder 22. The cylinder 22 has one end pivotally mounted to the frame member 26 through the support bar 28 and a downwardly extending arm 29 connected to the support bar 28, and an opposite end pivotally connected to the scraper bar 20. As the extendable arm 23 of the cylinder 22 is extended (through the application of pressurized fluid), the pin 40 is caused to rotate counter-clockwise (as viewed in FIG. 2) so that the scraper bar assembly which includes scraper bars 20, 42 and 44 and there corresponding brush segments likewise rotate in a counter-clockwise direction. Since this actuation can be performed from the cab of the truck using a cylinder 22, the cylinder is preferred over the crank 46, which would require one individual to manipulate the crank while the other individual drove the truck to rotate the wheels.
A pair of support plates 48 and 50 (FIG. 5) are mounted respectively between the bars 42 and 20, as well as between bars 44 and 20. Any suitable means, such as welding, may be used to rigidly connect the support plates 48 and 50 between the scraper bars 42, 44 and 20. As shown in FIG. 2, the support plate 48 may be made of angle-steel. As shown in FIG. 5(a), the plate 48 has a portion 48a to which a brush assembly 52 is adjustably mounted via fastening bolts received in slots, as clearly shown in FIG. 5. The brush assembly 52 includes a plurality of brush segments 54 which are individually mounted on a backing plate 56. The backing plate may be provided with slots so as to provide for either vertical or horizontal adjustment of the position of the brush segments 54. Each brush segment 54 is attached to the backing plate 56 by means of threaded fasteners 54a, and each includes a plurality of bristles 58 which are preferably made of heavy wire coated in plastic. As shown in FIGS. 4(a) and 4(b), the length of the bristles is selected or cut according to the desired shape of the overall brush assembly. For example, referring to FIG. 5, it can be seen that the brush assembly 60 mounted on the bar 20 has bristles chosen to have a length which conforms to the profile of the two tires 34a and 34b, thus constituting an hour-glass shape. On the other hand, the bristles of the brush assembly 52 have a substantially straight profile in order to correspond to the circumference of the tire and to an outer edge of the tire.
Referring to FIG. 3, a brush segment 62 of the brush assembly 60 includes bristles 64 which extend in a radially outward direction relative to the bar 20. A threaded fastener 66, such as a bolt, passes through a support block 68 of the brush segment 62 and into a threaded bore provided in the bar 20. During manufacture, the bristles can be attached to the support block 68 by applying a thermoplastic o thermosetting polymeric material over the bristles which are held on the surface of the block 68 in parallel alignment when the polymeric material hardens. Any conventional adhesive material can be used. When the polymeric material hardens, the bristles are placed between the corresponding scraper bar and support block 68. When the bolt is tightened, the bristles are forced into a groove 20a formed in the corresponding bar 20 so that the bristles are prevented from rotating.
Other types of brushes having other types of bristles may be employed. Moreover, the present invention can be practiced by providing a minimal amount of structure, such as employing only the center bar 20 which may be of greater width, so as to touch the two tires 34a and 34b simultaneously at their closest point to each other. This would have the tendency to remove most of the mud between the tires without having to use bristles. Thus, the structure illustrated in FIG. 6, having the brush assemblies removed from the sake of illustration, can be viewed as another embodiment of the invention in which only a middle bar 20 is mounted on a pivot pin 40. The addition of side bars 42 and 44 and the brush assemblies represent a particularly preferred embodiment of the present invention.
Also, while the present invention has been described in detail with respect to a single tire scraper, it should be readily understood that a tire scraper would be provided on each set of dual wheels provided on the rear axles of the truck.
Numerous modifications and adaptations of the present invention will be apparent to those so skilled in the art and thus, it is intended by the following claims to cover all such modifications and adaptations which fall within the true spirit and scope of the invention.
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A tire scraper for removing mud from a vehicle having dual tires, includes a plurality of scraper bars, each carrying a plurality of brush assemblies. An actuator moves the pivotal support member between a first retracted position and a second deployed position.
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FIELD
[0001] The present description relates to methods and a system for starting an engine of a hybrid vehicle. The methods may be particularly useful for hybrid vehicles that include a driveline integrated starter/generator.
BACKGROUND AND SUMMARY
[0002] Hybrid vehicles may be required to meet emissions regulations for hydrocarbons, carbon monoxide, and oxides of nitrogen. One way to meet emissions regulations is to couple a three-way catalyst to an engine of the hybrid vehicle so that engine emissions are oxidized and reduced to more desirable gases. However, even with a three-way catalyst, a hybrid vehicle may not meet emissions regulations because the three-way catalyst may have to reach a light-off temperature (e.g., a temperature where catalyst efficiency reaches a threshold efficiency) before engine exhaust gases may be processed. One way to shorten an amount of time a catalyst takes to reach light-off temperature is to retard engine spark timing away from minimum spark advance for best torque (MBT). By retarding spark timing, exhaust gases may transfer additional heat to the engine's exhaust system and its components. Nevertheless, retarding engine spark timing may be insufficient to heat a catalyst to a light off temperature soon enough to meet emissions regulations. Therefore, it would be desirable to provide a way to reach catalyst light off temperature sooner.
[0003] The inventors herein have recognized the above-mentioned disadvantages and have developed a method, comprising: operating an engine with a substantially constant air mass and spark timing in response to catalyst temperature less than a threshold; varying engine torque as engine speed varies while operating the engine with the substantially constant air mass; and providing driver demand torque via engine torque and motor torque while operating the engine with the substantially constant air mass.
[0004] By operating an engine with a substantially constant air mass flowing through the engine, substantially constant spark retard, and varying engine torque as engine speed varies, it may be possible to provide the technical result of quickly heating a catalyst while producing a desired driver demand torque. In particular, the engine air mass may be selected to provide a desired rate of thermal energy from the engine to a catalyst so that the catalyst lights off within a desired time even in the presence of varying vehicle speed and driver demand torque. A motor coupled to the engine may augment or lower engine torque to provide a driver demand torque at a torque converter impeller as engine speed changes during vehicle acceleration and deceleration. In this way, flow of air through an engine may be held substantially constant even as engine speed changes so that a catalyst lights off in a repeatable fashion as a vehicle accelerates or decelerates.
[0005] The present description may provide several advantages. In particular, the approach may improve vehicle emissions. Further, the approach may improve vehicle drivability during engine starting. Additionally, the approach may allow more accurate air-fuel ratio control while engine emissions components are being heated to operating temperature.
[0006] The above advantages and other advantages, and features of the present description will be readily apparent from the following Detailed Description when taken alone or in connection with the accompanying drawings.
[0007] It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The advantages described herein will be more fully understood by reading an example of an embodiment, referred to herein as the Detailed Description, when taken alone or with reference to the drawings, where:
[0009] FIG. 1 is a schematic diagram of an engine;
[0010] FIG. 2 shows an example vehicle driveline configuration;
[0011] FIG. 3 shows an example hybrid vehicle operating sequence; and
[0012] FIG. 4 shows an example method for operating a hybrid vehicle driveline.
DETAILED DESCRIPTION
[0013] The present description is related to improving hybrid vehicle emissions after an engine is started. The hybrid vehicle may include an engine as is shown in FIG. 1 . Further, the engine may be included in a driveline of the hybrid vehicle as is shown in FIG. 2 . Engine emissions may be reduced via heating a catalyst by operating an engine and driveline integrated starter/generator (DISG) as shown in the sequence of FIG. 3 . The engine and DISG may be operated according to the method of FIG. 4 in the system of FIGS. 1 and 2 to provide the operating sequence shown in FIG. 3 .
[0014] Referring to FIG. 1 , internal combustion engine 10 , comprising a plurality of cylinders, one cylinder of which is shown in FIG. 1 , is controlled by electronic engine controller 12 . Engine 10 includes combustion chamber 30 and cylinder walls 32 with piston 36 positioned therein and connected to crankshaft 40 . Flywheel 97 and ring gear 99 are coupled to crankshaft 40 . Starter 96 (e.g., low voltage (operated with less than 30 volts) electric machine) includes pinion shaft 98 and pinion gear 95 . Pinion shaft 98 may selectively advance pinion gear 95 to engage ring gear 99 . Starter 96 may be directly mounted to the front of the engine or the rear of the engine. In some examples, starter 96 may selectively supply torque to crankshaft 40 via a belt or chain. In one example, starter 96 is in a base state when not engaged to the engine crankshaft. Combustion chamber 30 is shown communicating with intake manifold 44 and exhaust manifold 48 via respective intake valve 52 and exhaust valve 54 . Each intake and exhaust valve may be operated by an intake cam 51 and an exhaust cam 53 . The position of intake cam 51 may be determined by intake cam sensor 55 . The position of exhaust cam 53 may be determined by exhaust cam sensor 57 .
[0015] Fuel injector 66 is shown positioned to inject fuel directly into cylinder 30 , which is known to those skilled in the art as direct injection. Alternatively, fuel may be injected to an intake port, which is known to those skilled in the art as port injection. Fuel injector 66 delivers liquid fuel in proportion to the pulse width from controller 12 . Fuel is delivered to fuel injector 66 by a fuel system (not shown) including a fuel tank, fuel pump, and fuel rail (not shown).
[0016] In addition, intake manifold 44 is shown communicating with turbocharger compressor 162 . Shaft 161 mechanically couples turbocharger turbine 164 to turbocharger compressor 162 . Optional electronic throttle 62 adjusts a position of throttle plate 64 to control air flow from air intake 42 to compressor 162 and intake manifold 44 . In one example, a high pressure, dual stage, fuel system may be used to generate higher fuel pressures. In some examples, throttle 62 and throttle plate 64 may be positioned between intake valve 52 and intake manifold 44 such that throttle 62 is a port throttle.
[0017] Distributorless ignition system 88 provides an ignition spark to combustion chamber 30 via spark plug 92 in response to controller 12 . Universal Exhaust Gas Oxygen (UEGO) sensor 126 is shown coupled to exhaust manifold 48 upstream of catalytic converter 70 . Alternatively, a two-state exhaust gas oxygen sensor may be substituted for UEGO sensor 126 .
[0018] Converter 70 can include multiple catalyst bricks, in one example. In another example, multiple emission control devices, each with multiple bricks, can be used. Converter 70 can be a three-way type catalyst in one example.
[0019] Controller 12 is shown in FIG. 1 as a conventional microcomputer including: microprocessor unit 102 , input/output ports 104 , read-only memory 106 (e.g., non-transitory memory), random access memory 108 , keep alive memory 110 , and a conventional data bus. Controller 12 is shown receiving various signals from sensors coupled to engine 10 , in addition to those signals previously discussed, including: engine coolant temperature (ECT) from temperature sensor 112 coupled to cooling sleeve 114 ; a position sensor 134 coupled to an accelerator pedal 130 for sensing force applied by foot 132 ; a position sensor 154 coupled to brake pedal 150 for sensing force applied by foot 152 , a measurement of engine manifold pressure (MAP) from pressure sensor 122 coupled to intake manifold 44 ; an engine position sensor from a Hall effect sensor 118 sensing crankshaft 40 position; a measurement of air mass entering the engine from sensor 120 ; and a measurement of throttle position from sensor 58 . Barometric pressure may also be sensed (sensor not shown) for processing by controller 12 . In a preferred aspect of the present description, engine position sensor 118 produces a predetermined number of equally spaced pulses every revolution of the crankshaft from which engine speed (RPM) can be determined.
[0020] In some examples, the engine may be coupled to an electric motor/battery system in a hybrid vehicle as shown in FIG. 2 . Further, in some examples, other engine configurations may be employed, for example a diesel engine.
[0021] During operation, each cylinder within engine 10 typically undergoes a four stroke cycle: the cycle includes the intake stroke, compression stroke, expansion stroke, and exhaust stroke. During the intake stroke, generally, the exhaust valve 54 closes and intake valve 52 opens. Air is introduced into combustion chamber 30 via intake manifold 44 , and piston 36 moves to the bottom of the cylinder so as to increase the volume within combustion chamber 30 . The position at which piston 36 is near the bottom of the cylinder and at the end of its stroke (e.g. when combustion chamber 30 is at its largest volume) is typically referred to by those of skill in the art as bottom dead center (BDC). During the compression stroke, intake valve 52 and exhaust valve 54 are closed. Piston 36 moves toward the cylinder head so as to compress the air within combustion chamber 30 . The point at which piston 36 is at the end of its stroke and closest to the cylinder head (e.g. when combustion chamber 30 is at its smallest volume) is typically referred to by those of skill in the art as top dead center (TDC). In a process hereinafter referred to as injection, fuel is introduced into the combustion chamber. In a process hereinafter referred to as ignition, the injected fuel is ignited by known ignition means such as spark plug 92 , resulting in combustion. During the expansion stroke, the expanding gases push piston 36 back to BDC. Crankshaft 40 converts piston movement into a rotational torque of the rotary shaft. Finally, during the exhaust stroke, the exhaust valve 54 opens to release the combusted air-fuel mixture to exhaust manifold 48 and the piston returns to TDC. Note that the above is shown merely as an example, and that intake and exhaust valve opening and/or closing timings may vary, such as to provide positive or negative valve overlap, late intake valve closing, or various other examples.
[0022] FIG. 2 is a block diagram of a vehicle 225 including a driveline 200 . The driveline of FIG. 2 includes engine 10 shown in FIG. 1 . Driveline 200 may be powered by engine 10 . Engine 10 may be started with an engine starting system shown in FIG. 1 or via driveline integrated starter/generator (DISG) 240 . DISG 240 (e.g., high voltage (operated with greater than 30 volts) electrical machine) may also be referred to as an electric machine, motor, and/or generator. Further, torque of engine 10 may be adjusted via torque actuator 204 , such as a fuel injector, throttle, etc.
[0023] An engine output torque may be transmitted to an input side of driveline disconnect clutch 236 through dual mass flywheel 215 . Disconnect clutch 236 may be electrically or hydraulically actuated. The downstream side of disconnect clutch 236 is shown mechanically coupled to DISG input shaft 237 .
[0024] DISG 240 may be operated to provide torque to driveline 200 or to convert driveline torque into electrical energy to be stored in electric energy storage device 275 . DISG 240 has a higher output torque capacity than starter 96 shown in FIG. 1 . Further, DISG 240 directly drives driveline 200 or is directly driven by driveline 200 . There are no belts, gears, or chains to couple DISG 240 to driveline 200 . Rather, DISG 240 rotates at the same rate as driveline 200 . Electrical energy storage device 275 (e.g., high voltage battery or power source) may be a battery, capacitor, or inductor. The downstream side of DISG 240 is mechanically coupled to the impeller 285 of torque converter 206 via shaft 241 . The upstream side of the DISG 240 is mechanically coupled to the disconnect clutch 236 .
[0025] Torque converter 206 includes a turbine 286 to output torque to input shaft 270 . Input shaft 270 mechanically couples torque converter 206 to automatic transmission 208 . Torque converter 206 also includes a torque converter bypass lock-up clutch 212 (TCC). Torque is directly transferred from impeller 285 to turbine 286 when TCC is locked. TCC is electrically operated by controller 12 . Alternatively, TCC may be hydraulically locked. In one example, the torque converter may be referred to as a component of the transmission.
[0026] When torque converter lock-up clutch 212 is fully disengaged, torque converter 206 transmits engine torque to automatic transmission 208 via fluid transfer between the torque converter turbine 286 and torque converter impeller 285 , thereby enabling torque multiplication. In contrast, when torque converter lock-up clutch 212 is fully engaged, the engine output torque is directly transferred via the torque converter clutch to an input shaft (not shown) of transmission 208 . Alternatively, the torque converter lock-up clutch 212 may be partially engaged, thereby enabling the amount of torque directly relayed to the transmission to be adjusted. The controller 12 may be configured to adjust the amount of torque transmitted by torque converter 212 by adjusting the torque converter lock-up clutch in response to various engine operating conditions, or based on a driver-based engine operation request.
[0027] Automatic transmission 208 includes gear clutches (e.g., gears 1-6) 211 and forward clutch 210 . The gear clutches 211 (e.g., 1-10) and the forward clutch 210 may be selectively engaged to propel a vehicle. Torque output from the automatic transmission 208 may in turn be relayed to wheels 216 to propel the vehicle via output shaft 260 . Specifically, automatic transmission 208 may transfer an input driving torque at the input shaft 270 responsive to a vehicle traveling condition before transmitting an output driving torque to the wheels 216 .
[0028] Further, a frictional force may be applied to wheels 216 by engaging wheel brakes 218 . In one example, wheel brakes 218 may be engaged in response to the driver pressing his foot on a brake pedal (not shown). In other examples, controller 12 or a controller linked to controller 12 may apply engage wheel brakes. In the same way, a frictional force may be reduced to wheels 216 by disengaging wheel brakes 218 in response to the driver releasing his foot from a brake pedal. Further, vehicle brakes may apply a frictional force to wheels 216 via controller 12 as part of an automated engine stopping procedure.
[0029] Controller 12 may be configured to receive inputs from engine 10 , as shown in more detail in FIG. 1 , and accordingly control a torque output of the engine and/or operation of the torque converter, transmission, DISG, clutches, and/or brakes. As one example, an engine torque output may be controlled by adjusting a combination of spark timing, fuel pulse width, fuel pulse timing, and/or air charge, by controlling throttle opening and/or valve timing, valve lift and boost for turbo- or super-charged engines. In the case of a diesel engine, controller 12 may control the engine torque output by controlling a combination of fuel pulse width, fuel pulse timing, and air charge. In all cases, engine control may be performed on a cylinder-by-cylinder basis to control the engine torque output. Controller 12 may also control torque output and electrical energy production from DISG by adjusting current flowing to and from field and/or armature windings of DISG as is known in the art.
[0030] When idle-stop conditions are satisfied, controller 12 may initiate engine shutdown by shutting off fuel and spark to the engine. However, the engine may continue to rotate in some examples. Further, to maintain an amount of torsion in the transmission, the controller 12 may ground rotating elements of transmission 208 to a case 259 of the transmission and thereby to the frame of the vehicle. When engine restart conditions are satisfied, and/or a vehicle operator wants to launch the vehicle, controller 12 may reactivate engine 10 by craning engine 10 and resuming cylinder combustion.
[0031] Referring now to FIG. 3 , an example hybrid vehicle operating sequence is shown. The sequence of FIG. 3 may be provided by the system of FIGS. 1 and 2 executing the method of FIG. 4 stored as instructions in non-transitory memory. The vertical lines at T 1 -T 5 represent particular time of interest during the sequence.
[0032] The first plot from the top of FIG. 3 is a plot of vehicle speed versus time. The Y axis represents vehicle speed and vehicle speed increases in the direction of the Y axis arrow. The X axis represents time and time increases from the left to right side of the figure.
[0033] The second plot from the top of FIG. 3 is a plot of active transmission gear versus time. The Y axis represents active transmission gear and the active transmission gears are indicated along the Y axis. The X axis represents time and time increases from the left to right side of the figure.
[0034] The third plot from the top of FIG. 3 is a plot of engine and DISG speed versus time. The Y axis represents engine and DISG speed and engine and DISG speed increases in the direction of the Y axis arrow. The X axis represents time and time increases from the left to right side of the figure. The engine and the DISG are coupled together during the sequence via the driveline disconnect clutch.
[0035] The fourth plot from the top of FIG. 3 is a plot of driver demand torque versus time. The Y axis represents driver demand torque and driver demand torque increases in the direction of the Y axis arrow. The X axis represents time and time increases from the left to right side of the figure.
[0036] The fifth plot from the top of FIG. 3 is a plot of engine air mass or mass of air flowing through the engine versus time. The Y axis represents engine air mass and engine air mass increases in the direction of the Y axis arrow. The X axis represents time and time increases from the left to right side of the figure.
[0037] The sixth plot from the top of FIG. 3 is a plot of DISG torque versus time. The Y axis represents DISG torque and DISG torque increases in the direction of the Y axis arrow. The X axis represents time and time increases from the left to right side of the figure. Horizontal line 302 represents a maximum DISG torque at DISG speeds below a DISG speed where the DISG changes from having a constant maximum torque output to having a constant maximum power output.
[0038] The seventh plot from the top of FIG. 3 is a plot of engine torque versus time. The Y axis represents engine torque and engine torque increases in the direction of the Y axis arrow. The X axis represents time and time increases from the left to right side of the figure.
[0039] At time T 0 , a driver inputs a driver demand torque after a cold engine start and vehicle speed begins to increase. The engine air mass or air flowing through the engine is at a predetermined constant level. The DISG torque begins to increase in response to the driver demand torque and the engine torque begins to decrease so that DISG torque plus engine torque meets the driver demand torque at a torque converter impeller that is downstream of the DISG. The engine speed increases since the DISG and engine are coupled and because the combined DISG and engine torque is increasing in response to the driver demand torque. The transmission is in first gear and the vehicle speed begins to increase in response to the driver demand torque.
[0040] At time T 1 , the transmission shifts into second gear. The transmission shifts in response to the driver demand torque and vehicle speed. The vehicle speed continues to increase and the engine speed and DISG speed decrease in response to shifting into a higher gear. The driver demand torque is slowly being reduced in response to a driver operating the accelerator pedal, and the engine air mass remains constant even though engine speed is reduced. Engine air mass may be held constant when engine speed is reduced by opening the engine's throttle and/or advancing intake valve timing. Opening the engine throttle and/or advancing intake valve timing increases engine torque. The DISG torque is reduced in response to the increase in engine torque.
[0041] Between time T 1 and time T 2 , the engine's throttle is closed (not shown) to maintain constant engine air flow as engine speed and DISG speed increase. Closing the engine's throttle reduces intake manifold pressure so that engine cylinders produce less torque for each combustion event. Consequently, engine torque decreases in response to engine speed increasing and maintaining constant engine air flow.
[0042] At time T 2 , the transmission shifts from second gear to third gear in response to vehicle speed and driver demand torque. The engine and DISG speed are reduced in response to the transmission entering third gear. The engine air mass remains constant and the engine torque increases in response to the decrease in engine speed to maintain the constant engine air mass. The engine torque is increased via opening the engine's throttle or advancing intake valve opening timing. The DISG torque is reduced in response to increasing engine torque. The engine torque plus the DISG torque provides the desired driver demand torque at the vehicle's torque converter impeller.
[0043] At time T 3 , the vehicle speed has reached a higher level and the driver reduces the driver demand torque via partially releasing the accelerator pedal. The engine torque increases to maintain engine air flow and DISG torque is decreased in response to the decreased driver demand torque and the increased engine torque. The engine speed and DISG speed are reduced in response to the reduced driver demand torque. The transmission remains in third gear and the vehicle speed begins to decrease.
[0044] Between time T 3 and time T 4 , the driver demand torque remains low and the engine speed and DISG speed decrease in response to the low driver demand torque. The engine torque increases a slight amount to maintain the engine air amount and the DISG torque decreases in response to the increase in engine torque. The vehicle speed continued to slow.
[0045] At time T 4 , the driver increases the driver demand torque via applying the accelerator pedal. The transmission remains in third gear and the engine and DISG speed begin to increase in response to the combined DISG torque and engine torque providing the driver demand torque. The engine torque decreases as the engine speed increases to maintain the constant engine air flow. The DISG torque increases with the increasing driver demand torque and decreasing engine torque.
[0046] At time T 5 , the DISG torque reaches torque limit 302 . Torque limit 302 may be a maximum engine torque at the present DISG speed. The maximum DISG torque is a function of DISG speed. DISG torque is maintained at the maximum DISG torque and engine torque is increased so that the DISG torque plus engine torque provides the driver demand torque at the vehicle's torque converter impeller. The engine air flow is increased to increase engine torque after the DISG is at its maximum torque. Thus, if the DISG provides its maximum torque and additional torque is needed to meet driver demand torque, the engine air mass may be increased to meet the driver demand torque. In this way, the engine air flow may be held at a constant flow until driver demand torque exceeds maximum DISG torque plus engine torque when the engine is operated with the predetermined constant air mass.
[0047] Referring now to FIG. 4 , a method for operating a hybrid vehicle driveline is shown. The method of FIG. 4 may be included in the system of FIGS. 1 and 2 as executable instructions stored in non-transitory memory. Additionally, the method of FIG. 4 may provide the operating sequence shown in FIG. 3 .
[0048] At 402 , method 400 judges if the engine is being cold started. Alternatively, or in addition, method 400 may judge if the engine is operating within predetermined conditions after a cold start, or if the engine is operating within predetermined conditions after a warm engine start. The predetermined conditions after cold and/or warm start may be that a catalyst temperature is less than a first threshold temperature and/or that engine temperature is less than a second threshold temperature. The engine may be considered to be cold started when engine and/or exhaust component temperature is less than a threshold temperature (e.g., 20° C.) and before the engine has been operating for a predetermined amount of time or before the engine has reached a threshold temperature. If method 400 judges that the engine is being cold started or if the engine is operating within predetermined conditions after a start, the answer is yes and method 400 proceeds to 404 . Otherwise, the answer is no and method 400 proceeds to 450 .
[0049] At 450 , method 400 adjusts the engine air mass in response to the driver demand torque and spark is adjusted to knock limited or MBT spark timing. For example, if driver demand torque increases, the engine air amount increases. If driver demand torque decreases, the engine air amount decreases. Additionally, the engine air-fuel ratio averages a near stoichiometric air-fuel ratio. Method 400 proceeds to exit after engine air-fuel ratio is adjusted.
[0050] At 404 , method 400 determines engine speed. In one example, engine speed is determined via measuring time between engine positions via an engine position sensor. Further, method 400 determines driver demand torque at 404 . In one example, driver demand torque may be based on accelerator pedal position and vehicle speed. Specifically, vehicle speed and accelerator pedal position are used to index a table containing empirically determined driver demand torques. The table outputs the driver demand torque based on the accelerator pedal position and vehicle speed. Method 400 proceeds to 406 after engine speed is determined.
[0051] At 406 , method 400 determines desired engine air mass or the desired amount of air to flow through the engine. In one example, the desire engine air mass is empirically determined and stored in a table or function that is indexed based on engine temperature and/or catalyst temperature. Additionally, the table or function may be indexed via time since engine stop. The table may contain desired engine air mass amounts that allow a catalyst in the engine exhaust system to reach a desired temperature within a threshold amount of time. The desired engine air mass may be a substantially constant value (e.g., varying less than 10%) from the time since engine speed reaches a threshold speed after engine stop until a catalyst reaches a desired temperature or until driver demand exceeds a threshold torque, including all time between. Further, in some examples, the substantially constant air mass may be based on engine temperature or catalyst temperature during engine starting. For example, the engine air mass may be a greater value for lower catalyst and engine temperatures, though the engine air mass remains constant from a time the engine reaches a threshold speed after engine stop until predetermined conditions are achieved (e.g., the catalyst or engine reach a threshold temperature). For example, if engine temperature is 20° C. during a first start, the engine air flow may be X Kg/sec. However, if engine temperature is 15° C. during a second start, the engine air flow may be Y Kg/sec, where Y is greater than X. The respective X and Y air masses may flow through the engine from the time since engine speed reaches a threshold speed after engine stop until a catalyst reaches a desired temperature or until driver demand exceeds a threshold torque. The desired engine air mass is output from the table and method 400 proceeds to 408 .
[0052] At 408 , method 400 determines a desired spark retard from minimum spark advance timing for best engine torque (MBT). In one example, the spark retard from MBT is empirically determined and stored in a table or function that may be indexed based on time since engine stop and/or engine or catalyst temperature. The table or function outputs a spark retard and method 400 proceeds to 410 . In one example, the spark retard from MBT spark timing may be substantially constant (e.g., changing by less than 5 crankshaft angle degrees) from the time since engine stop until a catalyst reaches a desired temperature or until driver demand exceeds a threshold torque.
[0053] At 410 , method 400 determines desired engine torque to provide the desire engine air mass determined at 406 . In one example, the desired engine air flow determined at 406 is multiplied by a fuel to air ratio to determine a fuel flow rate. The fuel flow rate may be used to index a table or function that outputs engine torque based on fuel flow rate and engine speed. The table or function outputs empirically determined engine torque values corresponding to the engine torque produced at the present engine speed when engine fuel flow is based on the desired air flow and fuel to air ratio. Method 400 proceeds to 412 after the desired engine torque is determined.
[0054] At 412 , method 400 determines the desired DISG or motor torque. In one example, the desired motor torque is determined via the following equation:
[0000]
T
MOT
=T
DD
−T
DES
—
ENG
[0000] where T MOT is the desired motor torque, T DD is the driver demand torque, and where T DES — ENG is the desired engine torque determined at 410 . Method 400 proceeds to 414 after desired motor torque is determined.
[0055] At 414 , method 400 judges if motor torque (e.g., T MOT ) is less than maximum motor torque (e.g., T MOT — MAX ). If so, the answer is yes and method 400 proceeds to 416 . Otherwise, the answer is no and method 400 proceeds to 418 .
[0056] At 416 , method 400 determines the motor and engine torque commands. In particular, the motor torque command is T MOT — CMD =T MOT , or the motor torque command is the motor torque determined at 412 . The engine torque command is T ENG — CMD =T DES — ENG , or the engine torque command is the desired engine torque determined at 410 . Method 400 proceeds to exit after the engine and motor commands are determined.
[0057] Additionally at 416 , method 400 provides for operating the engine with a substantially constant air mass (e.g., air mass that changes by less than 10%) as a transmission shifts gears. Further, method 400 may upshift a transmission from a lower gear to a higher gear in response to speed of the motor being within a threshold speed of a speed where the motor transitions from providing a constant maximum torque to providing a constant maximum power. By upshifting the transmission, the maximum DISG torque may be held at a higher value than if the DISG speed were to continue increasing. Consequently, the engine may be held with a constant air mass flowing through engine even as the vehicle speed increases. Thus, method 400 may limit DISG speed to a speed less than a speed where the DISG transitions from providing a constant maximum torque to providing a constant maximum power to provide a greater maximum DISG torque.
[0058] During conditions where engine torque is greater than driver demand torque, the DISG may be transitioned from a motor mode (e.g., providing positive torque to the driveline) to a generator mode (e.g., providing negative torque to the driveline) while the engine operates at the substantially constant air mass.
[0059] At 418 , method 400 determines the motor and engine torque commands. In particular, the motor torque command is T MOT — CMD =T MOT — MAX , or the motor torque command is the maximum motor torque at the present motor speed. The engine torque command is T ENG — CMD =T DD −T MOT — MAX , or the engine torque command is the driver demand torque determined at 404 minus the maximum motor torque at the present motor speed. The engine torque is adjusted via adjusting throttle position, intake valve closing timing, and/or fuel injection. Motor torque is adjusted by adjusting an amount of current supplied to the motor. Further, if the motor torque command is negative, the motor is operated as a generator to absorb engine torque. Thus, at 418 the engine torque command increases with driver demand torque such that the engine air flow increases from the substantially constant air amount in response to driver demand torque being greater than maximum engine torque while the engine operates with the substantially constant air amount and maximum DISG torque at a present DISG speed. Method 400 proceeds to exit after the engine and motor commands are determined.
[0060] The engine torque may be adjusted via adjusting the amount of fuel injected and the engine throttle position or intake valve closing timing. In one example, as desired engine torque is adjusted to provide the desired engine air mass as engine speed changes, the throttle or intake valve timing may be adjusted to provide a desired intake manifold pressure that corresponds to the desired engine air-flow rate at the present engine speed. In particular, engine intake manifold pressure may be adjusted to provide the desired engine air mass via adjusting the engine throttle or intake valve closing time based on the following speed/density equation:
[0000]
P
=
R
·
T
·
Me
·
2
η
v
·
N
e
[0000] where Me is the desired engine air flow, R is a gas constant, T is air temperature, N e is engine speed, P is manifold pressure, and η v is engine volumetric efficiency. The intake manifold pressure may be closed loop control based on intake manifold pressure. For example, if intake manifold pressure is greater than desired based on intake manifold pressure feedback from a pressure sensor, the throttle may be closed further.
[0061] Thus, the method of FIG. 4 provides for a method, comprising: operating an engine with a substantially constant air mass and spark timing in response to catalyst temperature less than a threshold; varying engine torque as engine speed varies while operating the engine at the substantially constant air mass; and providing driver demand torque via engine torque and motor torque while operating the engine at the substantially constant air mass. The method includes where the spark timing is retarded from minimum spark timing for best engine torque. The method includes where engine torque is adjusted via adjusting a position of a throttle.
[0062] In some examples, the method includes where engine torque is further adjusted via adjusting an amount of fuel injected to the engine. The method also includes where engine torque is adjusted via adjusting a position of an intake cam or timing of an intake valve. The method includes where the engine is operated with the substantially constant air mass as a transmission shifts gears. The method also includes where the substantially constant air mass is varied in response to engine or catalyst temperature during engine starting. The method further comprises upshifting a transmission gear in response to speed of the motor being within a threshold speed of a speed where the motor transitions from providing a constant maximum torque to providing a constant maximum power.
[0063] The method of FIG. 4 also provides for: varying engine torque as engine speed varies while operating an engine at a substantially constant air mass in response to a temperature being less than a threshold and driver demand torque being less than a maximum engine torque plus a maximum driveline integrated starter/generator (DISG) torque, where the maximum engine torque is produced while the engine operates at the substantially constant air mass, and where the maximum (DISG) torque is at a present DISG speed; and providing driver demand torque via engine torque and DISG torque while operating the engine at the substantially constant air mass. In some examples, the method includes where the engine is operated with a substantially constant spark timing when the engine is operated with the substantially constant air mass. The method also includes where the temperature is a catalyst temperature or an engine temperature. The method further comprises increasing engine air amount from the substantially constant air amount in response to driver demand torque being greater than maximum engine torque while the engine operates with the substantially constant air amount and maximum DISG torque at a present DISG speed. The method further comprises upshifting a transmission gear in response to speed of the DISG being within a threshold speed of a speed where the DISG transitions from a constant maximum torque to a constant maximum power. The method includes where the substantially constant air mass is adjusted in response to a temperature at engine start. The method further comprises limiting DISG speed to a speed less than a speed where the DISG transitions from providing a constant maximum torque to providing a constant maximum power.
[0064] In some examples, the method of FIG. 4 provides for a method, comprising: varying engine torque as engine speed varies while operating the engine at a substantially constant air mass; transitioning a driveline integrated starter/generator (DISG) from a motor mode to a generator mode in response engine torque exceeding driver demand torque while the engine operates at the substantially constant air mass; and providing driver demand torque via engine torque and motor torque while operating the engine at the substantially constant air mass. The method further comprises increasing engine air amount from the substantially constant air amount in response to driver demand torque being greater than maximum engine torque while the engine operates with the substantially constant air amount and maximum DISG torque at a present DISG speed. The method further comprises upshifting a transmission gear in response to speed of the DISG being within a threshold speed of a speed where the DISG transitions from a constant maximum torque to a constant maximum power. The method further comprises limiting DISG speed to a speed less than a speed where the DISG transitions from providing a constant maximum torque to providing a constant maximum power. The method includes where the engine is operated with a substantially constant spark timing when the engine is operated with the substantially constant air mass.
[0065] As will be appreciated by one of ordinary skill in the art, the methods described in FIG. 4 may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the objects, features, and advantages described herein, but is provided for ease of illustration and description. Although not explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending on the particular strategy being used. Further, the described actions, operations, methods, and/or functions may graphically represent code to be programmed into non-transitory memory of the computer readable storage medium in the engine control system.
[0066] This concludes the description. The reading of it by those skilled in the art would bring to mind many alterations and modifications without departing from the spirit and the scope of the description. For example, 13, 14, 15, V6, V8, V10, and V12 engines operating in natural gas, gasoline, diesel, or alternative fuel configurations could use the present description to advantage.
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Systems and methods for improving emissions and drivability of a hybrid vehicle that includes a motor/generator and an engine are presented. The systems and methods may allow vehicle emissions regulations to be met while at the same time providing driveline torque that matches driver demand torque so that vehicle drivability may be maintained or improved.
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This is a continuation-in-part application of our Ser. No. 400,870, filed Sept. 26, 1973, now U.S. Pat. No. 3,881,525.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the conditioning of animal carcasses after slaughtering and skinning. The carcasses, with a smooth, bleached surface, are shrouded and placed in a cool atmosphere and the carcass temperature is lowered to about the freezing temperature.
Traditionally, meat shrouds were constructed of high moisture regain fabrics because these fabrics were initially and exclusively available, and because they were found satisfactory for conditioning carcasses in the sense that the carcasses could be stored in a reasonably orderly fashion, permitted to breathe without excessive dehydration, all the while presenting a reasonably acceptable appearance both in the shroud and after removal of the shroud. Secondary attributes of the high moisture regain meat shroud were a high degree of blood absorption, smoothing of the surface, maintenance of "bloom" in the meat, and distribution of moisture on the carcass. Disadvantages of these high moisture regain shrouds included the strong odor which lingered on the shroud even after washing, and the short life resulting partially from the fact that most high moisture regain fabrics were not of sufficient durability. The meat industry was lacking in a shroud which would stand hard use and repeated washing and which would, in fact, wash clean. Such a shroud would indeed be a meritorious advance in the art.
2. Description of the Prior Art
Meat shrouds have been produced from cotton, ramie, rayon and polyester staple. Before the introduction of polyester staple in shrouds, generally speaking, moisture regain, wicking, water swelling, water retention, and high wet-modulus were considered essential characteristics to be sought in meat shrouds primarily to prevent the dehydration of meat, but secondarily in order to absorb blood so that the surface of the meat be rendered as bloodfree and as presentable as possible. Moisture retention in the carcass being the primary consideration, standard acceptable moisture absorption percentages in commercial shrouds were of the order of 120-160. percent. Moreover, it was and is considered essential that meat shrouds have high strength and resistance to tear and to soil and stain release as well as stability to withstand chlorine bleaching without serious fiber damage. Meat shrouds are laundered after each use and they must be reasonably clean for reuse. Polyester staple shrouds were recently introduced because polyester is known for excellent durability, and it had been found that fibers of polyethylene terephthalate, although having a generally low moisture regain, wicking action, water retention, etc., could be used in staple form without sacrifice of fabric moisture regain, wicking action, and swelling; and therefore in staple form, at least, low moisture regain fibers could be used in meat shrouds. Staple polyester meat shrouds were thereupon adopted by the industry; but it was found that shrouds constructed of staple polyester fibers had one deficiency inherent in the staple form of fabric, and that is they had a tendency to shed or deposit occasional parts of a fiber on the carcass, especially after having been washed repeatedly. These individual fibers, usually of a fraction of an inch in length, while of no particular significance from a health and sanitation point of view were more conspicuous than cellulosic fiber deposits, due to accumulation of electrostatic charge on the fibrils, and appeared somewhat more like animal hair which is considered a source of possible contamination originating from animal skin. The industry had, therefore, prior to the present invention no completely satisfactory conditioning shroud which was both apparently and inherently sanitary, durable, and which would foster an acceptable appearance to the carcass both inshrouded and out of the shroud, all the while retaining during the shroud period sufficient moisture to prevent meat dehydration.
SUMMARY OF THE INVENTION
In accordance with the present invention, the disadvantages of the prior art shrouds are avoided and durability is achieved through the use of the more durable low moisture regain fibers in filament form rather than staple form, unforseeably retaining moisture in the carcass without high fabric absorption. As a result, shrouds are easily washed and do not maintain the objectionable odor of the high regain, high wicking shrouds.
It is an advantage of this invention that the new meat shroud does not leave a hair-like deposit on the carcass. It is another advantage of this invention that it has extremely high breaking strength, grab strength, tear strength and skewer strength. It is yet another advantage of this invention that shrouds are provided with good soil and stain release.
BRIEF DESCRIPTION OF THE DRAWING
Reference will be made to the drawing in which FIGS. 1 and 2 are general perspective views of sides of beef clothed with shrouds.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with this invention, meat shrouds are provided, a major portion of which comprise a low moisture regain filament having a denier of from about 4- 8, and a tenacity of at least about 4 grams per denier, the fabric being characterized by a skewer strength of at least about 80 pounds (36,288 g), a grab strength of at least about 200 pounds (90,720 g) in both warp and fill direction, a simulated carcass relative moisture retention capability of no less than about 1, and a fabric moisture absorption of no more than about 65 percent. We have discovered, for example, that filament polyester or nylon meat shrouds made in accordance with these specifications can be even more effective than presently used 100% ramie, cotton, or other cellulosic cloth, in preventing the dehydration of whole beef carcasses.
In FIGS. 1 and 2, two sides of beef are shown suspended from conventional hooks 3 and 4. The shrouds 5 and 6 are shown wrapped snugly and smoothly about the skinned surfaces of the carcass. No strings or ties are used at either hindshanks or foreshanks the extremities of which are not covered. The shrouds are secured to the edges 10, 11 and 12 of the visceral cavities 7 and 8 as by skewers 13.
The terms used above are employed in the usual meaning in the textile art except as follows:
"Skewer strength" is a laboratory test designed to measure the units of force required to rupture the fabric when strained by a skewer of similar design to that actually used in a packing plant during the shrouding operation. After wetting, a specimen from the fabric is punctured by the skewer near one end and the opposite end is clamped in the stressing jaw of a tensile tester at a constant rate of extension. The cross-wise yarns are pulled against the skewer until a number have ruptured. The force is recorded automatically on a chart calibrated in convenient units. The average of the individual yarn breaks for each principle direction is reported for the sample. The value obtained is a function of the individual yarn strength plus the support of the adjacent yarns. Calculation of the average force is based on ASTM Standard D-2261 "Tearing Strength of Fabric by Tongue Method (Constant Rate-of-Extension Tensile Testing Machine)." The average of the five highest peaks recorded on the chart is reported. Specimens having filling yarns parallel to the long dimension are used for testing the warp yarns, and specimens with the warp yarns parallel to the long dimension are used for the test of the filling yarns. All specimens are soaked in distilled water for two hours, removed and blotted lightly to remove surface water. The skewer position is determined by means of a 3 (7.62 cm.) square template drilled with a 1/8 in. (0.315 cm.) diameter hole in the center. Using the template, the skewer is positioned 11/2 in. (3.81 cm.) from the end of the sample. Before inserting the skewer, a pencil or similar instrument is used to spread the yarns in the form of a hole. The skewer projection is fastened to the upper grip of the tensile tester and the other end of the sample is clamped in the lower grip. The tensile tester is operated with cross-head speed (rate of extension) of 5 in./min. (12.7 cm./min.), a chart speed (recorder) of 10 in./min. (25.4 cm./min.), a load scale of 200 pounds (90,720 g), a jaw separation (between clamps) of 6 in. (15.24 cm.), and with jaw faces (smooth) at 1 in. × 3 in. (2.44 cm. × 7.62 cm.).
The "grab strength" test or "grab" test is a standard method of test for textiles fabrics and is known as ASTM D-1682-64 (Reapproved 1970) of the American National Standards Institute.
By "low-moisture regain" fiber or filament is meant a fiber or filament having an inherent moisture regain of less than about five. Low regain fibers include nylon, acrylic, polyester, and polypropylene, to name but a few. Not all low-moisture regain fibers or filaments are suitable for the production of meat shrouds. Acrylic fibers, for example, are lacking in tenacity.
By "simulated carcass relative moisture retention capability" is meant the relative capability of the shroud to hold the moisture in the carcass, as reflected by the following carborundum stone test. Shroud fabric samples are cut into pieces about 63/4 in. × 8 in. (17.14 cm. × 20.3 cm.). Sixty milliliters of distilled water are absorbed into each of two carborundum stones 6 in. × 2 in. × 1 in. (15.24 cm. × 5.08 cm. × 2.54 cm.). The fabric specimen is wrapped around one of the stones and secured by straight pins. One stone is left unwrapped to use as a control. The stones are hung by a string and weighed; then they are hung in a conditioning chamber at 70° F (38° C) and 50 percent relative humidity for a given period of time. Unless otherwise specified, simulated carcass relative moisture retention, as used herein, reflects a conditioning time of twenty hours. Simulated carcass relative moisture retention capability (MRC) is determined as follows: ##EQU1##
As used herein the words "major portion" must be construed very broadly because fabrics can be constructed of any percentage of various component fibers or filaments and variations therein will affect the product only in a matter of degree. The examples will show meat shrouds constructed of 100 percent flat yarn filament, of flat and textured polyester filament totalling 100 percent, and of polyester and nylon yarns totalling 100 percent. Of course, combinations of polyester filament and polyester staple as well as polyester filament and other cellulosic and non-cellulosic components including nylon staple or filament, and cotton are also contemplated within the purview of this invention, to the extent that they do not increase the fabric moisture absorption to greater than about 70 percent or otherwise seriously detract from the fabric properties explained above.
By "moisture absorption" or "moisture absorbency" is meant the amount of moisture in terms of weight percent (based on the weight of the fabric) which remains on a 22 cm. × 22 cm. fabric sample after soaking in distilled water at room temperature for 15 minutes, followed by removal from the water and dripping from one corner of the sample for 30 seconds.
EXAMPLES
Meat shrouds were constructed according to the specifications shown in Table 1. Twist employed was only that necessary for yarn handling.
TABLE I______________________________________ Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5______________________________________WarpFilament Type PET PET PET PET Nylon Denier 5.2 5.2 5.2 5.2 6.0 Tenacity 8 8 8 8 9.4 Elongation 20% 20% 20% 20% 13%WarpYarn Denier 1000 1000 1000 1000 840 Filaments 192 192 192 192 140 Texture no no no no noFillingFilament Type PET PET PET PET PET Denier 5.2 4.9 4.9 5.2 5.2 Tenacity 8 4.2 4.2 8 8 Elongation 20% 34% 34% 20% 20%FillingYarn Denier 1000 330 660 1000 1000 Filaments 192 68 136 192 192 Texture no yes yes no noFabricConstruc-tion Ends/inch 31 34 34 30 28 Ends/cm. 78.7 86.4 86.4 76.2 71 Picks/inch 26 27 28 25 24 Picks/cm. 66 68.6 71.1 63.5 60.9 Wt.oz/yd.sup.2 7.7 6.16 7.23 7.9 6.7 Wt.g/m.sup.2 261 209 245 267 227 Weave plain plain plain plain plain Heatset* no no no yes yes______________________________________ *60 sec. at 390° - 400°F (198° - 206°C)
Testing of the shroud samples of Examples 1-5, as against a commercial cotton shroud is shown at Table II.
TABLE II______________________________________ Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Cotton______________________________________GrabStrength(lbs.) Warp 738 553.5 579.0 641 602 78 Fill 628 126.2 262.3 552 531 108GrabStrength(g) Warp 334756 251067 26263 290757 273067 35380 Fill 284860 57244 118979 250387 240861 48988SkewerStrength(lbs.) Warp 199 82.9* 143.6* 222 227 19 Fill 216 43.6* 71.3* 167 314 24SkewerStrength(g) Warp 90266 37603 65137 100699 102967 8618 Fill 97977 19776 32341 75751 142430 10886MRC (16 hr.) 1.27 1.18 1.17 1.15 1.02 0.8MRC (20 hr.) 1.59 1.59 1.19 1.04 0.82Absorbency ±48% ±48% ±48% ±48% ±58% ±153%______________________________________ *Yarns did not break; they pulled out of fabric
It will be noted that in all of the above described examples, moisture absorbency of the shroud fabrics was inherently low (of the order of 48-58 percent). High filament content fabric blends having a small percentage of high moisture regain component would be expected to run somewhat higher than this. For example, a fabric blend containing 85 percent polyester filament and 15 percent cotton might be expected to have a moisture absorbency of about 70-80 percent.
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Meat shrouds comprised of inherently low moisture regain filament provide non-shedding durable meat shrouds suitable for conditioning meat carcasses without excessive dehydration.
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This is a continuation of copending application Ser. No. 07/880,486 filed on May 6, 1992, which is a continuation of Ser. No. 550,143 filed Jul. 9, 1990 which is a division application of application Ser. No. 07/236,643 filed Sep. 27, 1988 which is a continuation application of application Ser. No. 06/829,142 filed Dec. 9, 1985, all abandoned.
FIELD OF THE INVENTION
The present invention relates to an apparatus for receiving, conveying and/or impacting of material in which are included fractions of different sizes, densities, elasticity, moisture-content and the like the apparatus including at least one shaftless spiral in which each spiral is disposed in a preferably closed casing and, more precisely, there are provided drive means, for the rotation of the spiral or spirals, repectively, in conjunction with that portion of the casing where the material is received, and there are provided, at least for one of the combinations of casing - spiral, counterpressure members which arrest or brake the movement of the material in conjunction with that portion of the casing which serves as a discharge portion for the material.
BACKGROUND
Material of the type mentioned by way of introduction needs to be moved in many different contexts, both in industrial operations and in, for example, municipal refuse disposal and management (ref-use handling, screenings from the wastewater treatment plants and so on). Consequently, such material is handled in large quantities daily and it is a reality that this handling cannot be effected without meeting a number of problems. These are because the material is, as a rule, difficult to handle, for example in that it is bulky and needs to be compacted in order to attain an acceptable level of transport economy. When the material is wet, it needs to be compacted in order to reduce the moisture-content so as thereby to make for greater ease of handling. For compacting material of the above-indicated type, the prior Art calls for the employment of separate compactors or screw presses.
One disadvantage inherent in hitherto employed combinations of conveyors and compactors is that the combinations require a great deal of space and are costly. In certain applications, hydraulic compactors are used, and in other applications, screw presses. The hydraulic compactors take up a great deal of space and operate intermittently, which occasions problems in, for example, the formation of material "bridges" at the infeed section, while the conventional screw presses find difficulty in swallowing the bridge and plug forming materials here under discussion. This is because the screw presses have a center shaft or axle about which ensnaring material such as textiles, plastic sheeting, strips etc. become wound and cause plug formation in the material flow.
SUMMARY OF THE INVENTION
The present invention contemplates a conveyor apparatus in which is included means for compaction of the material being conveyed and in which the above-indicated disadvantages are obviated to a remarkable extent. The invention relates to a combination of a shaftless spiral and a casing. The combination of spiral and casing creates a compact unit of equipment which makes for reliable convevance of the material and is used, according to the invention, to realize a compaction of the material at same time as the material is enclosed, which entails that the surrounding environment is not affected. In certain embodiments of the present invention, the employment of compaction reduces the moisture-content in the material, while in other embodiments, the compaction of the material constitutes the basis of a batchwise discharging of the material from the apparatus.
The apparatus includes at least one shaftless spiral which is disposed in a preferably enclosed casing of, for example, U-shaped and/or circular cross-section. A drive means for the rotation of the spiral is disposed in conjunction with that portion of the casing where the material is fed into the combination of casing and spiral, while in the other section of the casing, i.e. in conjunction with the discharge portion of the casing, there is provided a zone in which the casing is of a cross-section which entails that the casing completely surrounds the spiral with slight play. Moreover, the casing is provided with an end region in the extension plane of the spiral, in which the spiral is not enclosed by the casing and/or in which a counterpressure member is disposed. In this zone and/or in conjunction with the end section, compaction of the material takes place. In that portion of the end section where the spiral is not enclosed by the casing, there is a braking or arresting effect on the material which leads to its compaction. In certain embodiments, the compaction is further amplified in that the spiral is provided with progressively diminishing pitch. The spiral is completely free, i.e. is not journalled in that end which is directed towards the discharge section of the casing.
In one embodiment of the present invention, the counter-pressure member consists of a spring-loaded counterpressure plate which is movably journalled in the upper defining surface of the casing and/or in conjunction with the discharge opening of the casing. In certain embodiments, the counterpressure plate is disposed in a receptacle chamber. In other embodiments, the braking effect of the casing on the material is amplified in that the casing, most proximal the discharge opening, is provided with reduced inner cross-section.
In yet a further embodiment, the counterpressure member consists of a receptacle device, for example a container, a hose etc., the member being shiftable in the axial direction of the casing. During rotation of the spiral, the material is conveyed into the receptacle device, the material moving the receptacle device in the axial direction of the spiral.
In still a further preferred embodiment of the apparatus, the counterpressure member consists of a shaftless spiral disposed in a casing, this casing having an infeed opening connected to the discharge opening of the delivering casing. That casing which discharges the material is, in this instance, of an orientation which entails that its axis is directed towards the center axis of the spiral and the receiving combination of casing and spiral. The pitch, speed and/or radial extent of the spiral blades are, in the receiving combination, adapted so as to occasion a braking of the material movement before the material reaches the discharge opening of the disclosed casing. Hereby, it is possible in such operation to attain a substantially complete filling of the space in the receiving casing. The substantially complete filling constitutes a precondition for being able to convey the material upwardly in a more or less vertical direction. Thus, according to the present invention, it is possible to dispose the receiving combination with its axis directed, for example, horizontally, vertically, or therebetween.
In certain embodiments, the casing is provided with drainage openings which, preferably, are located in that region of the casing where compaction of the material takes place. In such an instance, an orientation of the casing is advantageously selected so as to entail that the discharge section of the casing is placed higher than its infeed section, whereby, on compaction, the pressed out liquid is conveyed in a direction opposite to the direction of movement of the material and is drained out from the casing through the previously-mentioned drainage openings.
The nature of the present invention and its aspects will be more readily understood from the following brief description of the accompanying Drawings, and discussion relating thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying Drawings:
FIG. 1 is an axial section through an apparatus according to the present invention;
FIGS. 1a-c are sections taken along the lines A--A, B--B, and C--C in FIG. 1;
FIG. 2 shows the material distribution in the longitudinal direction of the apparatus:
FIGS. 3, 4a 4b, 4c , and 5 illustrate embodiments of the apparatus according to the present invention provided with counter-pressure members for braking the material on its movement;
FIGS. 6a and b are partial sections through embodiments of the apparatus according to the present invention, in which the casing of the apparatus is provided with drainage openings;
FIGS. 7a and b are partial sections through embodiments of the apparatus according to the present invention, in which this is provided, in conjunction with its discharge opening with a shiftable receptacle member;
FIGS. 8a and b are partial sections through one embodiment of the apparatus according to the present invention, in which this, in conjunction with its discharge opening, cooperates with a conveyor apparatus which includes a casing surrounding a shaftless spiral; and
FIGS. 9a-c show details of the free end of the spiral.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the Drawings, FIGS. 1 and 2 illustrate the invention in one embodiment which shows the fundamental construction and function of the invention. In these Drawing Figures, there is shown an apparatus 1 which includes an elongate, tube-like casing 2 in which is placed a shaftless spiral 3. At its one end, the casing is provided with an infeed opening 14 which connects to an up-warding-directed drum 16. A motor 4 drives the spiral 3 through the intermediary of a gearing and journalling unit 30. The other end of the casing constitutes the discharge portion 18 of the apparatus, which is provided with a discharge opening 24. The spiral is solely journalled in connection with the gearing and journalling unit, while that end of the spiral which is directed towards the discharge portion is fully free. Thereby, the shaftless spiral 3 defines a free central annular passage 3A extending longitudinally over the length of the spiral whereby substantially the entire cross section of the casing is available for travel of material therethrough.
Seen in the axial direction of the casing, the combination of spiral and casing is divided into an infeed zone 20, a transport zone 21, a precompaction zone 22 and a compaction zone 23. The cross-sections through each respective zone in the illustrated embodiment are apparent from Figs. 1a-c. It will be appreciated from these Figures that the cross-section of the casing in the precompaction zone is substantially circular and surrounds the spiral with slight play. FIG. 1 also shows in by solid lines a relatively abrupt transition between the tranport zone 21 and the precompaction zone 22. However, in certain physical applications, the embodiment shown by broken lines is selected, with a relatively continuous transition between the cross-sections of the transport zone and the precompaction zone.
FIG. 2 shows in particular how the material flow 40 encompasses a relatively small portion of the cross-section of the casing as long as the material is in the transport zone 21, and how the material, on its passage through the precompaction zone, takes up a steadily increasing part of the cross-section in order, in the compaction zone proper, substantially to fill out the entire cross-section
FIGS. 3 and 4a 4b and 4c show how the combination of spiral and casing is provided with a counterpressure member 25, 8, for arresting or braking the movement of the material in the compaction zone 23 of the casing. In the embodiment illustrated in FIG. 3, the counter-pressure mentor 25 is formed in that the movement of the material is braked during movement in the longitudinal direction of the casing, because of friction against the inner surface of the casing. In certain physical applications, the braking effect is amplified in that the casing is, in the region of the compaction zone 23, provided with reduced inner cross-section.
FIG. 4a shows, first, one embodiment in which the counterpressure member consists of a counterpressure plate 8a disposed in association with the discharge opening 24 and pivotally journalled in conjunction with the upper region of the discharge opening, and movable in the direction of the double-headed arrow A; and secondly, an embodiment in which the counterpressure member consists of a counterpressure plate 8b which is pivotal and preferably return spring-biased in the upper defining surface 27 of the casing 2. FIG. 4b shows a partial longitudinal section and FIG. 4c a view taken along the line D--D in FIG. 4b of one embodiment in which the counterpressure member consists of a split cone 34. For example, the cone comprises two halves 34a and 34b and is openable under the counteraction of springs 35 whose spring force is adapted to provide that counterpressure which is requisite to attain the intended compaction of the material.
FIG. 5 shows one embodiment in which the counterpressure plate 8a, in conjunction with the discharge opening 24, is disposed in a receptacle chamber 7. In the embodiment illustrated in this Figure, the counterpressure plate is journalled in the upper defining surface of the chamber, but the journalling may, for example, correspond to that of those embodiments as shown in FIG. 4.
FIGS. 6a and b show embodiments in which the casing 2, in conjunction with the precompaction zone 22 and the compaction zone 23, is provided with drainage openings 33.
FIGS. 7a and b show embodiments of the present invention in which the counterpressure member consists of a receptacle device 26, 28, shiftable in the axial direction of the casing and, in FIG. 7a, comprising a container 26, while in FIG. 7b, a hose 28. in this instance, the hose 28 is drawn out from a magazine 29. In certain embodiments, braking means 36 are provided for restricting the withdrawal of the hose from the magazine. In the Figures, an arrow F designates a force which is counter-directed to the movement of the container. The arrow represents a device, for example a hydraulic cylinder. In FIG. 7a, it is shown that, in certain embodiments, the hose 28 cooperates with the container 26 (broken lines) and is brought into abutment with the inner surfaces of the container according as the hose is filled with material from the casing. Thus, FIGS. 7a and b show embodiments of the invention in which the material surrounded by the container and/or the hose is compacted.
FIGS. 8a and b show one embodiment of the invention in which the apparatus 1 includes at least one supplementary conveyor apparatus 50 comprising a casing 52 and a shaftless spiral 53 placed therein. The spiral is driven by a motor 54 by the intermediary of a gearing and journalling unit 51 and its speed is, thus, for example by modification of the gear ratio, adjustable to any desired level. The direction of the first spiral 3 and/or a central shaft of the discharge end 18 of the casing is towards the central axis of the spiral 53 of the conveyor apparatus. The opening surface area of the discharge opening 24 of the casing 2 substantially agrees with the cross-sectional area of the receiving casing 52, both of the casings being substantially sealingly interconnected. The conveyor apparatus 50, is, in certain embodiments, disposed to move the material essentially horizontally, while in other embodiments, movement is effected during alteration of the level of the material. There are also embodiments of the present invention in which the casing 52 of the conveyor apparatus 50 with the spiral placed therein, has a substantially vertical direction. In this instance, the free end of the spiral is directed upwardly.
FIGS. 9a-c show embodiments of the free end 31-32 of the spiral 3. In FIG. 9a, the end 31 of the spiral terminates in such a manner that its blade height continuously diminishes from the inner end outwardly, i.e. the center hole of the spiral increases progressively. FIGS. 9b and c show embodiments in which the end 32 of the spiral is disposed for a step reduction of its blade height.
Material which is supplied to the apparatus 1 through the infeed opening 14 in the casing 2 is moved in a direction towards the discharge opening 24 by rotation of spiral 3. As will be apparent from FIG. 2, a gathering of material takes place in the precompaction zone 22 partly in that the spiral 3, in certain embodiments, has a smaller pitch than in the transport zone 21, and partly in that the movement of the material is braked in the compaction zone 23 and/or by the counterpressure men,pets 8, 25, 26, 28, and 50. As a result, the material, in the compaction zone, as a rule substantially fills out the entire cross-section of the casing.
In FIGS. 3, 4a 4b, 4c and 5 braking is effected of the movement of the material in the compaction zone 23 by friction against the inner wall of the casing in the compaction zone (FIG. 3), by the action of the counterpressure plates 8a, 8b (FIGS. 4 and 5), or by a combination of friction and pressure which is obtained in that the cross-section (FIG. 3) of the casing diminishes, or alternatively in that the casing terminates in the cone 34 (FIG. 4b).
In the embodiments illustrated in FIGS. 6a and 6b, a reduction is effected of the liquid-content of the material, during passage through the precompaction zone 22 and the compaction zone 23. In many examples of physical application, the casing 2 is, in such instances, disposed such that the material is moved slightly upwardly when it passes in a direction towards the discharge opening 24. Hereby, drainage of the material will be facilitated, since a portion of the liquid will pass in a direction opposite to the direction of movement of the material and substantially in the center of the shaftless spiral, before the liquid runs out through the drainage openings 33. As a result, it will be possible for the liquid to reach the drainage openings of the casing in a region where the material has not yet had time to be compacted to any appreciable degree. Hence, as seen in FIGS. 6a and 6b the drainage openings extend over an axial extent of the casing which increases gradually from the top of the casing to the bottom of the casing. The drainage openings at the bottom of the casing extend from the beginning of the precompaction zone 22 whereas the drainage openings at the top of the casing extend from the beginning of the compaction zone 23.
On movement of material into the container 26 or into the hose 28 (Cf. FIGS. 7a and b), the container, the hose--or alternatively the hose in combination with the container--is progressively forced out from the casing 2 by the action of forces from the material, at the same time as the material is compacted and then attains, as a rule, a degree of compaction which is in addition to the previously-attained compaction.
In the embodiment illustrated in FIGS. 8a and b, the conveyor apparatus 50 constitutes a counterpressure member in that the dimensions, pitch and speed of the spiral 53 have been selected such that the material is braked in its movement on passage out from the discharge opening 24 of the casing 2. There will hereby be obtained the desired compaction of the material when this is located in the casing 52 of the receiving combination, and thereby requisite filling of the casing of the receiving combination.
The above-described counterpressure members are, in certain embodiments, combined so that, for example, there will be included in one and the same apparatus, a ccounter-pressure plate 8a, b, and a terminating conical portion of the casing; a counterpressure plate 8a, b, and a shiftable receptacle member 26, 28; a cone 34 and the receiving casing 52 with spiral 53; and so on.
In certain physical applications of the invention, a braking of the material takes place in the precompaction zone to such a great extent that at least that section of the casing located most proximal the compaction zone will be as good as completely filled with material. The thus compacted material is thereafter caused to leave casing through its discharge opening 24 in batches whose size is determined by the rotation of the spiral (the angular alteration which the spiral undergoes), in conjunction with each discharge occasion. Hence, the present invention offers a simple and reliable technique for the batchwise discharge, with a relatively high degree of accuracy, of material from an apparatus according to the present invention.
The above detailed description refers only to a limited number of embodiments of the present invention, but the skilled reader of this Specification will readily perceive that many modifications and embodiments of the present invention are conceivable without departing from the spirit and scope of the appended Claims.
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A method and apparatus for conveying and compacting material which includes fractions of different sizes, densities, elasticity, moisture-content etc. wherein a shaftless spiral is disposed in a casing and the spiral is driven in rotation at an end of the casing where the material is fed into the casing. At the opposite end of the casing, i.e. the end located adjacent a discharge section of the casing, the casing surrounds the spiral with slight play, and, moreover, the casing extends in an end region below the spiral to form a correction zone. Counterpressure brakes the movement of the material to compact the material in the compaction zone. The casing is provided with drainage holes in the compaction zone for discharge of liquid expressed from the compacted material during passage through the compaction zone.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to the treatment of a base metal containing concentrate.
[0002] The recovery of a base metal such as copper from a concentrate, which contains arsenic, using a bioleaching process, can be problematic for it is necessary to avoid producing a bioleach residue which is contaminated with arsenic.
[0003] U.S. Pat. No. 6,461,577 addresses the problem of arsenic toxicity of extremely thermophilic bacterial cultures by means of a two-stage leaching process. In a first mesophilic stage a major part of the arsenic contained in the material being treated is leached from the material and then oxidised from As(III) to As(V). The remaining leachable metal content of the material being treated is leached out in a second thermophilic stage. The concentration of pentavalent arsenic falls quickly and the toxic effect thereof on the thermophilic bacteria thus falls at the same rate.
[0004] It is desirable though to remove the soluble arsenic as ferric arsenate which passes EPA limits and is safe for land disposal and which, to the extent possible, is not in a bioleach residue.
SUMMARY OF INVENTION
[0005] The invention provides a method of treating a concentrate containing at least one base metal which includes the steps of subjecting the concentrate to a primary mesophilic and moderate thermophilic bioleaching process to leach sulphides in the concentrate, processing a residue of the primary bioleach process to recover at least one metal from the primary bioleach residue, subjecting a residue from the metal recovery process to a thermophilic secondary bioleaching process to release the at least one base metal from the metal recovery residue into solution, and recovering the at least one base metal at least from the solution produced by the thermophilic secondary bioleaching process.
[0006] The primary bioleaching process may be carried out at a temperature of from 35° C. to 50° C.
[0007] Preferably the at least one base metal is also recovered from a solution produced by the primary bioleach bioleaching process.
[0008] The method preferably includes the step of preleaching the concentrate, before the primary bioleach bioleaching process, using leach solution from at least one of the bioleaching processes. Preferably the leach solution is derived from the primary bioleaching process and the thermophilic secondary bioleaching process.
[0009] The preleaching step is used to remove easily leachable base metal from the concentrate before the primary bioleaching process. Elemental sulphur which may accumulate during the preleach step due to rapid leaching of easily leachable sulphides, may be removed during the bioleaching stages, especially during the thermophilic secondary bioleaching process at elevated temperatures.
[0010] The primary bioleaching process may be carried out in a series of continuously stirred tank reactors which are operated at a temperature of from 35° C. to 50° C. in the presence of an active mixed culture of mesophilic and moderate thermophilic microorganisms.
[0011] A mixed culture of mesophile (20° C. to 40° C.) and moderate thermophile (40° C. to 55° C.) microorganisms is preferably used to maximise sulphide bioleaching and sulphur biooxidation during the treatment process. The mixed culture may contain microorganisms like Leptospirillum ferrooxidans and Acidithiobacillus caldus , a good iron oxidiser and a good sulphur oxidiser respectively.
[0012] The primary bioleach process may also contain thermophilic microorganisms, which are not effectively active at the temperature range of 35° C. to 50° C. Such microorganisms will, however, still be living but will be dormant or slowly metabolising. When the temperature increases during the thermophilic secondary bioleaching process these microorganisms will reactivate their activity. This may be very useful for base metal concentrates, as the thermophilic secondary bioleaching stage would be continuously re-inoculated.
[0013] The pH of the concentrate or pulp in reactors in which the primary bioleaching is carried out may be controlled at a value of from 1,2 to 1,7. This may be achieved by the addition of limestone or raffinate produced in the base metal recovery step, to the reactors.
[0014] Oxygen may be supplied to the concentrate in the reactors in the form of enriched air which may contain from 95% to 98% oxygen, during at least part of the bioleaching processes.
[0015] An objective of operating the primary bioleaching process under the aforementioned conditions is to maximise the leaching of the sulphides in the concentrate and to maximise mass loss, and to minimise the precipitation in pentavalent form of arsenic which may be present in solution. The product from the primary bioleach residue may contain high concentrations of elemental sulphur due to the maximised bioleaching conditions.
[0016] In the metal recovery process toxic silver may be removed from the primary bioleaching residue. The silver may be removed using a brine leaching process.
[0017] The thermophilic secondary bioleaching process may be carried out in a series of continuously stirred tank reactors at a temperature of from 65° C. to 80° C. in the presence of active quantities of extreme thermophilic microorganisms.
[0018] The method may include the step of controlling the pH of the pulp in the thermophilic reactors at a value of from 1,0 to 1,7. This may be achieved by the addition of limestone or raffinate produced in the metal recovery step. Oxygen & carbon dioxide may be supplied to the reactors in the form of enriched gas containing from 95% to 98% oxygen and 1% to 5% carbon dioxide.
[0019] An objective of operating the thermophilic secondary bioleaching process under the aforementioned parameters is to maximise the oxidation of sulphides minerals and mass loss, and to minimise the precipitation in pentavalent form of arsenic which may be present in solution.
[0020] Furthermore sulphur oxidation at thermophilic temperature conditions is maximised and thus any elemental sulphur produced during the proceeding preleach and primary bioleach may be fully oxidised. This is very important if further treatment of the thermophilic secondary bioleach residue is required for precious group metals (PGM's) recovery like gold. Elemental sulphur increases cyanide consumption during cyanidation to recover gold and thus contributes significantly to the increase in cyanidation costs. Additionally, elemental sulphur not oxidised decreases the acid produced in the bioleach solution and thus may decrease the effectiveness of any preleach step using recycled bioleach solution.
[0021] As indicated the at least one base metal is recovered from the leach solutions produced by the bioleaching processes. Preferably the pH of the solution produced in the preleaching step is adjusted to maximise recovery of the at least one base metal using solvent extraction techniques.
[0022] Arsenic present in the solution may be caused to precipitate as ferric arsenate by increasing the pH of the solution to at least 2.
[0023] The pH of the solution may be increased by the addition of limestone slurry to the solution.
[0024] The pH adjustment may be carried out in a series of continuously stirred tank reactors which are operated at a temperature of from 60° C. to 80° C.
[0025] The at least one base metal, eg. copper, may be recovered by concentrating the copper and stripping, followed by cathode production by electrowinning.
BRIEF DESCRIPTION OF THE DRAWING
[0026] The invention is further described by way of example with reference to the accompanying drawing which is a flow sheet illustrating various steps in a method of treating a concentrate obtaining at least one base metal in accordance with the principles of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0027] In the method of the invention a concentrate 10 which contains a base metal such as copper and which may have a high arsenic content is subjected to a preleaching step 12 . In this step the fresh concentrate is contacted with bioleach overflow solutions 14 and 16 respectively produced in subsequent primary and thermophilic secondary bioleaching stages 18 and 20 .
[0028] The solutions 14 and 16 are rich in ferric and remove easily leachable copper from the feed 10 . This ensures a lower residual copper tenor in the bioleaching tanks in the stages 18 and 20 .
[0029] The product 22 of the preleaching stage is subjected to solid/liquid separation 24 . An overflow solution 26 from the separation step 24 is directed to a pH adjustment stage 28 while the underflow 30 , diluted with water 32 and raffinate 34 from a solvent extraction section 36 , is fed to the primary bioleaching stage 18 .
[0030] The purpose of the primary bioleaching stage 18 is to oxidise sulphide minerals in the feed and release base metals of interest into solution. The bioleaching is carried out in a series of continuously stirred tank reactors which are operated at a temperature of 35° C. to 50° C. in the presence of active quantities of mesophilic and moderate thermophilic microorganisms.
[0031] The pH of the pulp of the reactors in the primary bioleaching stage is controlled at a value of from 1,2 to 1,7 by the addition of limestone 40 or raffinate 34 . Oxygen 42 , required for the oxidative reaction, is supplied in the form of enriched air with an oxygen content of from 95% to 98%.
[0032] By operating the primary bioleaching stage 18 under the aforementioned conditions the oxidation of the sulphide minerals and the mass loss are maximised while, if arsenic is present in the feed, the precipitation thereof in pentavalent form is minimised.
[0033] The product 44 of the primary bioleaching section 18 reports to bioleach thickening and washing 46 . As has been indicated the overflow solution 14 is fed to the preleaching step 12 while the underflow 48 is the feed to a metal recovery section 50 .
[0034] The purpose of the step 46 is to separate the liquids and the solids so that the base metals of interest and arsenic, if present, report to the pH adjustment section 28 via the preleaching step 12 . In the metal recovery step 50 toxic silver 52 is removed from the primary bioleaching residue 48 using a brine leaching or other suitable method.
[0035] The residue 54 from the metal recovery step is repulped with water 56 and raffinate 34 and the resulting slurry is fed to the thermophilic secondary bioleaching stage 20 .
[0036] The purpose of the stage 20 is to oxidise, to the extent possible, the sulphide minerals and the elemental sulphur which were not leached in the primary bioleaching stage 18 . The base metals of interest are thereby released into solution. The thermophilic secondary bioleaching process is carried out in a series of continuously stirred tank reactors which are operated at a temperature of from 65° C. to 80° C. in the presence of active quantities of extreme thermophilic microorganisms.
[0037] The pH of the pulp in the thermophilic reactors is controlled at a value of from 1,0 to 1,7 by the addition of limestone 40 or raffinate 34 . Oxygen 42 required for the oxidative reactions is supplied in the form of enriched gas with an oxygen content of from 95% to 98%. Carbon dioxide 57 may be required for improved thermophilic cell growth is supplied in the form of enriched gas with a carbon dioxide content of 1% to 5% by volume. By operating the thermophilic secondary bioleaching sections under these conditions the oxidation of the sulphide minerals and the mass loss are maximised while the precipitation of arsenic which may be present in the slurry 54, in the form of pentavalent arsenic, is minimised.
[0038] The product 60 of the thermophilic bioleaching section 20 reports to a bioleach thickening and washing step 62 . The overflow solution 16 is fed to the preleaching section 12 while the underflow 64 is directed to a tailings pond 66 for disposal. If the underflow 64 contains PGM's then the underflow is directed to a metal recovery step 67 where the metal is removed from the underflow using cyanide as a leaching process for gold or other suitable method.
[0039] The purpose of the step 62 is to separate liquid and solids so that base metals of interest and arsenic, if present, are reported in solution to the pH adjustment section 28 via the preleaching stage 12 .
[0040] The pH adjustment section 28 includes a series of continuously stirred tank reactors which are operated at a temperature of from 60° C. to 80° C. The pH of the solution 26 is increased to a required level using limestone 40 or any other suitable neutralising agent. The product 70 of the pH adjustment section is then thickened in a step 72 . The thickener underflow 74 , which contains precipitated ferric arsenate, is directed to a tailings pond 76 for disposal. The overflow from the thickener step reports as pregnant leach solution (PLS) 80 to the solvent extraction section 36 .
[0041] The purpose of the pH adjustment section 28 is to increase the pH of the pregnant leach solution, which is fed to the solvent extraction section 36 , to above 2,0 so that the solvent extraction efficiency is maximised. Arsenic which is present in the solution 26 is caused, by the increase in the pH, to precipitate primarily as ferric arsenate which is not readily dissolved. The ferric arsenate passes EPA limits and is safe for land disposal.
[0042] In the solvent extraction section 36 dissolved copper is recovered from the pregnant leached solution. The copper is stripped followed by cathode production ( 84 ) by electrowinning.
[0043] In the process of the invention the base metal containing concentrate is subjected to primary mesophilic and or moderate thermophilic leaching, metal recovery and thermophilic secondary leaching in combination so that secondary sulphides are successfully and economically leached in the primary section, toxic silver is removed in the metal recovery section, and a residue containing unleached primary sulphides and elemental sulphur is leached to completion successfully and economically in the thermophile secondary section. If arsenic is present in the concentrate the primary and thermophilic secondary sections are operated so that the redox potential of the solutions produced result in the natural oxidation of As(III) to As(V). Arsenic precipitation in the bioleaching sections is intentionally minimised so that the arsenic is precipitated externally in the pH adjustment section 28 . This avoids the production of a bioleach residue contaminated with arsenic.
[0044] It is cost effective to reduce the arsenic reporting to the thermophilic stage 20 by causing the arsenic to precipitate in a separate dedicated process step ie. the pH adjustment section 28 . By minimising precipitation in the mesophilic stage 18 the mass loss throughout the process is maximised. This reduces the capital and operating cost of the downstream processes including the thermophilic section 20 .
[0045] Furthermore sulphur oxidation at thermophilic temperature conditions is maximised and thus any elemental sulphur produced during the proceeding preleach and primary bioleach may be fully oxidised. This is important if further treatment of the thermophilic secondary bioleach residue is required for precious group metals (PGM's) recovery like gold. Elemental sulphur increases cyanide consumption during cyanidation to recover gold and thus contributes significantly to the increase in cyanidation costs. Additionally, elemental sulphur not oxidised decreases the acid produced in the bioleach solution and thus may decrease the effectiveness of any preleach step using recycled bioleach solution.
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A method of recovering at least one base metal from a concentrate wherein a residue of a primary bioleach of the concentrate, under mesophilic and moderate themophilic conditions, is processed to recover at least one metal, and the base metal is recovered from a solution, produced by a secondary bioleach under thermophilic conditions, of a residue of the metal recovery process.
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RELATED APPLICATIONS
[0001] Related co-pending applications include application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H0021856-1161.1446101, entitled “A Graphical Approach to Setup Data Sharing between Two Controllers”; application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H0021854-1161.1448101, entitled “Protocol Independent Programming Environment”; application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H0021855-1161.1449101, entitled “Priority Selection Mechanism for Driving Outputs from Control Logic for Controllers of Various Protocols”; application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H0021858-1161.1450101, entitled “An Approach to Automatically Encode Application Enumeration Values to Enable Reuse of Applications across Various Controllers”; application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H212859-1161.1451101, entitled “An Approach for Switching between Point Types without Affecting Control Logic”; and application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H0024800-1161.1479101, entitled “Changeable BACnet Interface”.
[0002] Related co-pending applications include application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H0021856-1161.1446101, entitled “A Graphical Approach to Setup Data Sharing between Two Controllers”, is hereby incorporated by reference. Application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H0021854-1161.1448101, entitled “Protocol Independent Programming Environment”, is hereby incorporated by reference. Application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H0021855-1161.1449101, entitled “Priority Selection Mechanism for Driving Outputs from Control Logic for Controllers of Various Protocols”, is hereby incorporated by reference. Application Ser. No. ______, filed Dec. 30, 2009, Attorney Docket No. H0021858-1161.1450101, entitled “An Approach to Automatically Encode Application Enumeration Values to Enable Reuse of Applications across Various Controllers”, is hereby incorporated by reference. Application Ser. No.______ filed Dec. 30, 2009, Attorney Docket No. H212859-1161.1451101, entitled “An Approach for Switching between Point Types without Affecting Control Logic”, is hereby incorporated by reference. Application Ser. No. ______ filed Dec. 30, 2009, Attorney Docket No. H0024800-1161.1479101, entitled “Changeable BACnet Interface”, is hereby incorporated by reference.
[0003] U.S. patent application Ser. No. 12/256,444, filed Oct. 22, 2008, is hereby incorporated by reference. U.S. patent application Ser. No. 11/670,911, filed Feb. 2, 2007, is hereby incorporated by reference. U.S. patent application Ser. No. 11/620,431, filed Jan. 5, 2007, is hereby incorporated by reference. U.S. patent application Ser. No. 11/427,750, filed Jun. 29, 2006, is hereby incorporated by reference. U.S. patent application Ser. No. 11/564,797, filed Nov. 29, 2006, is hereby incorporated by reference. U.S. patent application Ser. No. 11/559,706, filed Nov. 14, 2006, is hereby incorporated by reference. U.S. patent application Ser. No. 10/809,115, filed Mar. 25, 2004, is hereby incorporated by reference.
BACKGROUND
[0004] The invention pertains to programming and particularly to various communication protocols of applications. More particularly, the invention pertains to knowledge of numerous protocols needed by application engineers.
SUMMARY
[0005] The invention is a mechanism for minimization or elimination of a need by application design engineers to have knowledge of one or more protocols while designing control logic applications. The mechanism may provide generic control logic applications that have versions automatically made to be used in controllers of various protocols.
BRIEF DESCRIPTION OF THE DRAWING
[0006] FIG. 1 is a diagram of a workbench for opening an application library;
[0007] FIG. 2 is a diagram of control logic with data points and function blocks;
[0008] FIG. 3 is a diagram of the workbench for invoking a configuration of a data point;
[0009] FIG. 4 is a diagram of the workbench for configuring general properties of the data point;
[0010] FIG. 5 is a diagram of the workbench for configuring specific properties of a certain protocol;
[0011] FIG. 6 is a diagram of the workbench for configuring specific properties of a another protocol; and
[0012] FIG. 7 is a diagram of the workbench for viewing the mapping of a data point to a network interface.
DESCRIPTION
[0013] Programming tools used by HVAC (heating, ventilation and air conditioning) application engineers may be quite complex and often expose details of the underlying communication protocols to users. This may force the application engineers to be protocol experts apart from being HVAC experts. This is not necessarily practical for an application engineer as there may be several communication protocols used in HVAC automation. Some protocols may involve those of LonTalk™ (LonTalk, Lon™, Lon), LonWorks™ (LonWorks), and BACnet (Bacnet). LonTalk and Lon are trademarks of Echelon Corp. BACnet is a communications protocol for building automation and control networks.
[0014] A Spyder™ (Spyder) programming tool may support programming of Lon Spyder controllers. Spyder is a trademark of Honeywell International Inc. Often, users may need to create the same control application twice, one for Lon Spyder and one for BACnet Spyder which can be time consuming and prone to mistakes. The applications may need to be replicated for the Lon and BACnet versions. Also, any small changes to a Lon application may need to be replicated in the BACnet version of the application.
[0015] The Spyder tool may have an application library that is used to create, modify and store Spyder applications for later use. This tool may allow engineers to design a generic application feature in the application library. When a user creates an application, the tool may automatically generate two network interface views (e.g., Lon and BACnet). The user may simply add points on the wire sheet, and tool can automatically create corresponding backend Lon network variables and BACnet objects. This way, one may keep applications generic for Lon and BACnet versions of the applications, and thus applications need not be replicated and any changes to the application may be reflected in both Lon and BACnet versions of the application.
[0016] A generic application may improve productivity of field engineers and keep the complexity of communication protocol hidden under the hoods of the system. Figures noted herein show steps that an engineer may go through to create generic applications reusable with various protocols. When an engineer drops a data point in the tool for the purpose of using it in the control logic, the tool may automatically create an underlying protocol object and maintain a mapping/reference between the point and the protocol object. The tool may maintain a reference for every protocol supported; that is, since Lon and BACnet are supported, the tool may maintain two references for every data point dropped by the user into the control logic. This approach may allow the tool to do automatic translation when the control logic is used in a target Spyder device.
[0017] The present approach may concern creating generic control applications for Spyder. The first step may be an opening the Spyder application library. This may be achieved by clicking on “window” 12 of a Niagara workbench as shown by screen 11 of FIG. 1 . “Side Bars” 13 may be clicked on to show a drop-down menu with “Spyder Library” 14 listed. “Spyder Library” 14 may be clicked on to open a Spyder application library. A control program 58 may be shown as indicated by a Nav (navigation) palette 59 menu. As a second step, control logic may be created by using data points and function blocks as shown by screens 11 and 15 of FIGS. 1 and 2 , respectively. As examples for an illustration, input points may include space temp 16 , set point 17 , AV4 Software 18 and an output point 19 for a damper. Function blocks may include PID 21 , priority override 22 and life safety app 23 . The Figures may also relate to VAV (variable air volume) aspects.
[0018] The space temp input point 16 may be connected to function block 21 with a link 38 . Setpoint input point 17 may be connected to function block 21 with a link 39 . An output of the PID (proportional-integral-derivative) function block 21 may be connected to an input of priority override 22 with a link 46 and life safety app may be connected to another input of priority override 22 with a link 48 . An output of priority override 22 may be connected to damper output point 19 .
[0019] A third step may invoke a configuration screen or menu 25 of the space temperature data point 16 by clicking on data point 16 . This step and resulting menu 25 are shown by screen 24 of FIG. 3 . “Configure Properties” of menu or screen 25 may be clicked on to get a dialog box or screen 27 for configuring general properties of data point 16 , as a fourth step shown by screen 26 of FIG. 4 . The properties may include point name 43 , point type 52 , type 57 , point category 61 and unit 62 . Input state box 63 may have entries spaces 64 , 65 , 66 and 67 for input low, output low, input high and output high, respectively. Box 27 may include a “Help” button 68 , “Sensor Limits” button 69 , “Advanced” button 28 , “OK” button 71 and “Cancel” button 72 .
[0020] “Advanced” button 28 of box 27 may be clicked on to get a dialog box or menu 31 to configure network interface specific properties. A fifth step may include configuring BACnet specific properties by selecting the respective tab 32 of dialog box 31 to get a box 81 for selection of the properties, as shown in screen 29 of FIG. 5 . These properties may include object name 73 , object instance 74 , object type 75 and significant event notification delta 76 . A box 77 may provide for GPU (guaranteed periodic update) selection and “Send Heart Beat” indication. Selected properties may be accepted by clicking on the “OK” button 78 or rejected by clicking on a “Cancel” button 79 .
[0021] The sixth step may include configuring Lon specific properties by selecting the respective tab 33 of dialog box 31 to get a box 82 for selection of the properties, as shown in screen 34 of FIG. 6 . Box 82 indicates NV (network variable) composition with specific properties for Lon. Such properties may include NV name copied from a standard list 85 or a custom selection 86 . Field properties 87 may include field name 88 , data category 89 , network data type 91 , internal data type 92 and value 93 may be selected and edited. The selections and edits may be saved under a UNVT (user network variable type) name 94 such as SNVT_temp_p. “SNVT” may be regarded as a standard network variable type. The “OK” button 35 or “Cancel” button 83 may be clicked on to accept the configured specific properties.
[0022] The seventh step may include viewing a mapping of a data point to the network interface by accessing corresponding views as shown by screen 36 of a wiresheet in FIG. 7 . Drop down menu 37 may be available for a selection of various views such as a NV configuration view (Lon) or an object configuration view (BACnet).
[0023] The Spyder tool may offer a graphical environment to program the Spyder controller. One may use a wiresheet view in the engineering mode (such as an example shown in screen 36 of FIG. 7 ) to use physical points, software points, and function blocks to build an application in the control program. The physical points, software points, and function blocks may be accessed using a palette 40 . One may drag these items on to the wiresheet and connect them, based on one's need, to develop application logic like that in screen 36 . The logic that one creates may then be stored in a Spyder library for reuse. Upon being satisfied with the logic one has created, one may download the same to the controller. The logic thus created may be tested for correctness by selecting simulation and online debugging modes.
[0024] One may note that changing NCI (network configuration input) values, configuration of a schedule block, or daylight savings option, puts the application in a quick download pending state. As long as the application has been downloaded at least once to the controller, these changes just trigger a quick download to the controller.
[0025] One may use the control program option to program the Spyder tool. To do this, one may expand Lon Spyder or BACnet Spyder in the Nav palette and double-click control program to display the wiresheet view; display the palette (from the menu bar, select Window>Sidebars>Palette to display the palette).
[0026] The palette may appear on the left pane with the following items. Lon Spyder is a device that one may drag on to the Lon network in the Nav palette 59 to create a new device. Note that one cannot drop this on to the wiresheet of any macro or control program or application. BACnet Spyder is a device that one may drag on to the BACnet network in the Nav palette 59 to create a new device. It may be noted that one cannot drop this on to the wiresheet of any macro or control program or application. Physical points may be modulating and binary inputs or outputs. Software points may be used to create a network input, network setpoints, or a network output.
[0027] Additional items may include analog function blocks, logic function blocks, math function blocks, control function blocks, data-function function blocks, zone arbitration function blocks, and built-in function blocks.
[0028] It may be noted that a macro may be a group of functional blocks grouped together that define a specific functionality. Commonly used program elements may be defined as macros so that they could be reused across applications. An application may include macros and logic that one can define and use in applications. Standard applications may be provided for the Spyder used to build application logic.
[0029] One may drag any of these noted items on to the wiresheet of a control program in its engineering mode and make the connections between physical points, software points, and function blocks to create a control program or an application.
[0030] A wiresheet view may be used to drag the physical points and function blocks to build the application logic. One may save a logic created to be used later and also shared with other users. One may build several applications and store them in a Spyder library along with standard applications.
[0031] After one has created the application logic and tested the logic using the simulation feature, the application logic may be downloaded to the controller. To download the application logic, one may: 1) on the Nav palette, right-click the device and select Actions>Download (the download dialog box may appear); and 2) select True under full download for a full download or false for a quick download. One may note that a quick download just downloads the modified items from a previous download where as with a full download the entire configuration may be downloaded to the controller replacing the existing configuration. However, if changes have been made to the sensor bus (SBus) wall module by an operator/tenant locally from the display on the wall module, and a full download is performed, the Spyder tool may download the entire configuration to the controller except the SBus (Sylk or sensor bus) wall module configuration. This may be done to avoid losing any changes made locally on the SBus wall module during a download operation. Then at 3), one may click OK. The application logic may be downloaded to the controller based on one's selection.
[0032] In the present specification, some of the matter may be of a hypothetical or prophetic nature although stated in another manner or tense.
[0033] Although the present system has been described with respect to at least one illustrative example, many variations and modifications will become apparent to those skilled in the art upon reading the specification. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications.
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A mechanism for constructing generic control logic with versions of the logic automatically generated and stored for one or more protocols. The complexity of the one or more protocols may be hidden under a hood of the mechanism from the view of engineers, programmers and users so as to improve their productivity relative to control logic designs and applications.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a light sensing apparatus including a photosensor.
2. Description of the Related Art
Some automotive vehicles are equipped with lamp control systems which automatically activate and deactivate head lamps and tail lamps in response to the brightnesses of vehicles' surroundings. In general, such system are referred to as automatic light systems.
The automatic light system uses a light sensing apparatus which is designed to sense illuminances in a predetermined range including a level corresponding to a twilight or a semi-darkness. A typical example of the illuminance range which can be sensed by the light sensing apparatus in the automatic light system extends from 0 to 1,000 1x.
There is a known system for a vehicle which corrects a meter luminance or an indicator luminance in response to the brightness of vehicle's surroundings. The meter luminance correcting system uses a light sensing apparatus which is designed to sense illuminances in a predetermined range generally wider than the illuminance range related to the light sensing apparatus in the automatic light system. A typical example of the illuminance range which can be sensed by the light sensing apparatus in the meter luminance correcting system extends from 0 to 10,000 1x.
A known air-conditioning system for a vehicle includes a light sensing apparatus used as a sunshine sensing apparatus. In the air-conditioning system, the temperature of air discharged into a vehicle interior is controlled in response to the intensity of sunshine which is sensed by the sunshine sensing apparatus. A typical example of an illuminance range which can be sensed by the sunshine sensing apparatus in the air-conditioning system extends from 1,000 to 100,000 1x.
The light sensing apparatuses in the automatic light system, the meter luminance correcting system, and the air-conditioning system include photosensors such as photodiodes or phototransistors. The light sensing apparatuses also include processing circuits which operate on the output signals of the photosensors. The photosensors and the processing circuits are designed to provide suitable S/N ratios.
Japanese published unexamined patent application 4-194626 discloses a photosensor circuit which includes an operational amplifier following a photosensor. In the photosensor circuit of Japanese application 4-194626, the resistance of an amplification feedback resistor connected to the operational amplifier can be changed between a first value and a second value. The first resistance value provides a first input-output characteristic of the operational amplifier. The second resistance value provides a second input-output characteristic of the operational amplifier which differs from the first input-output characteristic thereof. The resistance of the amplification feedback resistor is automatically changed between the first value and the second value in response to a light-dependent current flowing through the photosensor, that is, an output signal of the photosensor. Accordingly, the resultant input-output characteristic line of the operational amplifier has a bend point. Japanese application 4-194626 discloses that portions of the resultant input-output characteristic line which extend on opposite sides of the bend point are suited for a photosensor in an automatic light system and a sunshine sensor in an air-conditioning system respectively.
Japanese published unexamined patent application 6-344754 discloses that an amplifier connected to a photosensor enlarges an output signal of the photosensor, and a resultant output signal of the amplifier is fed to both an air-conditioner controller and a light controller. Japanese application 6-344754 teaches that an air-conditioning system including the air-conditioner controller responds to the output signal of the amplifier. Also, Japanese application 6-344754 teaches that an automatic light system including the light controller responds to the output signal of the amplifier.
Japanese published unexamined patent application 3-249525 discloses a light measuring apparatus which includes a photodiode followed by two operational amplifiers having different input-output characteristics respectively. In the light measuring apparatus of Japanese application 3-249525, one of the operational amplifiers is activated while the other is deactivated. Thus, the amplification of an output signal of the photodiode can be changed between two different characteristics.
Japanese application 4-194626, Japanese application 6-344754, and Japanese application 3-249525 disclose that the output signal of a single photosensor is processed and used for multiple purposes. It tends to be difficult to provide adequate S/N ratios for all the purposes.
U.S. Pat. No. 5,434,430 corresponding to Japanese published unexamined patent application 7-92086 discloses an optical drop detector circuit for a thermal ink jet printer. The optical drop detect circuit of U.S. Pat. No. 5,434,430 includes an optical sensor for providing an electrical output indicative of a presence of an ink drop, a transconductance amplifier responsive to the output of said optical sensor, first and second cascaded bandpass amplifiers responsive to the transconductance amplifier, a first comparator circuit responsive to the output of the cascaded bandpass amplifiers for providing an output pursuant to optical sensing of a first minimum ink drop size, and a second comparator circuit responsive to the output of the cascaded bandpass amplifiers for providing an output pursuant to optical sensing of a second minimum ink drop size.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved light sensing apparatus.
A first aspect of this invention provides a light sensing apparatus for different control systems which comprises a photosensitive element generating a light current depending on light incident thereto; a pre-circuit connected to the photosensitive element for generating separate basic signals in response to the light current generated by the photosensitive element; and processing circuits connected to the pre-circuit and being active simultaneously for converting said basic signals generated by the pre-circuit into conversion-resultant signals having different forms respectively, and for outputting the conversion-resultant signals to the control systems respectively.
A second aspect of this invention is based on the first aspect thereof, and provides a light sensing apparatus wherein at least one of the processing circuits comprises an oscillation circuit which oscillates at a frequency depending on related one of said basic signals generated by the pre-circuit.
A third aspect of this invention is based on the second aspect thereof, and provides a light sensing apparatus wherein said one of the processing circuits which comprises the oscillation circuit further comprises a bias circuit for providing related one of said conversion-resultant signals with a predetermined offset.
A fourth aspect of this invention is based on the second aspect thereof, and provides a light sensing apparatus wherein said one of the processing circuits which comprises the oscillation circuit further comprises a limiter circuit for clamping a condition of related one of said conversion-resultant signals when an illuminance related to said light is in a predetermined range.
A fifth aspect of this invention is based on the first aspect thereof, and provides a light sensing apparatus wherein said pre-circuit comprises a current mirror circuit.
A sixth aspect of this invention provides a light sensing apparatus comprising a photosensitive element generating a light current depending on light incident thereto; and an oscillation circuit connected to the photosensitive element for oscillation at a frequency depending on the light current generated by the photosensitive element, the oscillation circuit converting the light current into a frequency signal having a frequency depending on the light current.
A seventh aspect of this invention is based on the sixth aspect thereof, and provides a light sensing apparatus further comprising a bias circuit connected between the photosensitive element and the oscillation circuit for providing said frequency signal with a predetermined offset.
An eighth aspect of this invention is based on the sixth aspect thereof, and provides a light sensing apparatus further comprising a limiter circuit connected between the photosensitive element and the oscillation circuit for clamping the frequency of said frequency signal at a predetermined value when an illuminance related to said light is in a predetermined range.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a light sensing apparatus according to a first embodiment of this invention.
FIG. 2 is a diagram of the relation between a signal current and an illuminance in the light sensing apparatus of FIG. 1.
FIG. 3 is a time-domain diagram of a current, a voltage, and a signal in the light sensing apparatus of FIG. 1.
FIG. 4 is a diagram of the relation between a signal frequency and an illuminance in the light sensing apparatus of FIG. 1.
FIG. 5 is a schematic diagram of a portion of a light sensing apparatus according to a second embodiment of this invention.
FIG. 6 is a diagram of the relation between a signal frequency and an illuminance in the light sensing apparatus of FIG. 5.
FIG. 7 is a diagram of the relation between a signal frequency and an illuminance in the light sensing apparatus of FIG. 5.
FIG. 8 is a schematic diagram of a portion of a light sensing apparatus according to a third embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
With reference to FIG. 1, a light sensing apparatus includes a photosensitive element 1 such as a photodiode. The photosensitive element 1 is connected via a positive power supply terminal T1 and a ground terminal T2 to a dc power source so that a current iL depending on the illuminance related to light incident to the photosensitive element 1 flows therethrough. The current iL will be referred to as the light current hereinafter.
The light current iL flows from the photosensitive element 1 into a current mirror circuit 2 connected to the photosensitive element 1. The current mirror circuit 2 serves to generate currents i1 and i2 proportional to the light current iL.
The current mirror circuit 2 includes transistors 21, 22, and 23. The transistor 21 is connected between the photosensitive element 1 and the ground terminal T2. Specifically, the collector of the transistor 21 is connected to the photosensitive element 1. The bases of the transistors 21, 22, and 23 are connected in common to the photosensitive element 1. The emitters of the transistors 21, 22, and 23 are connected in common to the ground terminal T2. The currents i1 and i2, which are proportional to the light current iL, flow toward the collectors of the transistors 22 and 23 respectively.
A processing circuit 3 connected to the current mirror circuit 2 has a part through which the current i1 flows. The processing circuit 3 serves to process an illuminance signal represented by the current i1.
A processing circuit 4 connected to the current mirror circuit 2 has a part through which the current i2 flows. The processing circuit 4 serves to process an illuminance signal represented by the current i2.
The photosensitive element 1, the current mirror circuit 2, and the processing circuits 3 and 4 are fabricated and integrated on a common substrate. Thus, the photosensitive element 1, the current mirror circuit 2, the processing circuits 3 and 4, and the substrate compose a single semiconductor chip. The semiconductor chip has the positive power supply terminal T1, the ground terminal T2, and output terminals T3 and T4. The output terminals T3 and T4 are connected to the processing circuits 3 and 4 respectively. Output signals of the processing circuits 3 and 4 are transmitted to external control units via the output terminals T3 and T4 respectively.
The current mirror circuit 2 is a pre-circuit following the photosensitive element 1 and preceding the processing circuits 3 and 4.
The processing circuit 3 is designed to provide a current signal accurately representing an illuminance in a predetermined range, for example, 0 to 100,000 1x. The processing circuit 3 enables the photosensitive element 1 to be suitably used as a sunshine sensor for an air-conditioning system. It is preferable that the processing circuit 3 is designed to provide compatibility with a conventional sunshine sensor.
The processing circuit 3 includes an operational amplifier 31, a transistor 32, and resistors 33 and 34 which are connected to compose a current amplification circuit. The resistor 33 placed in an input side of the current amplification circuit is subjected to the current i1. A current signal proportional to the current iL flows through the emitter-collector path of the transistor 32 placed in an output side of the current amplification circuit. The collector of the transistor 32 is connected to the output terminal T3. The signal current flows through the output terminal T3. The signal current is an output current from the current amplification circuit. The output current Iout from the current amplification circuit in the processing circuit 3 is given as follows.
Iout=i1·(R1/R2)
where R1 and R2 denote the resistances of the resistors 33 and 34 respectively. Generally, the resistances R1 and R2 are adjusted so that the output current Iout will be accorded with or equivalent to an output signal of a sunshine sensor.
With reference to FIG. 2, the signal current or the output current Iout from the processing circuit 3 linearly varies with the illuminance in the range of 10 to 100,000 1x. This linearity means that a high S/N ratio is available throughout the illuminance range of 10 to 100,000 1x.
In FIG. 1, the processing circuit 4 is designed to provide a frequency signal accurately representing an illuminance in a predetermined range, for example, 0 to 10,000 1x. The processing circuit 4 enables the photosensitive element 1 to be suitably used as a photosensor for an automatic light system or a meter luminance correcting system.
The processing circuit 4 includes a current-to-frequency converter. An input side of the current-to-frequency converter is subjected to the current i2. The current-to-frequency converter generates and outputs a signal in response to the current i2. The output signal of the current-to-frequency converter has a frequency which varies in proportion to the magnitude of the current i2. The output side of the current-to-frequency converter is connected to the output terminal T4. Thus, the output frequency signal is transmitted via the output terminal T4.
Specifically, an input side of the processing circuit 4 is subjected to the current i2. The processing circuit 4 includes a capacitor 41, transistors 42a, 42b, 42c, and 43, and a comparator 44 which are connected to compose an oscillation circuit. The oscillation circuit oscillates at a frequency proportional to the magnitude of the current i2. As will be made clear later, the comparator 44 is provided with a hysteresis. The output terminal of the comparator 44 is connected via an inverter 49 to the output terminal T4 of the semiconductor chip. In the processing circuit 4, a stage preceding the oscillation circuit generates a current i21 proportional to the current i2. As will be made clear later, the capacitor 41 can be charged by the current i21. The transistors 42a, 42b, and 42c compose a switch for selectively discharging the capacitor 41 in response to the output signal of the inverter 49.
In the processing circuit 4, a non-inverting input terminal of the comparator 44 is subjected to a voltage across the capacitor 41. The oscillation circuit includes a series combination of resistors 46 and 47 which is connected across the dc power source. The junction between the resistors 46 and 47 is connected to an inverting input terminal of the comparator 44. Also, the oscillation circuit includes a series combination of a resistor 48 and a transistor 45 which is connected in parallel with the resistor 47. The transistor 45 serves to selectively connect and disconnect the resistor 48 in parallel to and from the resistor 47 in response to an output signal of the comparator 44. When the transistor 45 disconnects the resistor 48 from the resistor 47, the resistors 46 and 47 cooperate to apply a first predetermined threshold voltage Vref1 to the inverting input terminal of the comparator 44. When the transistor 45 connects the resistor 48 in parallel to the resistor 47, the resistors 46, 47, and 48 cooperate to apply a second predetermined threshold voltage Vref2 to the inverting input terminal of the comparator 44. The second predetermined threshold voltage Vref2 is lower than the first predetermined threshold voltage Vref1.
With reference to the portion (b) of FIG. 3, during a certain interval of time, the capacitor 41 remains charged by the current i21 so that the voltage across the capacitor 41 continues to rise. It should be noted that the current i21 is proportional to the current i2. When the voltage across the capacitor 41 reaches the first predetermined threshold voltage Vref1, the output signal of the comparator 44 changes from a low logic level to a high logic level. At the same time, as shown in the portion (c) of FIG. 3, the output signal of the inverter 49, which is transmitted via the output terminal T4 of the semiconductor chip, changes from a high logic level to a low logic level.
The change of the output signal of the comparator 44 to the high logic level causes the transistor 45 to fall into an on state so that the first predetermined threshold voltage Vref1 applied to the comparator 44 is replaced by the second predetermined threshold voltage Vref2. At the same time, the capacitor 41 starts to be discharged in response to the output signal of the inverter 49. In this case, the transistor 42a short-circuits the capacitor 41 in response to a great current i22 fed from the transistor 43, and hence the voltage across the capacitor 41 drops at a high rate.
When the voltage across the capacitor 41 drops below the second predetermined threshold voltage Vref2, the output signal of the comparator 44 changes from the high logic level to the low logic level. At the same time, as shown in the portion (c) of FIG. 3, the output signal of the inverter 49, which is transmitted via the output terminal T4 of the semiconductor chip, changes from the low logic level to the high logic level.
The change of the output signal of the comparator 44 to the low logic level causes the transistor 45 to fall into an off state so that the second predetermined threshold voltage Vref2 applied to the comparator 44 is replaced by the first predetermined threshold voltage Vref1. At the same time, the discharging of the capacitor 41 stops in response to the output signal of the inverter 49. Thus, the capacitor 41 starts to be charged by the current i21.
In this way, the output signal of the inverter 49, which is transmitted via the output terminal T4 of the semiconductor chip, periodically changes between the low logic level and the high logic level at a frequency depending on the current i21. Since the current i21 is proportional to the current i2, the frequency of the output signal of the inverter 49 depends on the current i2. The output signal of the inverter 49, that is, the output signal of the processing circuit 4, is of a binary form or a digital form.
With reference to the portions (a) and (b) of FIG. 3, as the current i2 (or the current i21) increases, the rate of the charging and discharging of the capacitor 41 increases and hence the frequency of the output signal of the inverter 49 (the output signal of the processing circuit 4) rises.
As understood from the previous explanation, the processing circuit 4 converts an analog current signal (the current i2) into a frequency signal of a digital form which is hardly affected by disturbance such as noise. Accordingly, the output signal of the processing circuit 4 is reliable and accurate.
With reference back to FIG. 1, a bias current circuit 5 is connected to the processing circuit 4 and the current mirror circuit 2. The bias current circuit 5 includes transistors 51 and 52, and a resistor 53. The bases of the transistors 51 and 52, and the collector of the transistor 52 are connected in common to one end of the resistor 53. The other end of the resistor 53 is connected to the positive power supply terminal T1. The emitters of the transistors 51 and 52 are connected in common to the ground terminal T2. The collector of the transistor 51 is connected to a point of a line along which the current i2 flows.
The current i2 is provided with a predetermined offset by a bias current i3 flowing into the collector of the transistor 51. As shown in the portion (a) of FIG. 3, the current i2 assumes a given positive value (a given non-zero value) equal to the bias current i3 when the illuminance at the photosensitive element 1 is approximately equal to zero. The current i2 linearly increases from the positive value i3 in accordance with an increase in the illuminance from about 0 to 10,000 1x. Therefore, the processing circuit 4 outputs a non-zero-frequency signal even when the illuminance at the photosensitive element 1 is approximately equal to zero. This is advantageous in deciding whether or not a signal line leading from the processing circuit 4 is broken by referring to the output signal of the processing circuit 4.
As shown in FIG. 1, the processing circuit 4 includes a limiter circuit 6. The limiter circuit 6 has transistors 61 and 62, and resistors 63, 64, and 65. The transistors 61 and 62 are connected to compose a comparator. The resistor 63 forms an input circuit followed by the comparator. The resistors 64 and 65 are connected in series to form a voltage dividing circuit. The junction between the resistors 64 and 65 is connected to the comparator. The series combination of the resistors 64 and 65 are connected across the dc power source. The resistors 64 and 65 cooperate to apply a predetermined reference voltage to the comparator. The output terminal of the comparator, that is, a circuit point P within the limiter circuit 6 is connected to the base of a transistor 40 located outside the limiter circuit 6. The transistor 40 is followed by a current mirror circuit (no reference character) for generating the previously-indicated currents i21 and i22.
A current i23 proportional to the current i2 is generated by a current mirror circuit (no reference character). The current i23 flows from the current mirror circuit into the resistor 63 within the limiter circuit 6. When the voltage across the resistor 63, which is proportional to the magnitude of the current i23, exceeds the predetermined reference voltage, the output signal of the comparator in the limiter circuit 6 (the voltage at the circuit point P) is in a high logic level state so that the transistor 40 is in an on stage. Therefore, in this case, the current i21 is clamped at a predetermined upper limit. Specifically, the upper limit of the current i21 depends on the predetermined reference voltage to the comparator within the limiter circuit 6. The upper limit of the current i21 can be adjusted according to the resistances of the resistors 64 and 65.
In the case where the output signal of the processing circuit 4 is used by only an automatic light system, it is preferable that the upper limit of the current i21 corresponds to slightly greater than an illuminance of 2,000 1x. In the case where the output signal of the processing circuit 4 is used by both an automatic light system and a meter luminance correcting system, it is preferable that the upper limit of the current i21 corresponds to an illuminance of about 10,000 1x.
As shown in the portions (a) and (c) of FIG. 3, when the current i21 reaches its upper limit, the frequency of the output signal of the processing circuit 4 reaches its upper limit. As shown in the portion (a) of FIG. 3, in the case where the upper limit of the current i21 corresponds to an illuminance of about 10,000 1x, the current i21 remains equal to its upper limit when the illuminance at the photosensitive element 1 is equal to or greater than about 10,000 1x. Also, as shown in the portion (c) of FIG. 3, the frequency of the output signal of the processing circuit 4 remains equal to its upper limit when the illuminance at the photosensitive element 1 is equal to or greater than about 10,000 1x. This frequency saturation is advantageous in preventing the occurrence of wrong operation of an automatic light system or a meter luminance correcting system due to an excessively high frequency of the output signal of the processing circuit 4.
With reference to FIG. 4, the frequency of the output signal of the processing circuit 4 rises in proportion to the illuminance at the photosensitive element 1 in the range equal to or less than about 10,000 1x. Even in the absence of light incident to the photosensitive element 1, the output signal of the processing circuit 4 has a predetermined non-zero frequency (a predetermined offset frequency) corresponding to the previously-indicated bias current i3. The predetermined non-zero frequency is provided by the bias current circuit 5. The frequency of the output signal of the processing circuit 4 remains equal to its upper limit when the illuminance at the photosensitive element 1 exceeds about 10,000 1x. This frequency saturation is provided by the limiter circuit 6.
As understood from the previous explanation, the current mirror circuit 2 serves to generate the signal currents i1 and i2 in response to the light current iL. The signal currents i1 and i2 are proportional to the light current iL. The signal currents i1 and i2 are separate from each other. The signal currents i1 and i2 are processed by the processing circuits 3 and 4 respectively. The separation between the signal currents i1 and i2 ensures that adequate S/N ratios are available regarding both the output signals of the processing circuits 3 and 4. The current mirror circuit 2 makes it possible to easily provide the signal currents i1 and i2 proportional to the light current iL.
As previously explained, compatibility with a conventional sunshine sensor can be provided by the processing circuit 3. This is an advantage of the light sensing apparatus of FIG. 1.
The processing circuit 4 outputs the frequency signal which is hardly affected by disturbance such as noise. Therefore, the output signal of the processing circuit 4 is accurate and reliable.
As previously explained, the processing circuit 4 outputs a non-zero-frequency signal even when the illuminance at the photosensitive element 1 is approximately equal to zero. This is advantageous in deciding whether or not a signal line leading from the processing circuit 4 is broken by referring to the output signal of the processing circuit 4.
The limiter circuit 6 provides the upper limit on the frequency of the output signal of the processing circuit 4. This is advantageous in preventing the occurrence of wrong operation of an automatic light system or a meter luminance correcting system due to an excessively high frequency of the output signal of the processing circuit 4.
Second Embodiment
FIG. 5 shows a portion of a second embodiment of this invention which is similar to the embodiment of FIG. 1 except for design changes indicated later. The second embodiment in FIG. 5 includes a processor 600 instead of the limiter circuit 6 (see FIG. 1). In addition, the transistor 23 in the current mirror circuit 2 (see FIG. 1) is replaced by transistors 23a and 23b. Currents i4 and i5 proportional to the light current iL flow into the collectors of the transistors 23a and 23b respectively.
With reference to FIG. 5, a current mirror circuit connected to the transistor 23a and including a transistor 71 generates a current i41 proportional to the current i4. The transistor 71 and a resistor 72 are connected in series. The series combination of the transistor 71 and the resistor 72 is connected across the dc power source.
A current mirror circuit connected to the transistor 23b and including a transistor 73 generates a current i51 proportional to the current i5. The transistor 73 and a resistor 74 are connected in series. The series combination of the transistor 73 and the resistor 74 is connected across the dc power source. A constant-current circuit 77 is connected across the resistor 74. The transistor 73, the resistor 74, and the constant-current circuit 77 are contained in the processor 600. The resistance of the resistor 74 is smaller than the resistance of the resistor 72.
The processor 600 includes a constant-current circuit 75 and a resistor 76 which are connected in series. The series combination of the constant-current circuit 75 and the resistor 76 is connected across the dc power source.
The processor 600 also includes an operational amplifier 78 having three non-inverting input terminals. A first non-inverting input terminal of the operational amplifier 78 is connected to the junction "a" between the transistor 71 and the resistor 72. A second non-inverting input terminal of the operational amplifier 78 is connected to the junction "b" between the transistor 73 and the resistor 74. A third non-inverting input terminal of the operational amplifier 78 is connected to the junction "c" between the constant-current circuit 75 and the resistor 76. The operational amplifier 78 selects the lowest voltage from among the voltages at the junctions "a", "b", and "c", and outputs the selected lowest voltage to the base of the transistor 40 following the processor 600.
As previously explained, the current i4 is proportional to the light current iL. The current i41 is proportional to the current i4. The current i41 flows through the resistor 72. The voltage across the resistor 72, which is proportional to the magnitude of the current i41, is inputted into the operational amplifier 78 via the junction "a".
As previously explained, the current i5 is proportional to the light current iL. The current i51 is proportional to the current i5. The current i51 flows through the resistor 74. An additional current provided by the constant-current source 77 also flows through the resistor 74. The voltage across the resistor 74, which is proportional to the magnitude of the sum of the current i51 and the additional current, is inputted into the operational amplifier 78 via the junction "b".
The constant-current circuit 75 generates a constant current i60. The constant current i60 flows through the resistor 76. The voltage across the resistor 76, which is proportional to the magnitude of the constant current i60, is inputted into the operational amplifier 78 via the junction "c".
The current i41 provides an illuminance-frequency characteristic line L31 in FIG. 6. The current i51 provides an illuminance-frequency characteristic line L32 in FIG. 6. The constant current i60 provides an illuminance-frequency characteristic line L33 in FIG. 6. The slope of the illuminance-frequency characteristic line L31 depends on the resistance of the resistor 72. The slope of the illuminance-frequency characteristic line L32 depends on the resistance of the resistor 74. Since the resistance of the resistor 72 is greater than the resistance of the resistor 74, the slope of the illuminance-frequency characteristic line L31 is steeper than the slope of the illuminance-frequency characteristic line L32.
The operational amplifier 78 selects the lowest voltage from among the voltages at the junctions "a", "b", and "c" which correspond to the illuminance-frequency characteristic lines L31, L32, and L33 respectively. The operational amplifier 78 outputs the selected lowest voltage to the base of the transistor 40 following the processor 600. As shown in FIG. 6, a resultant illuminance-frequency characteristic agrees with a combination of the solid portions of the illuminance-frequency characteristic lines L31, L32, and L33.
With reference to FIG. 7, an available signal frequency increases at a steep slope as the illuminance at the photosensitive element 1 increases from about zero to a first boundary point equal to about 1,000 1x. The relation between the signal frequency and the illuminance in this range is provided by the illuminance-frequency characteristic line L31. This illuminance range is designed for an automatic light system. The steep slope of the frequency increase provides a higher accuracy of the signal frequency. The available signal frequency increases at a gentle slope as the illuminance at the photosensitive element 1 increases from the first boundary point to a second boundary point equal to about 10,000 1x. The relation between the signal frequency and the illuminance in this range is provided by the illuminance-frequency characteristic line L32. The available signal frequency remains equal to its upper limit as the illuminance at the photosensitive element 1 exceeds the second boundary point. The relation between the signal frequency and the illuminance in this range is provided by the illuminance-frequency characteristic line L33.
Third Embodiment
FIG. 8 shows a portion of a third embodiment of this invention which is similar to the embodiment of FIG. 1 or the embodiment of FIG. 5 except for design changes indicated later.
In the embodiment of FIG. 8, a current mirror circuit connected to the photosensitive element 1 includes the transistor 21 and at least three transistors 24, 25, and 26. The transistors 21, 24, 25, and 26 are connected so that currents iLl, iL2, and iL3 proportional to the light current iL will flow into the collectors of the transistors 24, 25, and 26 respectively. Signals represented by the currents iL1, iL2, and iL3 are processed by processing circuits for different purposes respectively.
Other Embodiments
At least one of the processing circuits 3 and 4 in the embodiments of FIGS. 1 and 5 may be replaced by a processing circuit for a sun direction detecting sunshine sensor which outputs a plurality of current signals, a processing circuit designed to output a voltage signal, or a processing circuit for connection with an intra-vehicle LAN (local area network) which outputs serial data.
The current mirror circuits in the embodiments of FIGS. 1, 5, and 8 may be replaced by circuits which generate current signals or voltage signals having proportional relations with the light current iL.
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A light sensing apparatus for different control systems includes a photosensitive element which generates a light current depending on light incident thereto. A pre-circuit connected to the photosensitive element is operative for generating separate basic signals in response to the light current generated by the photosensitive element. Processing circuits connected to the pre-circuit are active simultaneously for converting the basic signals generated by the pre-circuit into conversion-resultant signals having different forms respectively. The conversion-resultant signals are outputted to the control systems respectively. At least one of the processing circuits may include an oscillation circuit which oscillates at a frequency depending on related one of the basic signals generated by the pre-circuit.
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This application is a divisional of U.S. patent application Ser. No. 09/997,222 filed Nov. 28, 2001, by applicants Tetsuji Ueda et al., now abandoned.
FIELD OF THE INVENTION
The present invention relates to a blank for an optical member of quartz glass which includes a contour of the optical member with an overdimension and has a surface which is defined by a lower side, an upper side opposite the lower side and spaced apart therefrom and by an outer edge extending around a center axis.
Furthermore, the present invention relates to a vessel for heat-treating a cylindrical blank for an optical member of synthetic quartz glass, which includes the contour of said optical member with an overdimension and comprises an interior for receiving said blank and SiO 2 powder for filling intermediate spaces, said interior having a removable upper side and a lower side opposite said upper side and spaced apart therefrom, and an outer edge connecting upper side and lower side and extending around a center axis.
Moreover, the invention relates to a method for producing a blank for an optical member of quartz glass, comprising a step of providing said blank which includes the contour of the optical member to be produced with an overdimension and has a surface which is defined by a lower side, an upper side opposite said lower side and spaced apart therefrom and by an outer edge extending around a center axis, and of subjecting said blank to a thermal treatment and subsequently cooling the same.
BACKGROUND
Conventionally, the technology of optical lithography comprising transferring a pattern on a photomask to a wafer by using a laser radiation has been widely used in the aligners for producing semiconductor integrated circuits because of its advantage in process cost as compared with other technologies using electron beam or an X-ray.
Recently, as the LSIs increase their fineness and the degree of integration, light sources having shorter wavelength are being used for the exposure, and there have been practically used an aligner using an i line (having a wavelength of 365 nm) which enables the formation of patterns 0.4 to 0.5 μm in pattern line widths, or a KrF excimer laser (emitting a radiation 248.3 nm in wavelength) which enables patterns 0.25 to 0.35 μm in pattern line widths. More recently, an ArF excimer laser (emitting a radiation 193.4 nm in wavelength), which enables the formation of patterns 0.13 to 0.2 μm in pattern line widths, has been developed, and the study to bring it in practical use is under way. However, the optical members for use in the ArF excimer laser lithographic apparatuses demand that they satisfy, at a never required high level, a further increased uniformity, high transmitting properties, an excellent resistance against laser radiations, etc.
As a material for an optical member satisfying the requirements above, a synthetic quartz glass of high purity is being used, and improvements in the optical transmittance and the resistance against laser radiations of such a material have been made by optimizing the production conditions, and, at the same time, a further improvement in optical characteristics such as uniformity and birefringence is being made. Among them, the improvement in uniformity and the reduction of birefringence can be realized only by applying a heat treatment (annealing treatment) accompanying a gradual cooling in the production process of the optical member to thereby remove the stress of the quartz glass. As such a heat treatment, a method comprising holding the quartz glass inside the heating furnace at a high temperature for a long duration of time has been believed to be a general method.
However, on lowering the temperature during the annealing treatment above, temperature distribution generates between the central portion and the outer peripheral portion of the object being treated. Such a temperature distribution remains as a difference in density even after the completion of the annealing treatment, and this led to an insufficient improvement concerning the distribution in refractive index and the birefringence.
Accordingly, in order to further improve the distribution in refractive index and the birefringence of a quartz glass, there has been proposed a method of applying the annealing treatment to the object while placing it inside a ring, a vessel, or a powder; the aim of which being controlling the temperature distribution by decreasing the rate of lowering the temperature for the outer periphery of the object. This method can surely improve the distribution in refractive index and the birefringence of a quartz glass to a certain degree, but the effect was found still unsatisfactory.
A blank of the generic type and a method of producing the same are known from EP-A 401 845. The production of a lens for a microlithographic device is described therein. To this end a rod-shaped ingot of synthetic quartz glass is cut down into a number of plate-shaped blanks, an optical member being normally obtained from each of the blanks. In comparison with the outer contour of the optical member to be produced, each of the blanks is provided with an overdimension which is removed in the course of the further manufacturing process.
The homogeneity of the quartz glass blank depends on both a uniform chemical composition and a homogeneous distribution of the so-called “fictive temperature” across the blank. The fictive temperature is a parameter which characterizes the specific network structure of the quartz glass. A standard measuring method for determining the fictive temperature on the basis of a measurement of the Raman scattering intensity at a wave number of about 606 cm −1 is described in “Ch. Pfleiderer et al.: “The UV-induced 210 nm absorption band in fused silica with different thermal history and stoichiometry”; J. Non-Cryst. Solids 159 (1993) 145–143”.
To reduce mechanical stresses within the plate-shaped blank and to achieve a homogeneous distribution of the fictive temperature, the blank is normally annealed with great care. EP-A 401 845 suggests an annealing program in which the blank is subjected to a holding time for 50 hours at a temperature of about 1100° C. and is subsequently cooled in a slow cooling step at a cooling rate of 2°/h to 900° C. and then in a closed furnace to room temperature. During such a temperature treatment local changes in the chemical composition of the blank, in particular in the areas near the surface, may occur because of an outdiffusion of components. In this respect a particularly long annealing time of the blank for setting a distribution of the fictive temperature that is as uniform possible may even have a disadvantageous effect on the homogeneity of the blank.
The surface of the known blank is defined by an even lower side, an even upper side opposite thereto and by an outer cylindrical surface which connects upper side and lower side. The surface surrounds the contour of the member with an overdimension. An increase in the overdimension alone does not constitute a preferred measure for reducing outdiffusion from the area of the contour of the member during annealing, for larger dimensions of the blank require longer annealing times to ensure a uniform distribution of the fictive temperature within the contour of the member. Longer annealing times increase the manufacturing costs, which in turn promotes outdiffusion. Moreover, a large overdimension entails higher manufacturing costs because of larger losses in material.
SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a blank from which optical members of a high homogeneity can be made. It is a further object of the invention to provide a vessel for heat treatment and a heat treatment method capable of efficiently heat-treating a synthetic quartz glass for optical use and improved in homogeneity.
As for the blank, this object starting from the above-mentioned blank is achieved according to the invention in that there is provided a surrounding thickened portion which begins in the area of the outer edge and extends towards the center axis and in which the distance between lower side and upper side is larger than in the area of the center axis.
As has already been mentioned, the homogeneity of the quartz glass is substantially determined by the distribution of the fictive temperature on the one hand and by the distribution of the chemical components of the quartz glass on the other hand. Some of the chemical components to be paid attention to with respect to homogeneity are the hydroxyl groups (OH), the Si—H groups (SiH) and molecularly dissolved hydrogen (H 2 ). A basic prerequisite for homogeneous quartz glass is that said components are homogeneously distributed within the SiO 2 network. The local concentration of the components OH, Si—H and H 2 at any desired point “X” within the blank is obtained due to a balanced reaction which can be described as follows:
Si—O—Si+H 2 ⇄Si—OH+Si—H (1)
The position of the equilibrium depends on the temperature, the OH—, SiH— and the hydrogen concentration. Apart from the local temperature, particular attention must here be paid to the local hydrogen concentration because this concentration can be strongly influenced by outdiffusion during annealing on account of the high diffusion constant of hydrogen in quartz glass, whereas the OH concentration is hardly influenced by the annealing process.
The invention exploits the finding that the position of the chemical equilibrium according to equation (1) has not only direct impacts on the homogeneity of the quartz glass, but also influences the setting of the fictive temperature. It has been found that a homogeneous distribution of the fictive temperature can only be achieved if the position of the balanced reaction (1) is homogeneously distributed at the same time.
Since both the fictive temperature and the chemical equilibrium according to (1) depend on the concentration of the participating components and also on the absolute temperature, an ideal temperature distribution is one that is as homogeneous as possible at any time during annealing (in particular during the cooling phase), on the boundary condition that the absolute concentrations of said chemical components are also homogeneously distributed in the blank at the beginning of the process. However, the setting of the equilibrium distribution of temperature and hydrogen is counteracted by the heat conduction of the blank on the one hand and by the diffusion of hydrogen in quartz glass on the other hand.
Nevertheless, the cylindrical plate geometry of the blank which has so far been standard during temperature treatment can also be improved under these boundary conditions, for the plate geometry is not suited for achieving a homogeneous distribution of said components and a homogeneous temperature distribution in the area of the contour of the member for the following reasons:
1. When a quartz glass blank is cooled, a temperature gradient is automatically obtained which ascends from the interior to the exterior and descends in said direction during the heating-up phase. Therefore, a locally different chemical equilibrium according to equation (1) is automatically obtained within the quartz glass blank in dependence upon the local temperature. 2. In the course of the temperature treatment the hydrogen content decreases because of outdiffusion within the quartz glass blank (unless outdiffusion is counteracted, e.g. by maintaining a sufficiently high partial H 2 pressure in the ambient atmosphere). In this process the areas of the quartz glass blank near the surface are first depleted with formation of a concentration gradient from the interior to the exterior, which also results in a locally different setting of the chemical equilibrium (1). 3. A temperature gradient according to 1, as well as a concentration gradient and, as a consequence, a locally different chemical equilibrium (1) according to 2, result in a locally different viscosity. The viscosity, in turn, has also an effect on the setting of the local network structure of the quartz glass and thus on the fictive temperature, so that local differences in the viscosity curve over time also result in an inhomogeneous distribution of the fictive temperature.
The effects described under 1, to 3. (temperature gradient, concentration gradient, locally different viscosity curve), which are disadvantageous with respect to homogeneity, are reduced in the method according to the invention by a thickened portion extending around the outer edge. Within this thickened portion the distance between lower side and upper side, and thus the distance between the contour of the member and the free surface, is larger than in the area of the center axis of the blank. The thickened portion begins in the area of the outer edge, i.e. directly on or slightly behind the same, and extends from there over the whole surface of the blank or a part thereof towards the center axis.
“Contour of the member” means the area of the blank which is reduced by the overdimension and from which the optical member is made in the end. The contour of the member is of a rectangular shape surrounding the dimensions of the optical member.
The thickened portion forms part of the overdimension of the blank. According to the invention the overdimension is here larger on the peripheral portion than in the central portion. It has been found that smaller temperature gradients are formed in the area of the contour of the member due to such an accumulation of quartz glass mass in the peripheral portion of the blank during cooling in the process of the temperature treatment. Peripheral effects which may promote an outdiffusion of hydrogen are minimized because a substantial part of the mass of the blank is concentrated in the peripheral portion. The diffusion of hydrogen out of the area of the member contour is thereby reduced, resulting in this portion in a smaller gradient of the hydrogen concentration. In the end the thickened portion does not significantly increase the overall mass of the blank and the material factor because the additional overdimension can substantially be limited to the edge of the blank.
The geometry of the outer edge of the blank is not decisive for the success of the teaching according to the invention. The outer edge will normally form the edge between upper side or lower side and an outer cylindrical surface; however, it can e.g. also constitute an inwardly or outwardly curved or tapering lateral boundary of the blank.
The thickness of the thickened portion is larger in the area of the outer edge than in the area of the center axis. Accordingly, the distance between lower side and upper side decreases from the edge to the interior. The distance may be shortened in one or several steps. However, it has been found to be of particular advantage when the distance between lower side and upper side decreases continuously across the thickened portion when viewed from the outer edge towards the center axis. Thus, the thickened portion decreases continuously from the outside to the inside over at least a part of the surface of the blank. The continuity of the decrease in the thickened portion counteracts the formation of sudden changes in temperature or concentration within the blank, in particular within the contour of the member. Moreover, the material factor is thereby kept low.
It has turned out to be of particular advantage when the distance decreases faster (more) than linearly. The decrease is e.g. in accordance with an exponential or parabolic function. The thickened portion is here a concave curve from the outside to the inside (hereinafter called “concave annealing form”). It has been found that a concave annealing form during heating and cooling yields a temperature profile which is particularly homogeneous in time and space and has a small gradient within the contour of the member. In comparison with the known blank in the form of a cylinder-shaped plate, as described at the outset, a concave annealing form yields a smaller time change in the heat flow and thus a more homogeneous temperature profile along any desired radial axis within the blank. This is not only an important precondition for the production of low-stress blanks, but also for a homogeneous extension of the position of the chemical equilibrium according to equation (1).
It is true that a spatial temperature gradient can also not be avoided in the case of a concave annealing form. However, on account of the more uniform heat flow during cooling or heating, the maximum temperature difference in the area of the contour of the member is much smaller in the case of a concave annealing form than in a plate-like preform, so that a rather flat temperature distribution is obtained. At the same time, this constitutes a suitable precondition for a more homogeneous distribution of the position of the equilibrium (1) within the contour of the member.
Furthermore, the formation of a gradient of the hydrogen concentration can also not be prevented in the case of a concave annealing form. Nevertheless, a concave annealing form within the contour of the member yields a more homogeneous hydrogen distribution than in the case of a plate-like form. This can be attributed to the fact that the concave annealing form leads to an extension of the mean diffusion path length together with an adjustment of the diffusion path lengths along any radial axes within the blank. In comparison with the plate-like form, this results in a narrower distribution of the diffusion path lengths.
In the final analysis, all of these points contribute to the fact that with a concave annealing form the position of the equilibrium (1) along any radial axis within the blank, and thus also the distribution of the fictive temperature and the viscosity curve over time along said axis, are more homogeneous than in a plate-shaped blank.
Instead of the above-explained exponential or parabolic decrease in the distance between lower side and upper side across the thickened portion, the distance in an alternative, but equally preferred embodiment of the blank of the invention decreases linearly (hereinafter also called linear annealing form). With a temperature treatment using a linear annealing form, the effects regarding the formation of a smaller gradient of the temperature and hydrogen concentration within the blank, and the distribution of the position of the equilibrium (1) within the contour of the member are smaller than in the case of the concave annealing form, but the linear annealing form is easier to manufacture and therefore particularly suited for applications of the optical member where lower demands are made on optical homogeneity.
Preferably, the thickened portion begins on the outer edge. As a result, overdimension and thus material factor and manufacturing costs can be kept small.
Furthermore, it has been found to be of advantage when the thickened portion extends from the center axis to the outer edge. This results in a simplified manufacture of the blank, and geometrical steps and accompanying sudden changes in physical and chemical parameters, which might contribute to optical inhomogeneities, are avoided. Moreover, the above-explained advantageous effect of the thickened portion with respect to a reduction of temperature gradient, concentration gradient and locally different viscosity curve within the contour of the member can be observed over the whole cross-section thereof.
An embodiment of the blank is preferred in which the lower side and the upper side are provided with a thickened portion. The thickened portions facing one another at the lower side and the upper side are normally of a similar or ideally identical geometry. In the last-mentioned case the blank exhibits mirror symmetry, the mirror plane extending in a direction perpendicular to the center axis and in the center between lower side and upper side. The symmetry of the blank facilitates an adjustment of the homogeneity in the optical member, in particular the adjustment of a symmetrical curve of the refractive index.
As for the vessel, the above object is achieved according to the invention starting from the above-mentioned vessel in that said upper side and said lower side in the area of said center axis have a higher thermal conduction than in the area of said outer edge.
The vessel for heat-treating synthetic quartz glass for optical use according to the present invention is utilized for the heat treatment of a synthetic quartz glass blank as an object to be treated, said synthetic quartz glass blank being enclosed inside said vessel in such a manner that SiO 2 powder is filled therein and subjected to heat treatment in a heating furnace; wherein, the space for enclosing the synthetic quartz glass object is flat and cylindrical in shape, and, when seen the vessel as a whole with flat cylindrical synthetic quartz glass to be treated being enclosed and with SiO 2 powder filling the interstices, the degree of heat emission at the center is set higher or lower than that of the surroundings in order to exhibit the function described hereinafter. Since a conventionally employed heating furnace is readily applicable, further explanation thereof is omitted hereinafter.
The cooling rate during annealing of a quartz glass blank is made non uniform by the vessel according to the invention. This shows advantageous effects with respect to the formation of a smaller gradient of the temperature and the hydrogen concentration within the blank and with respect to the distribution of the position of the equilibrium within the contour of the optical member to be produced from it. In this respect reference is made to the above explanations regarding the blank of the invention and the preferred developments thereof.
(1) The vessel according to the invention is a vessel for heat-treating a cylindrical blank for an optical member of synthetic quartz glass, which includes the contour of said optical member with an overdimension and comprises an interior for receiving said blank and SiO 2 powder for filling intermediate spaces, said interior having a removable upper side and a lower side opposite said upper side and spaced apart therefrom, and an outer edge connecting upper side and lower side and extending around a center axis, characterized in that said upper side and said lower side in the area of said center axis have a higher thermal conduction than in the area of said outer edge.
It shows the features according to the following preferred embodiments
(2) The vessel described in (1), wherein lower side and upper side in the area of said outer edge have a larger wall thickness than in the area of said center axis. (3) The vessel described in (2), wherein upper side and lower side are each equipped with a surrounding thickened portion which begins in the area of said outer edge and extends towards said center axis and in which the wall thickness is greater than in the area of said center axis. (4) The vessel described in (3), wherein the wall thickness of lower side and upper side decreases continuously across said thickened portion when viewed from said outer edge towards said center axis. (5) The vessel described in (4), wherein said wall thickness decreases faster than linearly. (6) The vessel described in (4), wherein said wall thickness decreases linearly. (7) The vessel described in (3), wherein the wall thickness of lower side and upper side decreases in steps across said thickened portion when viewed from said outer edge towards said center axis. (8) The vessel described in (2), wherein the wall thickness of upper side and lower side is reduced by recesses whose number, depth or width is each time larger in the area of said center axis than in the area of said outer edge, with the proviso that said upper side and said lower side have a higher thermal conduction in the area of said center axis than in the area of said outer edge. (9) The vessel described in (1), wherein said interior is defined by walls of quartz glass. (10) The vessel described in (9), wherein said upper side and said lower side are made from quartz glass of a higher thermal conductivity, and said outer edge from quartz glass of a lower thermal conductivity. (11) The vessel described in (1), wherein said SiO 2 powder is a synthetically produced SiO 2 powder having a sodium content of less than 30 wt. ppb. (12) The vessel described in (1), wherein said SiO 2 powder is a synthetically produced SiO 2 powder having a hydrogen content of at least 1.0×10 19 molecules/cm 2 . (13) The vessel described in (1), wherein the outer diameter of said upper side is smaller than the inner diameter of said outer edge.
As for the method, the above-mentioned object starting from the above-mentioned method is achieved according to the invention in that measures are provided which during cooling keep the heat conduction in the area of said outer edge lower than in the area around said center axis.
The method shows the advantageous effects with respect to the formation of a smaller gradient of the temperature and the hydrogen concentration within the blank and with respect to the distribution of the position of the equilibrium (1) within the contour of the member. In this respect reference is made to the above explanations regarding the blank of the invention and the preferred developments thereof.
According to a first aspect of the method, the measures which during cooling keep the heat conduction in the area of said outer edge lower than in the area around said center axis consist in using a blank as described above, which is a blank for an optical member of quartz glass which includes a contour of said optical member with an overdimension and the surface of which is defined by a lower side, an upper side opposite said lower side and spaced apart therefrom and by an outer edge extending around a center axis. The blank is characterized by that there is provided a surrounding thickened portion which begins in the area of said outer edge and extends towards said center axis, and in which the distance between lower side and upper side is greater than in the area of said center axis.
The blank according to the invention is characterized by a surrounding thickened portion which begins in the area of the outer edge and extends in the direction of the center axis and in which the distance between lower side and upper side is greater than in the area of the center axis of the blank. When a blank of such a configuration is subjected to an annealing treatment for eliminating mechanical stresses, the thickened portion develops advantageous effects with respect to the formation of a smaller gradient of the temperature and the hydrogen concentration within the blank and with respect to the distribution of the position of the equilibrium (1) within the contour of the member. In this respect reference is made to the above explanations regarding the blank of the invention and the preferred developments thereof.
According to a second aspect of the method, the measures which during cooling keep the heat conduction in the area of said outer edge lower than in the area are measures consist in introducing said blank into a vessel as described above, which is a vessel for heat-treating a cylindrical blank for an optical member of synthetic quartz glass, which includes the contour of said optical member with an overdimension and comprises an interior for receiving said blank and SiO 2 powder for filling intermediate spaces, said interior having a removable upper side and a lower side opposite said upper side and spaced apart therefrom, and an outer edge connecting upper side and lower side and extending around a center axis, wherein said upper side and said lower side in the area of said center axis have a higher thermal conduction than in the area of said outer edge. The preferred method additionally comprises filling intermediate spaces between said blank and said vessel with SiO 2 powder and in subjecting said blank surrounded by said SiO 2 powder in said vessel to a thermal treatment by introducing said vessel into a furnace and by heating and subsequently cooling the same.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall now be explained in more detail with reference to embodiments and a drawing. The drawing is a schematic illustration showing in detail in
FIG. 1 A diagram showing a heat treatment vessel according to an embodiment of the present invention together with a synthetic quartz glass body to be treated and with SiO 2 powder, wherein (A) shows a vertical cross section view, and FIG. 1(B) shows a cross section view taken along line B—B in FIG. 1(A) ,
FIG. 2 A diagram showing the temperature distribution with cooling obtained on the case according to the present invention and in a prior art example, wherein (A) shows a case of the present example and (B) shows a case of a prior art example,
FIG. 3 A diagram showing the fluctuation in refractive index Δn of a synthetic quartz glass for optical use achievable in the present example and in a prior art example, wherein (A) shows a case of the present example and (B) shows a case of a prior art example,
FIG. 4 A vertical cross section of a heat treatment vessel according to another embodiment of the present example,
FIG. 5 A vertical cross section of a heat treatment vessel according to a still other embodiment of the present example,
FIG. 6 A vertical cross section of a heat treatment vessel according to a yet other embodiment of the present example,
FIG. 7 A diagram showing an example of a temperature profile employed in the heat treatment method for a synthetic quartz glass for optical use according to the present invention,
FIG. 8 A vertical cross section of a heat treatment vessel used in Example 1,
FIG. 9 A vertical cross section of a heat treatment vessel used in Example 2,
FIG. 10 A vertical cross section of a heat treatment vessel used in Example 3,
FIG. 11 A diagram showing the table provided therein the optical properties and the like for the Examples and Comparative Examples,
FIG. 12 a first embodiment of a blank according to the invention for an optical member, in a side view,
FIG. 13 a blank for an optical member according to the prior art, in a side view,
FIG. 14 a second embodiment of a blank according to the invention for an optical member, in a side view, and
FIG. 15 a further embodiment of a blank according to the invention for an optical member, in a side view.
DETAILED DESCRIPTION
Referring to the attached drawings, a specific example of the vessel 10 for use in the heat treatment is described below.
Referring to FIG. 1 , the vessel 10 for heat treatment comprising a cylindrical enclosing space 10 a similar to the flat cylindrical synthetic quartz glass blank G to be enclosed therein, and is equipped with a circular side wall 12 , a bottom plate 14 constituting a bottom wall, and a lid 16 constituting an upper wall. The circular side wall 12 and the bottom plate 14 may be provided separated or integrated into a monolithic body.
The volume of the enclosing space 10 a of the vessel 10 for heat treatment is provided 1.5 times or larger than the volume of the synthetic quartz glass blank to be treated, and particularly preferably, it is provided at a volume 2 to 10 times as large as that of the synthetic quartz glass blank.
Since the synthetic quartz glass blank G to be treated is provided at a diameter of from 50 to 200 mm and a thickness of about 30 to 200 mm, the volume of the space 10 a for enclosing the object is, preferably, in a range of from 450 to 250000 cm 3 .
The bottom plate 14 and the lid 16 above each have a concave lens-like shape on one side. The curved plane of the concave plane provided on one side may be a secondary curved plane, a spherical plane, or an aspheric plane. The degree of concave of the spherical plane is determined by measuring the rate of heat emission of various portions on cooling, i.e., the difference in cooling rate. This is described hereinafter.
The Na content of the vessel 10 for heat treatment preferably contains Na at a concentration of 100 ppb or less, particularly preferably 40 ppb or less, and further preferably, 5 ppb or less. Although the amount of Na that reaches the synthetic quartz glass blank G is limited because Na discharged from the vessel, etc., is mostly trapped by the SiO 2 powder described hereinafter, the Na content of the vessel 10 above is preferably limited in the range above.
Further, in the present invention, the vessel 10 for heat treatment above is filled with SiO 2 powder 20 (see FIG. 1 ) in such a manner that it covers the surroundings of the synthetic quartz glass blank G that is the object to be treated. As the SiO 2 powder, there can be used a SiO 2 powder doped with hydrogen, which is obtained by previously subjecting the powder to a high pressure hydrogen treatment. In this case, the concentration of hydrogen molecules that are dissolved in the hydrogen-doped SiO 2 powder is preferably 1×10 19 molecules/cm 3 or higher, particularly preferably, 2 to 5×10 19 molecules/cm 3 , in average. The concentration of the dissolved hydrogen molecules may be taken by the average over the entire SiO 2 powder, and hence, the powder thus doped with hydrogen may be used mixed with a powder not doped with hydrogen.
The SiO 2 powder is provided to prevent hydrogen molecules from escaping from the synthetic quartz glass blank G that is heat treated as the object of the heat treatment. The total weight of the SiO 2 powder above preferably accounts for 25% or more, more preferably, for 50 to 200%, of the total weight of the synthetic quartz glass blank to be treated. If the total weight of the SiO 2 powder above should account for less than 25%, it becomes difficult to sufficiently achieve the object of preventing the discharge of hydrogen molecules from the synthetic quartz glass blank; if the total weight should exceed 200%, industrial excess generates as to impair the efficiency of the process.
The Na content of the SiO 2 powder above is preferably 30 ppb or lower, and particularly preferably, 10 ppb or lower. Although it is better for the lower the content of Na, the lower limit at present is about 5 ppb.
The SiO 2 powder above consists of particles in which 95% by weight or more thereof have a particle diameter in a range of, preferably, from about 0.1 to 1,000 μm, and more preferably, in a range of from about 0.5 to 500 μm. If a particle with a size more than 100 μm should be mixed, there is fear of making it impossible to dissolve sufficient amount of hydrogen molecules into a part of the powder during the high pressure hydrogen treatment; on the other hand, if a particle with a size less than 0.1μm should be mixed, there occurs a problem in handling, and this is not preferred. Furthermore, if the particle size of the powder becomes too large, it becomes difficult to achieve a sufficiently high packing density; hence, it is preferred that a powder containing particles exceeding 1,000 μm in particle diameter is not used. By also taking this point into consideration, it is preferred not to use a powder containing particles exceeding 1,000 μm in particle diameter. However, powders differing in particle size may be mixed so long as the particle diameter falls within a range of from 0.1 to 1000 μm, and it is more preferred to use a powder having a wider range in particle diameter, because such a powder often increases the packing properties. However, the effect of the present invention can be achieved so long as the particle diameter of the SiO 2 powder used substantially falls within the range above. More specifically, there is no practical problem even if less than 5% of the entire weight of the SiO 2 powder above should fall outside of the particle size range defined above.
In view of the conditions above, it is particularly preferred that the SiO 2 powder above is a synthetic quartz glass powder.
The method for heat treating a synthetic quartz glass for optical use by performing a heat treatment in the heating furnace according to the present invention comprises using the vessel for heat treatment described above, while covering the surroundings of the synthetic quartz glass blank to be treated with SiO 2 powder. The heat treatment may be carried out in air. The temperature and the time of retention, the heating rate, the cooling rate, and other thermal treatment conditions may be set similar to those generally used in an ordinary heat treatment.
In accordance with the present invention, there can be obtained a synthetic quartz glass for optical use having a fluctuation in refractive index Δn of 1.0×10 −6 or less along the direction of the radius. Such an effect is achieved in the present invention, because, as is shown by dots and lines in FIG. 2(A) , the use of the vessel for heat treatment above achieves an approximately uniform cooling rate in the direction of the radius (of the entire structure inclusive of the vessel for heat treatment, the synthetic quartz glass blank, and the SiO 2 powder) during cooling. In contrast to this, in case of using a vessel having a bottom plate and a lid of a uniform thickness, as shown in FIG. 2(B) , the cooling rate generally tends to become higher for the surroundings as compared with the central portion while the density of the material increases towards the peripheral portions. Hence, the fluctuation in refractive index Δn increases as is shown in FIG. 3(A) . In accordance to the present invention, on the contrary, the fluctuation in refractive index Δn can be minimized as shown in FIG. 3(B) .
As described above, in accordance with the present invention, the fluctuation in refractive index Δn along the direction of the radius of the synthetic quartz glass for optical use can be controlled by controlling the cooling rate in each of the portions. Thus, in case of using a plurality of glasses in combination, they can be assembled in such a manner to correct the fluctuation in refractive index Δn of other glasses.
To set the cooling rate of the synthetic quartz glass blank to be treated (i.e., of the entire structure inclusive of the vessel for heat treatment, the synthetic quartz glass blank, and the SiO 2 powder) uniform along the direction of radius during cooling by a method other than that described above, the cross section of the bottom plate 14 a and the lid 16 a may be provided in a step-wise morphology as shown in FIG. 4 ; otherwise, as shown in FIG. 5 , there can be employed means such as providing slits 22 a and 22 b to the central portion of the bottom plate 14 a and the lid 16 a.
Furthermore, as shown in FIG. 6 , the diameter of the bottom wall 14 c and the upper wall 16 c may be set slightly smaller than the inner diameter of the side wall 12 a , while constituting the bottom wall 14 c and the upper wall 16 c with a quartz glass having a relatively high degree of heat emission and employing a quartz glass having a relatively low degree of heat emission for the side wall 12 a . As a quartz glass having a relatively high degree of heat emission, there can be mentioned a transparent quartz glass, and, as a quartz glass having a relatively low degree of heat emission, there can be mentioned an opaque quartz glass.
In case the bottom plate and the lid are provided at a uniform thickness, the present inventors knew through experience that, depending on the temperature conditions and the like during cooling, there occurs a case in which the cooling rate at the central portion of the synthetic quartz glass blank to be treated becomes higher.
In such a case, it is preferred to control the cooling rate by setting the thickness and the like of the bottom plate and the lid reversed to the case above.
More specifically, in enclosing the flat cylindrical synthetic quartz glass blank to be treated in the vessel with SiO 2 powder filling the interstices and considering the whole structure, the degree of heat emission of the central portion may be set higher than that of the peripheral portion depending on the cooling conditions. In such a case, for instance, the bottom wall and the upper wall may be provided in a convex shape, the thickness of the central portions of the bottom wall and the upper wall is increased in a step-wise manner toward the center portion, or the thickness of the central portions of the bottom wall and the upper wall may be set larger than that of the peripheral portions. Otherwise, in case of a shape shown in FIG. 6 above, the bottom wall and the upper wall may be constructed from a quartz glass having a relatively high degree of heat emission while constructing the side wall with a quartz glass having a relatively low degree of heat emission.
The synthetic quartz glass for optical use available by the present invention contains dissolved hydrogen molecules at a concentration of 2.0×10 17 molecules/cm 3 or higher, and yields an initial transmittance of 99.7% or higher for a radiation 193.4 nm in wavelength. Particularly preferably, the concentration of dissolved hydrogen molecules is 5×10 17 molecules/cm 3 or higher. If the concentration of dissolved hydrogen molecules should be lower than 2×10 17 molecules/cm 3 , the desired resistance against laser radiation cannot be achieved. The upper limit of the concentration of the dissolved hydrogen molecules at present is approximately 5×10 19 molecules/cm 3 .
In the synthetic quartz glass for optical use available by the present invention, the content of Na is preferably 10 ppb or lower, and particularly preferably, 5 ppb or lower. The fluctuation in refractive index Δn along the direction of radius is preferably 1.0×10 −6 or lower.
An embodiment for practicing the present invention is described more specifically below by partly making reference to the drawings. However, it should be understood that the size, materials, shapes, relative arrangement, etc., that are described in the embodiment below are provided simply as examples or explanatory means unless otherwise described, and are by no means limiting the present invention.
As samples of synthetic quartz glass for use as an optical member, four synthetic quartz glass bodies (objects to be treated) each 200 mm in outer diameter and 60 mm in thickness prepared by direct method were prepared. The synthetic quartz glass bodies all contained Na at a concentration of 5 ppb or lower and hydrogen molecules (H 2 ) at a concentration of 1.8×10 18 molecules/cm 3 , and yielded an initial transmittance of 99.8% for a radiation 193.4 nm in wavelength. These samples were treated in the air in the following manner in accordance with the temperature profile shown in FIG. 7 .
EXAMPLE 1
Referring to FIG. 8 , there was used a synthetic quartz glass vessel, which comprises a bottom plate 14 and a lid 16 each provided with a concave (spherical) lens shape on one side and having an outer diameter of 250 mm, a maximum thickness of 40 mm and a minimum thickness of 15 mm, and provided with a side wall 5 mm in thickness. A synthetic quartz glass body, i.e., the object of the treatment, was placed at the center of the vessel, and 2.9 kg of powder consisting of particles 63 to 710 μm in size was filled to bury the synthetic quartz glass body. Then, the heat treatment above was applied to the synthetic quartz glass body. More specifically, the synthetic quartz glass body was subjected to heat treatment by placing it in a heat treatment furnace in the state shown in FIG. 8 . Thus, the total weight of the synthetic quartz glass powder accounted for 70% of the weight of the synthetic quartz glass body.
EXAMPLE 2
As shown in FIG. 9 , a synthetic quartz glass body was subjected to a heat treatment in a manner similar to Example 1 above except for using a vessel comprising a bottom plate 14 and a lid 16 having a step-wise shape on one side.
EXAMPLE 3
As shown in FIG. 10 , a synthetic quartz glass body was subjected to a heat treatment in a manner similar to Example 1 above except for using a vessel comprising a bottom plate 14 and a lid 16 each provided with slits on one side (at a slit interval of 5 mm for the portion corresponding from the center to a radius of 50 mm, at a slit interval of 10 mm for the portion 50 to 80 mm in radius, at a slit interval of 15 mm for the portion 80 to 110 mm in radius, and no slits for the portion exceeding 110 mm in radius).
COMPARATIVE EXAMPLE 1
A synthetic quartz glass body was subjected to a heat treatment in a manner similar to Example 1 above except for using a vessel comprising a bottom plate and a lid with a uniform thickness of 15 mm instead of the bottom plate and the lid described above.
COMPARATIVE EXAMPLE 2
A synthetic quartz glass body was subjected to a heat treatment in a manner similar to Example 1 above except for using a vessel comprising a bottom plate and a lid with a uniform thickness of 40 mm instead of the bottom plate and the lid described above.
Then, measurements were performed on the heat treated synthetic quartz glass objects obtained in the Examples and Comparative Examples above to obtain the fluctuation in refractive index Δn before and after the heat treatment, the birefringence after the heat treatment, an initial transmittance for a radiation 193.4 nm in wavelength, the concentration of hydrogen molecules (H 2 ) after the heat treatment, and the concentration of Na impurity.
The table given in FIG. 11 clearly reads that, in the synthetic quartz glass for optical use obtained as the object of the treatment in accordance with the Examples 1–3, the fluctuation in refractive index Δn is minimized to 0.9×10 −6 or even lower for the synthetic quartz glass G subjected to heat treatment. In contrast to this, the fluctuation in refractive index Δn for the synthetic quartz glass G subjected to heat treatment in accordance with the Comparative Examples was found to be as large as 1.7×10 −6 or even higher. Furthermore, the birefringence of the synthetic quartz glass G subjected to heat treatment in accordance with the Examples 1–3 was lowered to a value 0.45 nm/cm or even lower. In contrast to this, the birefringence of the synthetic quartz glass G subjected to heat treatment in accordance with the Comparative Examples was found to be as large as 1.4 nm/cm or even higher.
In the Examples 1–3 and Comparative Examples, the other characteristics were approximately the same; the initial transmittance for a radiation 193.4 nm in wavelength was each 99.8%, the concentration of hydrogen molecules (H 2 ) after the heat treatment was each about 5×10 17 molecules/cm 3 , and the Na concentration was each 2 ppb.
This method is extremely economical because it allows reuse of the vessel and the quartz powder.
Referring now to the blanks shown in FIGS. 12 to 15 :
Blanks 31 , 32 , 33 , 34 which are made from quartz glass and shown in FIGS. 12 to 15 are each substantially disc-shaped and configured to be rotationally symmetrical about a center axis 35 . Furthermore, blanks 31 , 32 , 33 , 34 are each in mirror symmetry along a mirror plane 36 extending in a direction perpendicular to the center axis 35 and the sheet plane. Each of blanks 31 , 32 , 33 , 34 has an upper side 37 , a lower side 38 and an outer edge 39 . They include an inner portion with a contour 40 of the optical member to be produced from the blank, the member being surrounded on all sides with an overdimension 41 . The distance between lower side 38 and upper side 37 in the area of the outer edge 39 is marked by a distance arrow A in each instance.
FIG. 13 illustrates a blank 32 as has so far been in use for producing lenses for microlithography. Blank 32 is characterized by a simple plate-shaped cylindrical geometry with an even upper side 37 and an even lower side 38 . The distance between lower side 38 and upper side 37 is constant across the whole plate. During the annealing process for reducing mechanical stresses (in particular during cooling), such a geometry of the blank creates distinct temperature gradients from the surface to the interior, in particular from edge 39 to the interior; these can also be noticed within the area of the contour 40 of the member. In dependence upon the local temperature within the blank 32 , this is accompanied by a locally different chemical equilibrium according to equation (1). Moreover, in the course of the temperature treatment the hydrogen content decreases because of outdiffusion, resulting in a concentration gradient from the interior to the exterior, which is again most strongly felt in the area of the edge 39 and accompanied by impacts within the contour 40 of the member. This concentration gradient also results in locally different settings of the chemical equilibrium (1) and of the viscosity. As a result, within the contour 40 there are areas of a different fictive temperature and of a different chemical composition which in the end appear as inhomogeneities, normally as refractive index variations, of the optical member.
In the blank 31 which is schematically shown in FIG. 12 , the formation of such inhomogeneities is minimized during annealing because of the special geometry of the blank. The blank 31 according to the invention is equipped with a concavely inwardly curved upper side 37 and an also concavely inwardly curved lower side 38 (concave annealing form). With such a geometry, the distance “A” between lower side 38 and upper side 37 decreases continuously from the edge 39 towards the center axis 35 . The blank 31 has an outer diameter of 300 mm. The distance A between upper side and lower side in the area of the center axis 5 is 80 mm, and it is 165 mm in the area of the outer edge 39 . The concave inner curvature, starting at the center line 35 , can be described by the following mathematical function:
y= 40+0.02 x 2 [mm]
The contour 40 of the member has the shape of a round even plate with an outer diameter of 250 mm and a thickness of 40 mm.
Thus, when compared with the blank 32 shown in FIG. 13 , the blank 31 is characterized by a thickened portion 42 which decreases from the outer edge 39 to the inside. In particular in the area of the outer edge 39 , this constitutes an increase in the overdimension 41 , which is also present otherwise.
Thanks to the thickened portion 42 , a flatter temperature gradient and a more homogeneous temperature profile than in blank 32 are achieved during the heating and cooling phases. At the same time, a more homogeneous curve of the position of the chemical equilibrium according to equation (1) within the contour 40 of the member is achieved in the blank 31 on account of the thickened portion 42 .
Moreover, the thickened portion 42 prevents hydrogen from diffusing out of the peripheral portions 39 of the blank 31 , whereby the mean diffusion path length is simultaneously extended on the whole. The concave shape of the surface of blank 31 , in particular, accomplishes an adaptation of the diffusion path lengths within the blank 31 and a narrow distribution of the diffusion path lengths so that, despite an outdiffusion of hydrogen during annealing of the blank 31 , a flatter gradient of the hydrogen concentration is obtained within the contour 40 of the member.
On the whole, a comparatively constant position of the chemical equilibrium (1) and thus a homogeneous distribution of the fictive temperature are achieved in the blank 31 within the contour 40 of the member.
FIGS. 14 and 15 show modifications of the ideal “concave annealing form” illustrated in FIG. 12 . In the blank 33 according to FIG. 14 , there is provided a thickened portion 42 within which the distance “A” between upper side 37 and lower side 38 decreases linearly from the outer edge 39 to an area around the center axis 35 . In the blank 34 according to FIG. 15 , there is provided a thickened portion 42 which is dumbbell-shaped in the illustrated cross-section. The effect of the thickened portions 42 illustrated in FIGS. 14 and 15 with respect to the setting of a high homogeneity in the area of the member contour 40 during annealing of blanks 33 and 34 is comparable with the blank 31 shown in FIG. 12 .
During annealing (in particular during cooling) using a blank 31 , 33 , 34 according to the present invention, one obtains—in the area of the member contour 40 —a flat temperature gradient, a flat gradient of the hydrogen concentration, a flat distribution of the position of the above-indicated chemical equilibrium (1), as well as locally similar time curves of the viscosity. This is accompanied by a high degree of homogeneity within the member contour 40 .
Pressing, forming and melting processes using suitable forms are particularly suited for producing blanks 31 , 33 and 34 .
From the results above, the effect of the present invention can be clearly understood.
The methods for measuring the physical properties and the like as described in Examples and Comparative Examples are as follows.
(1) Method for measuring the concentration of hydrogen molecules: A method as described in V. S. Khotimchenko et al., J. Appl. Spectrosc., 46, 632–635 (1987) was employed. (2) Method for measuring Na impurity concentration: A method using flameless atomic absorption spectroscopy was used. (3) Method for measuring the initial transmittance for a radiation 193.4 nm in wavelength: A measurement method comprising obtaining an apparent transmittance T % for a sample thickness of 10 mm, and calculating the value in accordance with (T/90.68)×100, by using the value 90.68% obtained by subtracting the loss due to Rayleigh scattering 0.18% from the theoretical transmittance 90.68% of a quartz glass for a radiation 193.4 nm in wavelength. (4) Method for measuring the fluctuation in refractive index Δn: A measuring method according to optical interference method using a He—Ne laser (emitting radiation at a wavelength of 633 nm) as light source was used. In the measurement above, the values are given for an area 180 mm in diameter. (5) Method for measuring birefringence: A retardation measuring method using a polarizer strain meter was used. (6) Method for measuring the particle diameter of the synthetic quartz glass powder: The powder was classified by using JIS standardized sieves having Nylon screens with apertures of 53 μm and 710 μm.
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An object of the present invention is to provide an improved blank such that an optical member of a high homogeneity can be obtained therefrom, and to provide a vessel and a heat treatment method for heat-treating a highly uniform synthetic quartz blank. In a first aspect of the invention a special designed blank is provided showing a concave shaped outer surface. In a second aspect of the invention a special designed vessel for heat-treating blanks is provided, whereby the degree of heat emission at the center is set higher than that of the surroundings.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to and claims the benefit of filing dates of the following U.S. Non-Provisional patent applications: (1) Ser. No. 60/012,343, entitled PROTECTED HYPODERMIC NEEDLE WITH AUTOMATIC AND MANUAL COVERING MEANS, filed Feb. 27, 1996; (2) Ser. No. 60/025,273, entitled HYPODERMIC DEVICES WITH SAFETY FEATURES, filed Sep. 12, 1996; and (3) Ser. No. 60/031,399, entitled HYPODERMIC DEVICES WITH IMPROVED SAFETY FEATURES, filed Nov. 19, 1996; (4) U.S. patent application Ser. No. 08/807,328 entitled NEEDLE TIP GUARD FOR HYPODERMIC NEEDLES, now issued as U.S. Pat. No. 5,879,337; filed Feb. 27, 1997; (5) U.S. patent application Ser. No. 09/172,185 entitled INTRAVENOUS CATHETER ASSEMBLY, now issued as U.S. Pat. No. 6,001,080, filed on Oct. 13, 1998; (6) U.S. patent application Ser. No. 09/144,398 entitled NEEDLE TIP GUARD FOR HYPODERMIC NEEDLES, now issued as U.S. Pat. No. 6,443,929, filed on Aug. 31, 1998; (7) U.S. patent application Ser. No. 09/846,706 entitled NEEDLE TIP GUARD FOR PERCUTANEOUS ENTRY NEEDLES, now issued as U.S. Pat. No. 6,629,959, filed Apr. 31, 2001; and the present application is a continuation of (8) U.S. patent application Ser. No. 10/442,376 entitled NEEDLE TIP GUARD FOR PERCUTANEOUS ENTRY NEEDLES, now U.S. Pat. No. 6,860,871, filed May 21, 2003, teachings of which are expressly incorporated herein and by reference.
BACKGROUND OF THE INVENTION
The advent of Human Immunodeficiency Virus (HIV), combined with the increasing incidence of other bloodborne pathogens such as Hepatitis B Virus (HBV) and Hepatitis C Virus (HCV), present healthcare workers with an occupational hazard unprecedented in modern medicine. The risk of contracting HIV from a needlestick injury is approximately 1 in 250, but for those who contract HIV infection as a result of a needlestick injury the risk becomes 1 in 1. The risk of contracting the more contagious HBV as a result of a needlestick injury ranges from 1 in 6 to 1 in 30.
There are also over twenty more known bloodborne pathogens which are transmitted via blood and bodily fluids. The presence of any of these pathogens in patients poses a risk to healthcare workers when invasive procedures are performed. Infectious diseases are now the third leading cause of death, behind heart disease and cancer, signifying a growing need for safer hypodermic equipment. Ten years ago, infectious diseases were classified as the fifth leading cause of death, they are now ranked third. This increase of infectious disease is attributed mainly to the over-use of antibiotics and the growing availability of re-usable, hollow-bore hypodermic equipment.
As the population of infected individuals increases, more people will be treated by healthcare workers, further increasing the odds of disease transmission from patient to healthcare worker. Also, the use of disposable hypodermic equipment is increasing at approximately 7% per annum. Additionally, a meaningful number of clusters of patient to patient transmission in the healthcare setting has been identified throughout the world. Early data suggests improper infection control techniques contribute directly to this increase: including improper use of hypodermic equipment, multiple-dose medicine vials; and failure to change protective gloves and gear for each new patient.
Recent studies also cite the discovery of significant blood contamination on re-usable blood collection vacuum tube holders which are routinely used to collect blood from different patients. Common practice is to ship one vacuum tube holder with 100 blood collection needles. It is likely that new routes of disease transmission will also be found in the future. Healthcare workers are increasingly at risk to disease transmission and nurses perform the majority of invasive hypodermic procedures, such as injecting medicine, collecting blood and inserting indwelling intravenous (I.V.) catheters. Nurses and other healthcare personnel are routinely injured by the exposed, sharp lancet of the needle after use on a patient. The critical time where a percutaneous injury can occur is from the moment the needle is withdrawn from the patient, or I.V. port, to the time the contaminated needle is safety discarded.
There are approximately 5.6 million workers in the United States (U.S.) whose jobs place them at risk for sustaining an accidental needlestick injury. Medical literature cites approximately one million reported needlestick accidents occur in the U.S. each year, with an additional two-thirds believed to be unreported. One million injuries per year translates to a needlestick injury, on average, every thirty-two seconds. Prior to the proliferation of HIV and serum hepatitis, a needlestick injury was considered a routine part of providing patient care. A needlestick injury now carries a life-threatening consequence and healthcare workers must live with this terror on a daily basis.
Hypodermic needles are used in a wide variety of invasive medical procedures with approximately 12 billion units being consumed on an annual basis. Basically, the great majority of hypodermic needles are intended for a single-use on an individual patient and are provided sterile in a variety of lengths and gauges. Hypodermic needles are normally discarded after a single use into a specially designed, puncture-proof biohazard container.
Hypodermic needles are used in medicine, science, veterinary medicine, the biotechnology and pharmaceutical industries, and also in the chemical industry. Medical and veterinary uses range from injecting medication or diluent into a patient or I.V. port, collecting blood, bodily fluids or specimens from patients and, preparing medication. The biotechnology and pharmaceutical applications mainly involve research where substances, liquids, gases or compounds are injected, mixed or withdrawn through a membrane or barrier into a specimen or controlled field. Chemical industry applications involve injecting or removing substances, liquids, gases or compounds to or from a specimen or controlled field. In each and every instance, whether medical or industrial, exposed needles pose a danger of injuring the user.
In medicine, in addition to the danger of contacting contaminated blood or bodily fluids, highly reactive or toxic substances are used for chemotherapy or therapeutic purposes. In the biotechnology, pharmaceutical and chemical industries, toxic, highly reactive, corrosive materials or substances are combined or withdrawn from a variety of experiments or projects.
Despite all the obvious dangers associated with the use of exposed hypodermics, and the availability of manually activated safety hypodermic devices, unguarded, exposed hypodermic needles still dominate the marketplace. This is due to the common practice in the industry where exposed hypodermic needles are sold at discounted prices and usually come packaged with other medical equipment and supplies. Medical institutions continue to purchase exposed hypodermics in this fashion simply for economic reasons.
The basic problem with many of the present day safety hypodermic devices is that they are meant to be manually activated, or in the language of the medical device industry, they are considered “active” devices. They may have safety shields, retractable needles, moveable sheaths or the like; but they generally require the user to complete another procedure to facilitate engagement of the safety mechanism. Although there are a number of retractable needle into syringe devices available, the manufacturing costs associated with these devices are prohibitively high.
What is needed is a low-cost safety hypodermic apparatus with a universal application.
BRIEF SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a needle point guard that effectively shields the sharpened distal tip of the needle after use.
It is another object of this invention to provide a safety hypodermic apparatus which is automatic and/or semi-automatic covering, fail-safe and single-use in nature.
It is another object of this invention to provide a safety hypodermic apparatus which looks similar to a standard, exposed, disposable hypodermic needled device (i.e., the needle and needle tip are exposed prior to performing the hypodermic procedure).
It is another object of this invention to provide a safety hypodermic apparatus which conforms to existing procedures for aspirating medication into a syringe, administering injections, and allowing unrestricted access for vascular access or catheter insertion.
It is yet another object of this invention to provide a safety hypodermic apparatus which provides an exposed sharpened tip for bevel-up needle viewing.
It is still another object of this invention to provide a safety hypodermic apparatus which automatically and/or manually entraps or captures the sharpened tip of the needle after use.
It is a further object of this invention to provide a safety hypodermic apparatus which allows medication or diluent to be aspirated into a syringe without prematurely activating the automatic and/or manually covering safety mechanism.
It is a still further object of the invention to provide a safety hypodermic apparatus which can be used with a double lancet needle for piercing a cartridge in a pre-filled syringe, or a stopper in a blood collection vacuum tube.
It is an additional object of this invention to provide a safety hypodermic apparatus which lends itself to automated manufacturing.
It is another object of this invention to minimize any mechanical resistance or component fatigue inherent to the stored energy components of the invention when the hypodermic needle is stored.
It is yet another object of the invention to leave the delicate, sharpened needle tip untouched during assembly procedures, ensuring the sharpest needle tip possible to minimize any patient discomfort during use of the hypodermic device.
It is a further object of the invention to reduce the number of components to the lowest possible number needed to accomplish the intended task of providing acceptable, low cost, fail-safe, single-use hypodermic devices for the healthcare industry.
It is yet another object of the invention to prevent catheter separation from the catheter carrying device until the needle tip is safely contained in a protective cover.
It is another object of the invention to provide a safety hypodermic apparatus that allows a protective cover to be used with long needles, such as epidural needles, spinal needles, or percutaneous entry needles for placing guidewires.
It is yet another object of the invention to provide a safety hypodermic apparatus that allows a protective cover to be used with needles that include a change in axis at the distal tip, such as implanted port needles, or needles with a “Huber” tip.
It is yet a further object of the invention to provide a safety hypodermic apparatus that allows a protective cover to be used with straight needle shafts, or bent needle shafts that include a change in axis at the distal tip, such as implanted port, needles or needles with a “Huber” tip.
It is yet another object of the invention to provide a safety hypodermic apparatus that includes a deformable retaining means for retaining and selectively releasing a protective member or cover.
It is another object of the invention to provide a safety hypodermic apparatus that includes a deformable retaining means that may be an integral part of a needle hub.
It is a further object of the invention to provide a safety hypodermic apparatus that includes a deformable retaining means that may be retrofitted to an existing needle hub.
It is another object of the invention to provide a safety hypodermic apparatus that includes a deformable retaining means that may include a gripping means.
In one embodiment the needle guard assembly of the present invention includes a needle guard that is slidably mounted on a hypodermic needle having a needle tip located at the distal end of the needle. The needle guard contains a movable needle trap that is biased against or toward the hypodermic needle. The needle trap advances over the tip of the needle, entrapping the needle tip as the needle guard is urged forward near the sharpened distal end of the hypodermic needle. A tether, or other limiting means, limits the forward movement of the needle guard along the needle. In one embodiment, the needle guard is manually urged forward along the shaft of the needle by the user. In yet another embodiment, a spring, or other biasing means, is used to move the needle guard along the shaft of the needle.
In another embodiment, a hypodermic needle is attached to a housing or hub. A coil spring is positioned between the hub, or housing, and the needle guard assembly. The spring provides the biasing force for advancing the needle guard assembly forward along the shaft of the needle. Prior to use, the needle guard assembly is releasably retained near the proximal end of the needle by a latching arm that is attached to the hub or housing. In one embodiment, the latching arm is automatically disengaged from the needle guard when a longitudinal compressive force is exerted on the retained needle guard. In yet another embodiment, the latching arm may be disengaged manually by the user.
In another embodiment, a hypodermic needle is attached to a housing or hub. A coil spring is positioned between the hub, or housing, and the needle guard assembly. The spring provides the biasing force for advancing the needle guard assembly forward along the shaft of the needle. Prior to use, the needle guard assembly is releasably retained near the proximal end of the needle by at least one protrusion that is selectively inserted into at least one aperture on a deformable member or housing. The needle guard is selectively released by squeezing the housing and expanding the housing diameter at the retaining interface to allow the protrusion to disengage from the aperture on the housing.
In another embodiment, a side-loadable needle guard assembly is provided that permits the needle tip protective device to be assembled without disturbing the delicate sharpened needle tip. In one embodiment the side-loadable needle guard assembly includes a slotted configuration. In yet another embodiment, the side-loadable needle guard assembly includes a “clam-shell” configuration.
In yet another embodiment, the needle guard assembly includes a coupling mechanism that prevents a mechanical separation from the catheter until the needle tip is safely contained within the needle trap. In one embodiment, the coupling mechanism includes an arm having a proximal end and a distal end. The proximal end of the arm is attached to the movable needle trap. The distal end of the arm includes a projection that is releasably retained within a recess of a catheter hub. Hence, as the needle trap moves inward to entrap the needle tip, the arm also moves inward. The inward movement of the arm causes the arm's distal projection to be released from the catheter hub recess, thereby permitting a separation between the needle guard assembly and the catheter hub.
Other objects and benefits of this invention will become apparent from the description which follows hereinafter when read in conjunction with the figures that accompany it.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a full side view of a prior art hypodermic needle attached to a hub.
FIG. 2 is a front view of the hypodermic needle hub shown in FIG. 1 .
FIG. 3A is a full side view of the hypodermic needle hub shown in FIG. 1 .
FIG. 3B is a full top view of the hypodermic needle hub shown in FIG. 1 .
FIG. 4 is a cross sectional view of the hypodermic needle hub shown in FIG. 1 .
FIG. 5 is a full side view of a hub in accordance with one embodiment of the present invention.
FIG. 6 is a cross sectional view of the hub shown in FIG. 5 .
FIG. 7 is a cross sectional view of the hub shown in FIG. 5 having a flange section for retaining a removable cover.
FIG. 8 is a full side view of the hub shown in FIG. 7 with the addition of a protrusion for engaging a removable cover.
FIG. 9 is a full rear view of the needle hub shown in FIG. 7 .
FIG. 10 is a full front view of the hub shown in FIG. 7 .
FIG. 11 is a full front view of a needle guard assembly in one embodiment of the present invention.
FIG. 12 is a full front view of the needle guard assembly shown in FIG. 11 .
FIG. 13 is a full outside view of a needle guard assembly and tether in one embodiment of the present invention.
FIG. 14 is a full side view of one embodiment of the present invention comprising a unitary construction.
FIG. 15 illustrates one embodiment of the present invention in a ready-to-use state.
FIGS. 16-18 illustrate the needle guard assembly being activated to cover the tip of a hypodermic needle.
FIGS. 19-22 illustrate other embodiments of the present invention.
FIG. 23 illustrates another embodiment of the present invention.
FIGS. 24 and 25 show the present invention attached to a blood collection device.
FIG. 26 shows the present invention included in a catheter device.
FIG. 27 shows the present invention unitarily attached to a syringe.
FIGS. 28 and 29 show a needle guard in accordance with one embodiment of the present invention.
FIG. 30 shows a needle trap that is biased against or towards the hypodermic needle.
FIG. 31 shows a needle entrapped within a needle guard assembly in one embodiment of the present invention.
FIG. 32 illustrates a tether in one embodiment of the present invention.
FIG. 33 illustrates a needle trap in one embodiment of the present invention.
FIG. 34 is a full open view of a needle guard assembly in one embodiment of the present invention
FIG. 35 is a exploded view of one embodiment of the present invention.
FIG. 36 is an isometric open view of the needle guard shown in FIG. 34 .
FIG. 37A shows the needle tip guard assembly of FIG. 35 in a ready to use state.
FIG. 37B shows the needle tip guard assembly of FIG. 37A after it has been activated.
FIGS. 38A and 38B show a needle tip protective device attached to a fillable syringe in a ready-to-use and shielded position, respectively.
FIGS. 39A and 39B show a needle tip protective device attached to a prefilled syringe in a ready-to-use and shielded position, respectively.
FIGS. 40A and 40B show a needle protective device attached to a prefilled cartridge.
FIGS. 41A and 41B show a needle protective device attached to a blood collection apparatus in a ready to use and shielded position, respectively.
FIGS. 42A and 42B illustrate another embodiment of the present invention.
FIG. 42C illustrates a needle guard assembly in one embodiment of the present invention.
FIGS. 43A and 43B show separate embodiments of the needle guard assembly of the present invention.
FIG. 44A illustrates another embodiment of the present invention.
FIG. 44B illustrates an enlarged cross-section view of the needle guard shown in FIG. 44A .
FIGS. 45A-C , 46 and 47 illustrate a needle hub in one embodiment of the present invention.
FIG. 48A-C illustrate several retrofit hub configurations in accordance with the present invention.
FIG. 49A shows a full side view of the present invention attached to a prior art needle hub.
FIG. 49B is a cross-sectional view of FIG. 49A .
FIG. 50 is cross-sectional side view of the present invention attached to a prefilled syringe.
FIG. 51 is cross-sectional side view of the present invention attached to a prefilled cartridge syringe hub.
FIG. 52 is a cross-sectional side view of the present inventions intergrally molded to a prefilled cartridge syringe hub.
FIG. 53 is cross sectional side view of a prior art I.V. catheter adapter.
FIG. 54 shows the present invention retrofitted to an I.V. catheter adapter.
FIG. 55 shows the present invention integrally molded to an I.V. catheter adapter.
FIG. 56 illustrates the present invention attachable to a blood collection device.
FIG. 57 illustrates a full front view of a needle guard assembly in one embodiment of the present invention.
FIG. 58 is a cross sectional side view of a prior art prefilled syringe cartridge hub.
FIG. 59 is a cross sectional side view of the present invention being threadedly attached to a glass cartridge hub.
FIG. 60 is a cross sectional side view of the present invention fixedly attached to a glass cartridge.
FIGS. 61-63 illustrate a catheter in accordance with one embodiment of the present invention.
FIG. 64-67 illustrate another embodiment of the present invention.
FIG. 68 illustrates a full side view of another embodiment of the present invention.
FIGS. 69-77 illustrate a needle guard assembly in accordance with one embodiment of the present invention.
FIG. 78 is a cross sectional side view of the present invention for use on a male luer syringe in a ready-to-use state.
FIG. 79 is a cross sectional side view of the present invention for use on a prefilled syringe or a prefilled cartridge syringe in a ready-for-use state.
FIG. 80 is cross sectional side view of the hub and cover shown in FIG. 78 .
FIG. 81 is a cross sectional view of the needle and cover shown in FIG. 79 .
FIGS. 82 and 83 illustrate a collar for use in one embodiment of the present invention.
FIG. 84 illustrates another embodiment of the present invention.
FIG. 85 illustrates yet another embodiment of the present invention.
FIG. 86 is a graph depicting the interaction of a resilient member and a sliding member without a needle guard notch.
FIG. 87 is graph depicting the interaction of resilient member and a sliding member with a needle guard notch.
FIGS. 88-94 illustrate a number of different embodiments of the present invention.
FIGS. 95 and 96 illustrates a full side view of a needle hub in one embodiment of the present invention.
FIGS. 97-102 show the embodiments of FIGS. 50 , 51 , 52 , 54 and 55 with a needle having a change in contour.
FIGS. 103-105 illustrate a catheter in yet another embodiment of the present invention.
FIGS. 106-108 show a cross sectional view of another embodiment of the present invention.
FIGS. 109-113 illustrate a side-loadable needle guard in one embodiment of the present invention.
FIGS. 114 and 115 show a needle guard assembly for use in a catheter.
FIGS. 116 and 119 show a needle trap in one embodiment of the present invention.
FIG. 117 is a full top view of a housing in one embodiment of the present invention.
FIG. 118 illustrates a cross sectional and cut-away view of a catheter introducer in one embodiment of the present invention.
FIGS. 120 and 121 illustrate catheter assemblies in yet other embodiments of the present invention.
FIGS. 122A-122C show an isometric view of a catheter in one embodiment of the present invention.
FIGS. 123 and 124 show a needle trap assembly for use in a catheter.
FIGS. 124-130 illustrate a needle guard in yet another embodiment of the present invention.
FIG. 131 illustrates a needle having an expanded change in profile near the sharpened tip.
FIG. 132 illustrates a needle having a reduced change in profile near the sharpened tip.
FIG. 133 illustrates a needle having an expanded change in profile near the sharpened tip limiting axial movement of a washer or bushing.
FIG. 134 illustrates a cross sectional view of the needle and washer shown in FIG. 133 .
FIG. 135 illustrates a washer shown in FIGS. 133 and 134 .
FIG. 136 illustrates an entrapped needle having a change in profile limiting the axial movement of a needle guard assembly that includes a washer or bushing in one embodiment of the present invention.
FIG. 137 illustrates an entrapped needle having a change in profile limiting the axial movement of a needle guard assembly that includes a protrusion to contain the needle within the needle guard.
FIG. 138 is a cross sectional front view of the needle and needle guard assembly shown in FIG. 137 .
FIG. 139 is a full front view of a needle guard assembly having a split line that is off set.
FIG. 140 is a full side view of a needle having a bend in the shaft, or change in axis, near the distal tip.
FIG. 141 is a cross sectional side view of a needle shown in FIG. 140 with a sliding cover being limited in movement by the change in axis of the needle shaft.
FIG. 142 is a cross sectional side view of a needle shown in FIG. 140 with a sliding bushing being limited in movement by the change in axis of the needle shaft.
FIG. 143 is a cross sectional side view of a needle guard assembly having a needle trap that is biased against or towards the hypodermic needle having a change in axis.
FIG. 144 shows a needle entrapped within a needle guard assembly shown in FIG. 143 .
FIG. 145 illustrates a full side view of a needle hub having a deformable member or housing.
FIG. 146 illustrates a full front view of the needle hub shown in FIG. 145 .
FIG. 147 illustrates a full top view of a needle hub having a deformable member or housing shown in FIG. 145 .
FIG. 148 illustrates a full top view of a needle guard apparatus of the present invention shown in a ready to use state having a needle guard being releasably retained in a needle hub having a distal deformable member or housing shown in FIG. 147 .
FIG. 149 illustrates a full front view of a needle guard assembly with an off set split line shown in one embodiment of the present invention.
FIG. 150 illustrates a full front view of the needle guard assembly of FIG. 148 being retained in a deformable housing shown in one embodiment of the present invention.
FIG. 151 illustrates a full front view of a needle guard assembly of FIG. 150 being selectively released by compressing and deforming the housing.
FIG. 152 illustrates an isometric view of a needle tip guard assembly being retained in a deformable member or housing in a ready to use state.
FIG. 153 shows the needle tip guard assembly of FIG. 152 after it has been activated.
DETAILED DESCRIPTION OF THE INVENTION
A needle tip protective device is described. In this regard, to the extent applicable, this application is related to and claims the benefit of filing dates of the following U.S. Non-Provisional patent applications: (1) Ser. No. 60/012,343, entitled PROTECTED HYPODERMIC NEEDLE WITH AUTOMATIC AND MANUAL COVERING MEANS, filed Feb. 27, 1996; (2) Ser. No. 60/025,273, entitled HYPODERMIC DEVICES WITH SAFETY FEATURES, filed Sep. 12, 1996; and (3) Ser. No. 60/031,399, entitled HYPODERMIC DEVICES WITH IMPROVED SAFETY FEATURES, filed Nov. 19, 1996; (4) U.S. patent application Ser. No. 08/807,328 entitled NEEDLE TIP GUARD FOR HYPODERMIC NEEDLES, now issued as U.S. Pat. No. 5,879,337; (5) U.S. patent application Ser. No. 09/172,185 entitled INTRAVENOUS CATHETER ASSEMBLY, now issued as U.S. Pat. No. 6,001,080, filed on Oct. 13, 1998; and U.S. patent application Ser. No. 09/144,398 entitled NEEDLE TIP GUARD FOR HYPODERMIC NEEDLES, filed on Aug. 31, 1998, the teachings of which are expressly incorporated here and by reference. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be obvious to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known structures and processing steps have not been shown in particular detail in order to avoid unnecessarily obscuring the present invention. Additionally, it should be noted that throughout this discussion reference will be made to a variety of hypodermic needle devices such as fillable syringes, prefilled syringes, prefilled cartridge syringes, blood collection devices, percutaneous entry needles, implanted port needles and catheters. It is appreciated, however, that the present invention is not limited to these devices, and may be used in any application where it is desirable to provide a protective covering at the tip of a needle or other elongated object.
Also keep in mind that the needle covering invention disclosed herein in regard to an I.V. catheter can easily be adapted to all types of other catheters where a needle may be used, including, but not limited to, neurological, urological, central venous, oximetry, thermodilution, PTCA, PTA, angiography, atherectomy, enlectrophysiology, suction and wound drainage, cardiovascular, pulmonary and spinal catheters. The needle covering invention described herein on a syringe can also be easily adapted to a blood collection needle, or any other needles used in invasive procedures, including, but not limited to, angiography, cardiovascular, ophthalmological, orthopedic, dentistry, veterinary, chemotherapy and arterial blood gas.
FIG. 1 is a full side view drawing of a prior art standard, exposed hypodermic needle 10 , having a sharpened needle tip 11 at the distal end with the opposite, or proximal end of the needle 10 attached to a hub 12 , with at least one flange 1 at the very proximal end for attaching the needle hub 12 to a male luer fitting, a needle nest 4 at the distal end of the needle hub 12 , for fixedly attaching the needle 10 , and a plurality of fins 2 on the needle nest 4 .
FIG. 2 is a full front view drawing of the prior art hypodermic needle hub 12 with an aperture creating a fluid/gaseous path to the hypodermic needle, a needle nest 4 for fixedly attaching the hypodermic needle 10 therein, with the needle nest 4 surrounded by a plurality of fins 2 and a plurality of flanges 1 .
FIG. 3A is a full side view drawing of the prior art hypodermic needle hub 12 with at least one flange 1 for attaching the needle hub 12 to a male luer fitting, a needle nest 4 for fixedly attaching the needle (not shown here) and a plurality of fins 2 .
FIG. 3B is a full top view drawing of the prior art hypodermic needle hub 12 with at least one flange 1 for attaching the needle hub 12 to a male luer fitting, a needle nest 4 for fixedly attaching the needle (not shown here) and a plurality of fins 2 .
FIG. 4 is a cross-sectional view of the prior art hypodermic needle hub shown in FIG. 2 along axis 4 - 4 comprising a hub portion 12 with a flange 1 , an aperture creating a fluid/gaseous path to the hypodermic needle (not shown here), a needle nest 4 for fixedly attaching a hypodermic needle (not shown here), and a plurality of fins 2 .
FIG. 5 is a full side view drawing of the hub section of the disclosed invention comprising a hypodermic needle hub 112 with at least one flange 101 for attaching the needle hub 112 to a male luer fitting, a needle nest 104 (not shown here) for fixedly attaching the needle (not shown in this view), an inner aperture creating a fluid/gaseous path between the needle hub 112 and the needle (not shown here), a protrusion 5 located at the distal end of the needle hub 112 , the protrusion being connected to the extended sidewall section 15 at the distal end of the needle hub 112 , and a moveable latching arm 26 with a finger pad 27 attached to the needle hub 112 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position on the needle hub 112 , said moveable latching arm 26 shown in the preferred molded position.
FIG. 6 is a cross-sectional side view of FIG. 5 . Needle hub 112 includes an inner aperture that provides a fluid/gaseous path between the needle hub 112 and the needle (not shown here). Arrow “M” indicates the directional movement of latch 26 .
FIG. 7 is a cross-sectional side view of FIG. 5 having a section 16 for removably holding a removable cover over the hypodermic needle.
FIG. 8 is a full side view of the hub 112 shown in FIG. 7 , with the addition of at least one protrusion 14 located adjacent to section 16 , said protrusion 14 being engagable with a removable cover. Protrusion 14 , in conjunction with a contacting member of removable cover, is positioned to facilitate attachment or removal of a hypodermic needle from a connecting device. Hub 112 also includes a protrusion or cleat 17 with a cap or holding means 18 to attach a tether.
FIG. 9 is a full rear view of needle hub 112 shown in FIG. 7 .
FIG. 10 is a full front view drawing of the disclosed hub invention comprising a hypodermic needle hub 112 with an extended wall section 15 , an aperture creating a fluid/gaseous path to the hypodermic needle (not shown), a needle nest 104 for fixedly attaching the needle (not shown), a protrusion 5 which can be used as a guide for aligning another component, a section 16 for removably holding a removable cover over the hypodermic needle (not shown here), a protrusion 14 located adjacent to section 16 for engaging a corresponding component of a removable cover (not shown), and a moveable latching arm 26 with a finger pad 27 attached to the needle hub 112 by a hinge section 23 (not shown).
FIG. 11 is a full front view of a needle guard assembly 22 positioned on the front of the hub 112 comprising a guide aperture 47 with a hypodermic needle 10 therethrough, said aperture 47 being created by coupling the open-faced sections of the needle guard assembly 22 together at a split line 43 , a protrusion 5 which is used as a guide for aligning the needle guard assembly 22 on the hub 112 whereby an aperture is created on the needle guard assembly 22 when the open-faced sections of the needle guard assembly 22 are coupled together, a section 16 for removably holding a removable cover over the hypodermic needle 10 , a protrusion 14 located adjacent to section 16 for engaging a corresponding component of a removable cover (not shown). In one embodiment needle guard 22 also includes a moveable latching arm that is attached to needle hub 112 by a hinge section. A tether (not shown), is generally used to fixedly attach needle guard 22 to hub 112 .
FIG. 12 is a full front view of the needle guard assembly 22 shown in FIG. 11 comprising a guide aperture 47 created by coupling the open-faced sections of the needle guard assembly 22 together at the split line 43 , a recess 25 with a protrusion 44 at the rear or inner end of the recess 25 , a tether 24 connected to a hinge section 28 and an aperture adjacent to the hinge section.
FIG. 13 is a full outside, top view of the needle guard assembly 22 and tether 24 as manufactured comprising an openfaced needle guard 22 with a hinge section 28 , with adjacent lands 39 which create an aperture when the needle guard assembly 22 is coupled together, a needle tip guard 41 with a hinge section 40 allowing the needle tip guard 41 to move, a recess 25 with a protrusion 44 and a tether 24 with a connector or loop 20 .
FIG. 14 is a full side view of a unitary, one piece embodiment of the invention comprising a hypodermic needle hub 112 , having at least one flange 101 , an extended wall section 15 , a protrusion 5 , a moveable latching arm 26 connected to said hub 112 by a hinge 23 , said latching arm having a finger pad 27 at the proximal end and a hooking protrusion 21 at the distal end, a protrusion 17 connecting a tether 24 to a slidable needle guard assembly 22 , with a moveable needle tip guard 41 and a hinge section 40 . In addition to serving as an alignment guide needle guard 22 , protrusion 5 may also serve as an aspiration stop when a needle is inserted into a medicine vial.
FIG. 15 is a full side view of the invention shown in the ready to use configuration comprising a hypodermic needle 10 with a sharpened tip 11 , a needle hub 112 , with at least one flange 101 , an extended sidewall section 15 , a section 16 for removably attaching a cover, a protrusion 14 located adjacent to section 16 , said protrusion 14 being engagable with a removable cover, said protrusion 14 in conjunction with corresponding member of removable cover, being positioned to facilitate attachment or removal of a hypodermic needle from a connecting device, a moveable latching arm 26 connected to hub 112 by a hinge 23 , said latching arm having a finger pad 27 at the proximal end and a hooking protrusion 21 at the distal end, said latching arm 26 releasably holding said needle guard 22 and a compressed resilient member 19 in a retained position, said needle guard 22 having a moveable needle tip guard 41 which is biasly contacting the hypodermic needle, a protrusion 5 on the hub 112 for aligning a needle guard assembly 22 to the needle hub 112 so the moveable latching arm 26 properly enters the corresponding recess 25 on the needle guard assembly 22 , said needle guard assembly 22 being connected to said hub 112 by a tether 24 .
FIG. 16 is a full side view FIG. 15 with a compressive longitudinal force being exerted on the needle guard assembly 22 , whereby the needle guard assembly 22 and compressed resilient member 19 move enough to release the hold by the protrusion 21 of the moveable latching arm 26 .
FIG. 17 is a full side view FIG. 15 with the released needle guard assembly 22 being urged to the distal end of the hypodermic needle 10 by the extending force of the resilient member 19 , said needle tip guard 41 is biasly contacting said hypodermic needle 10 by the inherent memory of the molded configuration of said needle tip guard 41 and/or the extending force of the surrounding resilient member 19 .
FIG. 18 is a full side view FIG. 15 with the resilient member 19 extended and still exerting force on the needle guard assembly 22 , said resilient member 19 assists inherently molded bias of needle tip guard 41 by urging said needle tip guard 41 inwardly and ahead of the sharpened needle tip, said needle guard assembly 22 is limited from advancing further by the extended tether 24 , with the sharpened hypodermic needle tip being entrapped within the needle guard assembly 22 , with the needle tip guard 41 now securely positioned ahead of the sharpened needle tip said needle tip guard 41 blocking the aperture guide of the needle guard assembly 22 , ensuring safe containment of the sharpened tip.
FIG. 19 is a full bottom view of FIG. 15 showing the elements of the invention and a rectangular finger pad configuration, although the finger pad configuration only needs to be suitable (round, square, triangular or the like) to facilitate a manual force to release the hold on retained needle guard assembly 22 , said needle guard assembly 22 having a recess 25 for engaging the distal end of the movable latching arm 26 to the corresponding section on the needle guard assembly 22 .
FIG. 20 is a full top view of FIG. 15 showing the elements of the invention and having a tether 24 which can have a round, square, elliptical or ribbon-like cross section and hinge section 28 . It is important to note that the tether can comprise either rigid or flexible characteristics, and can be unitary molded with other components, or be a separate component. A rigid tether would have to be able to slide along the side of a syringe, prefilled syringe or cartridge, blood collection needle holder or I.V. catheter when the device is used, and said tether could slide through an aperture which would limit the axial forward movement of the tether and needle guard. This rigid tether would have to have a proximal end larger than the aperture, so the tether would be limited in its slidable movement.
A flexible tether can be made more resilient or rigid by changing the molecular alignment of the molecules of the tether component by stretching, heating, radiation processing or the like. The tether can be manufactured separately, or connected to either the hub component, the needle guard assembly or the needle guard housing. The tether could be comprised from a single variety, or a combination of materials including, but not limited to: plastic resin, synthetic material, organic material, cloth, woven material, stranded material, metal, silk, or a composite material.
FIG. 21 is a full side view of FIG. 15 having an extended protrusion 105 for preventing premature release of the releasable needle guard assembly 22 . This embodiment can be used for blood collection purposes, indwelling catheter placement or preventing premature activation during medicine aspiration.
FIG. 22 is a full top view of FIG. 15 having an extended protrusion 105 for preventing premature release of the releasable needle guard assembly 22 .
FIG. 23 is a cross-sectional view of the invention ready for use having the elements described herein, with the resilient member 19 in a compressed position with the needle guard assembly releasably held by the protrusion 21 of the moveable latching arm 26 , an aperture for orienting said needle guard assembly 22 adjacent to said hub portion 112 , and an aperture 47 with a hypodermic needle 10 therethrough, said latching arm 26 having a protrusion 49 for engaging said needle guard assembly 22 when said needle guard assembly is moved toward said hub portion 112 , said protrusion 49 manually moves said latching arm 26 in an outward manner ensuring said latching arm 26 moves outwardly releasing the hold on the needle guard assembly 22 .
FIG. 24 is a full side view of the invention for blood collecting purposes showing the elements described and notated in the previous drawings in addition to a double-lancet hypodermic needle 110 having a sharpened tip 11 at the distal end and a sharpened tip 111 at the proximal end (see FIG. 25 ), a hub 212 having a threaded section for removably attaching the hub into a needle holder 45 (see FIG. 25 ) by means of threads 74 , and a piercable, collapsible cover 48 on the distal end of the needle 110 and a protrusion 105 .
FIG. 25 is a full side view of the invention for blood collecting purposes showing the elements described and notated in the previous drawings in addition to the invention being removably attached to a needle holder 45 , said needle holder 45 having a larger opening at the proximal end for inserting a removable blood collection tube, and a smaller opening at the distal end for removably attaching a blood collection needle 110 and hub 212 . A manual releasing means is activated by pressing the finger pad 27 in a downward or inward manner, this is indicated by the arrow “F” pointing toward the finger pad 27 .
It may be noted that the attachment means of connecting the invention to a blood collection needle holder 45 is not limited to the threaded means 74 shown throughout this application. Other attachment means, such as frictional engagement, snap fit, wedging or the like may also be used to accomplish the same function.
FIG. 26 is a full side view of the invention with a removable, indwelling catheter, having a hub 312 attached to a hollow bore needle 210 with a distal stylet 211 and a removable, indwelling catheter 51 and catheter hub 50 slidably disposed on said needle 210 . All other elements notated are described in the previous drawings.
FIG. 27 is a full side view of the invention in a ready to use state unitarily attached to a syringe 6 by the hub 112 . All other elements notated are described in the previous drawings.
FIG. 28 is a full front view of the needle guard assembly shown in an open-faced configuration comprising a needle guard assembly 22 having a hinge section 28 joining each section, a split line 43 where the sections mate together, an aperture guide 47 on each section, a recess 25 on one section having a protrusion 44 for joining with the corresponding element 144 on the other section of said needle guard assembly 22 , a moveable needle tip guard 41 and a post 36 for joining the needle guard assembly 22 sections together.
FIG. 29 is a full rear view of the needle guard assembly shown in an open-faced configuration comprising a needle guard assembly 22 having a hinge section 28 joining each section, a split line 43 where the sections mate together, an aperture guide 47 on each section, a protrusion 44 for joining with the corresponding element 144 on the other needle guard assembly 22 section, a moveable needle tip guard 41 , at least one post or protrusion 36 on one needle guard assembly 22 section which enters at least one corresponding slot 37 on the other needle guard assembly 22 section for securing the sections together.
FIG. 30 is a cross-sectional side view showing the interaction of the needle guard assembly 22 with the resilient member 19 and hypodermic needle 10 and sharpened needle tip 11 , comprising a moveable needle guard assembly 22 with a hypodermic needle 10 therethrough, with resilient member 19 urging the needle guard assembly 22 toward the distal end of the hypodermic needle 10 . The needle guard assembly 22 having a moveable needle tip guard 41 with a hinge section 40 , said needle tip guard 41 is molded in a manner whereby the needle tip guard 41 comprises an inherent biasing force toward the hypodermic needle 10 , another biasing force is exerted on the needle tip guard 41 by the extending force of the resilient member 19 , said needle tip guard 41 enters the corresponding recess 31 when said needle tip guard 41 advances beyond the sharpened needle tip 11 , said needle tip guard 41 slidably contacts said hypodermic needle 10 . The needle guard 22 is attached to a hub element 12 by means of a tether 24 as described and notated in the previous drawings.
FIG. 31 is cross-sectional side view showing containment of the sharpened needle tip 11 within the needle guard assembly 22 comprising a needle guard assembly 22 with a hypodermic needle 10 therethrough, said needle guard assembly 22 being urged beyond the distal end of the hypodermic needle 10 and sharpened needle tip 11 by the extending force of a resilient member 19 whereby the moveable, self-biasing needle tip guard 41 of the needle guard assembly 22 moves in front of the sharpened needle tip 11 , containing the sharpened needle tip 11 within the needle guard assembly 22 and behind the substantially impenetrable needle tip guard 41 having a hinge section 40 . Additionally, the extending force of the resilient member 19 urges the needle tip guard 41 inwardly to a covering position, said resilient member 19 surrounds both the needle guard assembly 22 and the outer wall of the needle tip guard 41 holding the needle tip guard 41 in a closed, protective position by a radially confining force. In the protected, closed position, the needle tip guard 41 enters the corresponding recess 31 of the needle guard assembly 22 , preventing movement and ensuring safe containment of the sharpened needle tip 11 within the needle guard assembly 22 . The needle guard 22 is attached to a hub or housing by means of a tether as described and notated in the previous drawings.
FIG. 32 is a full top view of a separate tether 24 with connecting loops 20 at the proximal and distal ends. This tether embodiment is used with a separate hub component and separate needle guard assembly component.
FIG. 33 is a cross sectional side view of the needle guard assembly 22 comprising a needle tip guard 41 having a hinge section 40 connected to the needle guard assembly 22 . Said needle tip guard 41 is molded in a self-biasing manner as shown and is moveable to an open and closed position. Said needle tip guard may comprise a substantially impenetrable plastic resin and/or a substantially impenetrable metal.
FIG. 34 is a full open view of the interior of the open-face needle guard assembly 22 as manufactured and before being joined together. Said needle guard assembly 22 comprising two joining sections which are connected by a hinge section 28 having a tether 24 , one needle guard assembly section having a moveable, self-biasing, substantially impenetrable needle tip guard 41 with a moveable hinge 40 connected to said needle guard assembly 22 , a post or protrusion 36 , a recess 25 with a protrusion 44 and a recess 38 for nesting said needle guard assembly 22 adjacent to the needle hub 112 , 212 or 312 as shown in the previous drawings; with the corresponding needle guard assembly section having a corresponding slot 31 for said needle tip guard 41 to enter, a slot 37 for receiving the corresponding post 36 , a proximal inner guide section 35 and a distal inner guide section 47 for the hypodermic needle 10 (not shown), a corresponding receiving section 144 for recess 25 and protrusion 44 , and a recess 38 for nesting said needle guard assembly 22 adjacent to the needle hub 112 , 212 or 312 as shown in other drawings herein.
FIG. 35 is a full, exploded view of the invention having the elements described herein the other accompanying drawings comprising a slidable needle guard assembly 22 in the closed face configuration having a tether 24 and loop 20 ; a resilient member 19 ; and a hypodermic needle 10 fixedly attached the needle hub. FIG. 36 shows needle guard assembly 22 in a full view, open-faced configuration. The open face, or “clam-shell” configuration of the needle guard make this embodiment feasible using standard injection molding techniques. The sharpened needle 10 is first attached to the hub portion 112 , then the needle 10 is coated with a friction-reducing lubricant, the resilient member 19 is concentrically disposed over the needle 10 and compressed, then the needle guard assembly 22 is assembled from the side of the needle 10 keeping the sharpened tip 11 from being contacted, the needle guard assembly 22 and tether 24 are then attached to the hub 122 by a connecting means 20 .
The extended wall section 15 can be eliminated for the invention to work, but shields the resilient member 19 . The elements of the needle guard assembly 22 , in relation to each other, and in relation to the bevel of the sharpened needle tip 11 , can also be oriented as may be deemed necessary to suit a specific procedure or purpose.
FIG. 37A is an isometric drawing of a needle tip protective device 500 in one embodiment of the invention. FIG. 37A shows protective device 500 in a ready-to use position. FIG. 37B shows the protective device 500 shielding the needle tip within the needle guard assembly 22 .
FIGS. 38A and 38B show a needle tip protective device 500 in one embodiment of the invention attached to a fillable syringe 501 in a ready-to-use position and a shielded position, respectively.
FIGS. 39A and 39B show a needle tip protective device 500 in one embodiment of the present invention attached to a prefilled syringe 502 in a ready-to-use position and a shielded position, respectively.
FIGS. 40A and 40B show a needle protective device 500 in one embodiment of the invention attached to a prefilled cartridge 503 . FIG. 40A shows the prefilled cartridge 503 before use. FIG. 40B shows the prefilled cartridge 503 after the protective device 500 is activated.
FIGS. 41A and 41B shows a needle protective device 500 in one embodiment of the invention attached to a blood collection device 504 in a ready-to-use position and a shielded position, respectively.
FIG. 42A illustrates a needle tip guard assembly in yet another embodiment of the present invention for protecting the distal tip 11 of a standard hypodermic needle 10 . The assembly 20 includes a needle guard 22 that is slidably mounted on needle 10 . Needle guard 22 contains a movable needle trap 41 that is biased against or toward the shaft of needle 10 . Needle trap 41 advances over the tip 11 of the needle 10 , entrapping the needle tip 11 , when needle guard 22 is positioned near the distal tip of needle 10 . FIG. 42B shows distal needle tip 11 captured within needle guard 22 . In the embodiment of FIG. 42A , needle guard 22 is moved forward along the shaft of needle 10 by the user. In FIG. 42A , needle trap 41 is shown as a detachable element of needle guard 22 that is insertable into a slot 80 located adjacent the proximal end of needle guard 22 . Needle trap 41 generally comprises a flexible metal member. Other impregnable materials that are not susceptible to fatigue may also be used. For example, some plastics or other resin based materials may be used. In such instances, needle trap 41 may be integrally molded with needle guard 22 . A recess 31 may be included within needle guard 22 for receiving needle trap 41 . A flexible tether 24 limits the forward movement of the needle guard 22 along the needle 10 . Other limiting means, such as, for example, a change in contour in needle 10 or the use of a rigid tether assembly may be used in lieu of the flexible tether. These limiting devices will be described in greater detail later in this description.
FIG. 42C shows needle guard 22 a that is another embodiment of the needle guard 22 shown in FIGS. 42A and 42B . The needle guard 22 a of FIG. 42C includes an integrally molded needle trap 41 a , a notch 61 a , a recess 61 b in trap 41 a , and needle guard 22 , respectively. A resilient member 102 is held within notch 61 a and recess 61 b . The stored energy of resilient member 102 urges needle trap 41 a toward or against needle 10 . Resilient member 102 may comprise a “v” shape or may simply comprise a member that has been curved to create a stored energy.
FIG. 43A is a full side view one embodiment of the present invention with the resilient member 119 extended and still exerting force on the needle guard assembly 22 , said resilient member 119 assists inherently molded bias of needle guard trap 41 by urging said needle guard trap 41 inwardly and in front of the sharpened needle tip 11 (see FIG. 33 ), said needle guard assembly 22 is limited from advancing further by the limiting tether 24 , with the sharpened hypodermic needle tip being entrapped within the needle guard assembly 22 , with the needle guard trap 41 now securely positioned in front of the sharpened needle tip 11 said needle guard trap 41 blocking the aperture guide opening 47 of the needle guard assembly 22 , ensuring safe containment of said sharpened tip 11 within the needle guard assembly 22 . The needle guard trap 41 is attached to the needle guard assembly 22 by a hinge section 40 . A hollow bore hypodermic needle 10 is fixedly attached to a hub 112 , said hub 112 having at least one proximal flange 101 for attaching said hub 112 to a male luer fitting, said hub 112 also having a flange 16 for removably attaching a protective storage cover (not shown), said flange 16 having at least one shoulder or projection 14 for interfacing with a corresponding portion of a storage cover to allow twisted attachment and/or removal of said hub 112 to or from a medical device, said hub also having a body portion 15 , a protrusion 5 , and a movable latching arm 26 , said latching arm 26 being fixedly attached to said hub body 15 by a hinge section 23 , said latching arm also having a hook 21 , a protrusion, cam, or ramp 49 and a finger pad or button 27 .
FIG. 43B shows the protective needle guard assembly of FIG. 43A attached to a syringe 6 . The protective needle guard assembly may be integral to syringe 6 , or may be attached as an add-on component.
FIG. 44A is a full side view of the disclosed invention with the resilient member 119 extended and still exerting an extending force on the needle guard assembly 22 , said resilient member 119 assists inherently molded bias of needle guard trap 41 by urging said needle guard trap 41 inwardly and in front of the sharpened needle tip 11 said needle guard assembly 22 is limited from advancing further by the limiting tether 24 , with the sharpened hypodermic needle tip 11 being trapped within the needle guard assembly 22 , with the needle guard trap 41 now securely positioned in front of the sharpened needle tip 11 . Said needle guard 22 having an extended slot section 44 a for releasably holding said needle guard assembly 22 in a retained position. Said extended slot section 44 a places the interface between the latching arm hook 21 and the needle guard assembly 22 away from any potential binding which may occur during needle insertion. If the retaining means interface is too close to the insertion surface, the latching arm 26 may be prevented from releasably holding the needle guard assembly 22 . A flexible projection 107 is included within the needle guard assembly for retaining the end coil of spring 119 in a locked position after the needle tip protection device has been activated. FIG. 44B illustrates a cross-sectional view of flexible projection 107 . The needle guard trap 41 is attached to the needle guard assembly 22 at a hinge section 40 . The needle 10 is fixedly attached to a hub 112 , said hub 112 having at least one proximal flange 101 for attaching said hub 112 to a male luer fitting, said hub also having a body portion 15 , a protrusion 5 , and a movable latching arm 26 , said latching arm 26 being fixedly attached to said hub body 15 by a hinge section 23 , said latching arm also having a hook 21 and protrusion 49 .
FIG. 45A is a full side view drawing of the needle hub 412 , in accordance with one embodiment of the invention comprising a hypodermic needle hub 412 with a flange 401 for attaching the needle hub 412 to a male luer fitting, a needle nest 404 for fixedly attaching the needle, a plurality of fins 402 , and a land 75 for attaching another component to the hub 412 .
FIG. 45B is a full top view of the needle hub 412 shown in FIG. 45B having a flange 401 for attaching the needle hub 412 to a male luer fitting, a needle nest 404 for fixedly attaching a needle, a plurality of fins 402 , and a land 75 for attaching another component to the hub 412 .
FIG. 45C is a cross sectional side view of FIG. 45A comprising a hypodermic needle hub 412 with a flange 401 for attaching the needle hub 412 to a male luer fitting a needle nest 404 for fixedly attaching the needle 10 , an aperture therethrough creating a fluid/gaseous path from the said hub 412 to said needle 10 , a plurality of fins 402 , and a land 75 for attaching another component to the hub 412 .
FIG. 46 is a full side view drawing of the disclosed invention comprising a hypodermic needle hub 412 with a flange 401 for attaching the needle hub 412 to a male luer fitting, a needle nest 404 for fixedly attaching the needle, at least one, or a plurality of shortened fins 403 , and a land 75 for attaching another component to the hub 412 .
FIG. 47 is a full front view drawing of FIGS. 45A and 46 comprising a hypodermic needle hub 412 with an aperture creating a fluid/gaseous path to the hypodermic needle 10 , a needle nest 404 having adjacent at least one, or a plurality of fins 402 or 403 , at least one, or a plurality of flanges 401 and a land 75 .
FIG. 48A is a is a full side view of the invention having a retrofitted hub portion 215 being fixedly attached to a hub portion 412 by a heatstake connection. Said hub portion 215 having an annular flange 16 for connecting a protective storage cover, a protrusion 17 for attaching a tether, said protrusion 17 having an aperture for insertably attaching or bonding the tether, said protrusion 17 having an angled proximal end to eliminate any possibility of the tether catching on the protrusion 17 when the needle guard 22 is activated. A hub portion 215 also includes a well or pocket 18 for removably inserting a tether in an out of the way fashion, and a retaining means 77 for releasably holding said needle guard 22 in a retained position adjacent to said hub portion 215 .
FIG. 48B is a full front view of the hub 215 described in FIG. 48A comprising a hypodermic needle hub 215 having an aperture with a plurality of slots which correspondingly fits onto the distal end of a hypodermic needle hub shown throughout this application, said slots accept the fin or fins 402 from said hub 412 , an annular flange 16 , a protrusion 17 for attaching a tether or the like, a well or pocket 18 for removably inserting a tether or the like, and a retaining means 77 having an aperture 78 for releasably holding said needle guard 22 in a retained position adjacent to said hub portion 215 .
FIG. 48C is a full front view of FIG. 48A comprising a hypodermic needle hub portion 215 , an aperture which correspondingly fits onto the distal end of a hypodermic needle hub shown throughout this application, an annular flange 16 . There is one slot shown with the aperture, and at least one slot is needed to secure the needle hub 412 and hub portion 215 together to keep the hub portion 215 and needle hub 412 aligned when a circumferential force is exerted on the adjacent components.
FIG. 49A is a full side view of the disclosed invention being fixedly attached to a prior art needle hub 12 having at least one flange 1 for attaching the needle hub 12 to a male luer fitting, a section 16 for removably holding a protective storage cover 54 over the hypodermic needle 10 (shown in other drawings in this application), a protrusion 5 located at the distal end of the hub portion 15 , said protrusion 5 being connected to the hub portion 15 at the distal end of the hub portion 15 , said section 16 having a shoulder 14 for twistedly attaching said invention to said storage cover, and a moveable latching arm 26 with a finger pad 27 , attached to the hub portion 15 by a hinge section 23 , said finger pad 27 having at least one protrusion for creating a more positive grip or contact with said finger pad 27 . Finger pad 27 also comprising a different, or bright color, which serves as a visual indicator for the user to easily locate the finger pad for manual release of said needle guard assembly 22 or the like, with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position adjacent to said hub portion 15 , said moveable latching arm 26 shown in the preferred molded position.
FIG. 49B is a cross-sectional side view of FIG. 49A showing the disclosed invention attached to a prior art needle hub 12 said needle hub 12 comprising a hypodermic at least one flange 1 for attaching the needle hub 12 to a male luer fitting, on one side a needle nest 4 for fixedly attaching the needle (not shown) said needle nest 4 having at least one, or a plurality of fins 2 and an inner aperture creating a fluid/gaseous path between the needle hub 12 and the needle. The invention is shown being retrofitted to said prior art hub 12 , said attachment means comprising a spin weld, sonic weld, heat weld, or mechanical attachment means as shown by the protrusion 64 being attached by means of a snap fit or friction fit, said needle nest 4 having a recess or slot manufactured to accept said protrusion 64 of hub portion 15 , said hub portion 15 having a protrusion 5 located at the distal end of the hub portion 15 , said protrusion 5 being connected at the distal end of the hub portion 15 , said hub portion 15 also having a section 16 for removably attaching a protective storage covers (not shown) said section 16 also having a means for creating a tortuous path preventing contamination from entering the sterile field created by enclosing the needle 10 , needle guard 22 and hub portion 15 within a protective storage cover. Hub portion 15 includes a moveable latching arm or lever 26 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having finger pad or button 27 , a protrusion 21 for retaining a component in a releasably held position adjacent to the hub portion 15 , said latching arm 26 also having a protrusion 49 for biasing the latching arm 26 in an outward manner when a compressive force is applied to the releasably held needle guard 22 with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hypodermic needle hub 12 .
FIG. 50 is a cross-sectional side view of the invention attached to a prior art glass pre-filled syringe 6 having a nest bead 7 and a hypodermic needle 10 showing the disclosed invention attached to said glass pre-filled syringe 6 . Hub body 15 is fixedly attached to syringe 6 at the nest bead 7 by the attaching section 65 ; said hub body 15 having a protrusion 5 located at the distal end of said hub portion 15 , said protrusion 5 being connected at the distal end of the hub portion 15 , said hub portion 15 having a fixedly attached tether 24 , said hub body 15 also having a section 16 for removably attaching a protective storage cover a moveable latching arm or lever 26 attached to the hub body 15 by a hinge section 23 , said lever 26 having a touch pad 27 , a protrusion 21 for retaining a component in a releasable position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging said latching arm 26 in an outward manner when a compressive force is applied to a releasably held needle guard with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub portion 15 .
FIG. 51 is a cross-sectional side view of the invention attached to a prior art pre-filled cartridge syringe hub 8 a having a fixedly attached needle 10 with a sharpened proximal end 111 and a sharpened distal end, said sharpened proximal end 111 for piercing the stopper of a medicine or fluid cartridge. Hub portion 15 is fixedly attached to said syringe hub 8 a at the needle nest 4 said hub portion 15 having a protrusion 5 located on said hub portion 15 , said protrusion 5 having an attachment section 17 with an aperture for inserting a tether (not shown), said attachment section 17 having an chamfered face on the proximal side to eliminate any possibility of the tether catching and hanging up on said attachment section 17 when said needle guard is released from a retained position, said hub portion 15 also having a section 16 for removably attaching a protective storage cover and a moveable latching arm or lever 26 with a touch pad 27 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasably held position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging the latching arm 26 in an outward manner when a compressive force is applied to a releasably held needle guard with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub body 15 .
FIG. 52 is a cross-sectional side view of the invention integrally molded to a pre-filled cartridge syringe hub 8 b having a fixedly attached needle 10 with a sharpened proximal end 111 and a sharpened distal end (not shown) said sharpened proximal end 111 is for piercing the stopper of a medicine or fluid cartridge. Integral hub portion 15 having a needle nest 4 , protrusion 5 located on said hub portion 15 , said protrusion 5 having an attachment section 17 with an slot for inserting a tether (not shown) said attachment section 17 having an chamfered face on the proximal side to eliminate any possibility of the tether 24 catching and hanging up on said attachment section 17 , said hub portion 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position adjacent to the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging the latching arm 26 in an outward manner when a compressive force is applied to a releasably held needle guard 22 (shown in other drawings in this application), with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub portion 15 .
FIG. 53 is a cross-sectional side view drawing of a prior art indwelling intravenous (I.V.) catheter 29 having a catheter mounting section 9 with a section 18 for removably attaching a protective storage cover, a fixedly attached hypodermic needle 10 , and a male section 78 for removably attaching an indwelling I.V. catheter hub 13 .
FIG. 54 is a cross-sectional side view an I.V. catheter having a mounting section 9 , a section 18 for removably attaching a protective storage cover a hypodermic needle 10 being fixedly attached to a needle nest 4 ; said catheter mounting section 9 being retrofitted with the present invention. The invention comprises a hub portion 15 being fixedly attached to said catheter mounting section 9 at the nest 4 by the attaching section 66 , said hub portion 15 having a protrusion 5 located at the distal end of said hub portion 15 , said protrusion 5 being connected to the hub portion 15 , said hub portion 15 having a fixedly attached tether 24 , said hub portion 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging the latching arm 26 in an outward manner when a compressive force is applied to the releasably held needle guard (not shown), with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub portion 15 .
FIG. 55 is a cross-sectional side view of the present invention integrally molded to an I.V. catheter mounting section 9 .
FIG. 56 illustrates a hub portion 15 of the present invention that may be attached to a blood collection device similar to that showing FIG. 25 .
FIG. 57 is a full front view of the needle guard assembly 22 of FIG. 11 further comprising at least one fin 63 protecting the movement of said latching arm 26 , allowing said latching arm 26 to freely disengage when the needle guard 22 is moved towards the hub 12 when said needle guard 22 contacts the protrusion 49 .
FIG. 58 . is a cross-sectional side view of a prior art pre-filled syringe cartridge comprising a glass cartridge 6 , a glass cartridge hub 68 having a needle nest 4 for fixedly attaching a needle 10 , said needle 10 having a sharpened distal end 11 said hub 68 also having a threaded section 67 .
FIG. 59 is a cross sectional side view of the invention being threadedly attached to a glass cartridge hub 68 , said glass cartridge 25 hub 68 being fixedly attached to a glass cartridge 6 , said hub 68 having a needle nest 4 for fixedly attaching a needle 10 , said needle 10 having a sharpened distal end (not shown) said hub 68 also having a threaded section 67 . Hub body 15 is fixedly attached to said glass cartridge hub 68 by the threaded section 67 , said hub 15 having a protrusion 5 located at the distal end of said hub portion 15 , said protrusion 5 being connected at the distal end of the hub portion 15 , said hub portion 15 having a fixedly attached tether 24 . Hub body 15 also includes a section 16 for removably attaching a protective storage cover ( FIGS. 78 and 79 ), a moveable latching arm or lever 26 with a touch pad 27 attached to the hub body 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging said latching arm 26 in an outward manner when a compressive force is applied to a releasably held needle guard with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub body 15 .
FIG. 60 is a cross sectional side view of the invention being fixedly attached to a glass cartridge 6 , comprising a hub 69 having a needle nest 4 for fixedly attaching a needle 10 , a hub portion 15 being integrally molded to said hub 69 ; said hub portion 15 having a protrusion 5 located at the distal end of said hub portion 15 , said protrusion 5 being connected at the distal end of the hub portion 15 , said hub portion 15 having a fixedly attached tether 24 , said tether 24 could also be fixedly attached to section 16 , said hub 69 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging said latching arm 26 in an outward manner when a compressive force is applied to a releasably held needle guard 22 , with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on hub 69 .
FIG. 61 is a cross sectional top view of the invention shown on an indwelling catheter 29 embodiment, having a movable needle guard 22 a and a separable indwelling I.V. catheter 29 , said catheter 29 being fixedly attached to a catheter hub 13 , an I.V. catheter mounting section 9 having a fixedly attached hollow bore hypodermic needle 10 having a sharpened distal end 11 ; a hub portion 15 having a section 16 for removably attaching a protective storage cover 54 , a slidable needle guard 22 a being fixedly attached to said hub portion 15 by means of a limiting tether, said needle guard 22 a having a projection or finger post 80 for advancing said separable catheter 29 and said needle guard 22 a along said hypodermic needle 10 so said catheter may be inserted into a blood vessel, said hypodermic needle 10 being slidable through a guide aperture 47 in said movable needle guard 22 a , said needle guard 22 a having a movable needle trap 41 with a corresponding slot 31 for receiving the needle trap 41 when said trap 41 moves beyond the needle tip 11 , said needle guard 22 a having an open collar or washer 30 for retaining the resilient member 19 on the proximal end of said needle guard 22 a , said resilient member 19 being slidably held on said needle guard 22 a by the notch or indentation 60 , said movable needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 a into notches 60 and/or 61 , said needle trap 41 also having a notch or indentation 61 for retaining said end coils of said resilient member 19 , with the distal end of said needle guard 22 a having a male section 78 for removably attaching an indwelling I.V. catheter hub 13 , with a section of said male section 78 having a movable arm 42 for releasably retaining a catheter hub 13 from said male section 78 during initial insertion of the catheter 29 into a patient. Said catheter hub 13 having an inner channel, recess, slot or undercut 32 for being releasably held by said movable arm 42 . Said movable arm 42 could also comprise a metal component which is inserted during or after said male section 78 is manufactured.
Said hub portion 15 could also comprise the latching arm 26 shown in other drawings in this application, otherwise said needle guard 22 a would be releasably held adjacent to said hub portion 15 prior to use by a frictional or wedged means. FIG. 62 is a cross sectional top view of the movable needle guard 22 a shown in FIG. 61 on an indwelling catheter embodiment, containing the elements shown and described in the movable needle guard 22 a , whereby the catheter 29 has been inserted in a blood vessel and the needle 10 is being retracted into said needle guard 22 a as the needle 10 is being pulled away from said catheter insertion site, whereby the movable arm 42 on the male section 78 is free to move where the needle has been residing within the distal male section 78 of the needle guard 22 a , allowing the catheter hub 13 to remain in the blood vessel and freely separate from the needle guard 22 a , with the needle trap 41 sliding on said needle 10 . The needle guard 22 a is attached to the hub portion 15 shown in FIG. 61 whereby a fixedly attached tether (not shown) limits the forward movement of the needle guard 22 a , safely trapping the needle tip 11 .
Said catheter hub 13 having an inner channel, recess, slot or undercut 32 for being releasably held by said movable arm 42 .
FIG. 63 is a cross sectional top view of the movable needle guard 22 a shown in FIGS. 61 and 62 on an indwelling catheter 29 embodiment, containing the elements shown and described in FIGS. 61 and 62 , including the movable needle guard 22 a , a tether (not shown) and catheter 29 , whereby the catheter 29 has been inserted in a blood vessel and the needle 10 is safely retracted within said needle guard 22 a where by the movable arm 42 has moved inwardly releasing the hold on the catheter hub 13 , with the needle trap 41 now safely trapping the needle tip 11 . Movable arm 42 includes a corresponding receiving slot 166 for receiving said movable arm 42 . Said needle guard 22 a having said movable needle trap 41 located within the corresponding slot 31 after said trap 41 has moved beyond the needle tip 11 . Said needle guard 22 a is attached to the hub portion 15 as shown in FIGS. 61 and 62 whereby a tether limits the forward movement of the needle guard 22 a , safely trapping the needle tip 11 . Said catheter hub 13 having an inner channel, recess, slot or undercut 32 for being releasably held by said movable arm 42 .
The movable arm protrusion 42 can comprise a “v” shaped configuration which allows the catheter hub 13 to separate even in the event the movable arm 42 has taken a set during storage. A set during storage could inhibit the separation of said catheter hub 13 from said mounting section 78 .
FIG. 64 is a cross-sectional side view of the present invention ready for use on a male luer syringe. FIG. 64 shows a full view of the hypodermic needle 10 comprising: a hub 12 with a fixedly attached needle 10 , a means for retaining a separate, movable needle guard 22 , said needle guard 22 having an aperture therethrough for said hypodermic needle 10 , whereby the needle guard 22 is retained in a ready to use position on said hub 12 , with said retained needle guard 22 being urged away from said needle hub 12 by a compressed resilient member 19 , said resilient member 19 being located between, among or amid said hub 12 and said needle guard 22 , said resilient member 19 also being located in an annular fashion surrounding a portion of said needle guard 22 , said needle guard 22 is fixedly attached to said needle hub portion 15 by means of a limiting tether 24 .
Said hub 12 having an aperture therethrough creating a fluid/gas path to said hypodermic needle 10 , at least one flange 101 for attaching the needle hub 12 to a male luer fitting, a needle nest 4 for fixedly attaching the needle 10 , said needle 10 having a sharpened distal end 11 and an unsharpened proximal end being fixedly attached to said hub 12 and an integral hub portion 15 having a protrusion 5 located at the distal end of said hub body 15 , said protrusion 5 being connected to the hub portion 15 , said protrusion 5 having a fixedly attached tether 24 , said hub portion 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 with a touch pad 27 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasably retained position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for biasing the latching arm 26 in an outward manner when a compressive force is applied to the releasably held needle guard 22 ; and a movable needle guard 22 having a proximal guide section 34 , an internal guide section 35 , with a recess or void 38 residing between said proximal guide section 34 and said internal guide section 35 , a distal needle guide aperture 47 , a receiving slot 31 to receive the needle trap 41 (not shown), a retaining area 44 a with an aperture 48 to receive said protrusion 21 , said needle guard 22 having a compressed resilient member 19 positioned at the proximal end of said needle guard 22 said with the resilient member 19 exerting an extending force on said needle guard 22 ; with said needle guard 22 being releasable held in a compressed position by the protrusion 21 of the moveable latching arm 26 on said hub portion 15 , an aperture for orienting said needle guard assembly 22 adjacent to said hub portion 12 , said aperture having the hub protrusion 5 positioned therethrough, said latching arm 26 having a protrusion 49 for engaging said needle guard assembly 22 when said needle guard 22 is urged toward said hub portion 12 , said needle guard 22 engages protrusion 49 and manually moves said latching arm 26 in an outward manner ensuring said latching arm 26 moves outwardly releasing the hold on the needle guard assembly 22 .
FIG. 65 is a cross sectional top view of FIG. 64 containing the elements shown and described in FIG. 64 with the releasably held needle guard assembly 22 being releasably held adjacent to said hub portion 15 , said guard assembly 22 being movable by the stored energy present in the compressed resilient member 19 , said resilient member 19 being slidably retained on said needle guard 22 by the notch or indentation 60 , said movable needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 into notches 60 and/or 61 , said needle trap 41 also having at least one notch or indentation 61 for releasably retaining said end coils of said resilient member 19 , said needle guard 22 having a proximal guide section 34 , a distal needle guide aperture 47 , a needle trap 41 biasly contacting said hypodermic needle 10 by the inherent memory of the molded configuration of said needle trap 41 and/or the extending force of the surrounding resilient member 19 , whereby the advancing movement of said needle guard 22 is limited by a fixedly attached tether 24 (not shown), said needle 10 having a sharpened distal end 11 and an unsharpened proximal end being fixedly attached to said hub 12 . Said needle trap 41 being hingedly attached to said needle guard 22 by a hinge section 40 , said needle guard 22 having a receiving slot 31 to receive the needle trap 41 , a distal needle guide aperture 47 .
FIG. 66 is a cross sectional top view of FIGS. 64 and 65 containing the elements described in FIGS. 64 and 65 with the releasably held needle guard assembly 22 being urged toward the distal end of the hypodermic needle 10 by the extending force of the resilient member 19 , having a needle trap 41 biasly contacting said hypodermic needle 10 by the inherent memory of the molded configuration of said needle tip guard 41 and/or the extending force of the surrounding resilient member 19 , whereby the advancing movement of said needle guard 22 is limited by a fixedly attached tether (not shown). Said resilient member 19 being slidably retained on said needle guard 22 by the notch or indentation 60 , said movable needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 into notches 60 and/or 61 , said needle trap 41 also having at least one notch or indentation 61 for releasably retaining said end coils of said resilient member 19 . Said needle trap 41 being hingedly attached to said needle guard 22 by a hinge section 40 , said needle guard 22 having an integral metal guard 75 and a distal needle guide aperture 47 . Said needle guard 41 also having a tapered or reducing proximal section 304 for non-binding access by the movable resilient member 19 . Said resilient member 19 being movably positioned in an annular manner about or around the proximal section of said needle guard 22 .
FIG. 67 is a cross sectional top view FIGS. 64 , 65 and 66 showing the needle tip 11 being trapped within the needle guard 22 by the movable needle guard 41 , comprising a hypodermic needle 10 having a sharpened tip 11 , said needle guard 22 being movably attached to said hub portion by means of a limiting tether (not shown), with the resilient member 19 extended and maintaining an extending force on the needle guard assembly 22 , said needle guard is prevented from advancing further by the limiting feature of said limiting tether, said needle guard 22 having only one notch 60 for maintaining an extending force of said resilient member 19 on said needle guard 22 , said needle guard 22 maintaining alignment on said hypodermic needle 10 by means of the guide sections shown throughout this application. Said proximal guide 34 is shown here maintaining the needle guard 22 in a substantially concentric manner on said hypodermic needle 10 . Said needle guard 41 also having a tapered or reducing proximal section 304 for non-binding access by the movable resilient member 19 .
FIG. 68 is a full side view of the invention without the needle 10 , comprising a hub 12 that is attachable to a male luer fitting, said hub 12 having at least one flange 101 at the proximal end a hub portion 15 , said hub portion 15 having a protrusion 5 , a protrusion 17 having an aperture for attaching a tether 24 , a movable latching arm 26 having a hook 21 and a protrusion 49 , said latching arm 26 being hingedly attached to said hub portion 15 by a hinge 23 , with said tether 24 being fixedly attached to a movable needle guard 22 , said needle guard 22 having a movable needle trap 41 being hingedly attached to said needle guard 22 by the hinge 40 , said needle trap 41 having at least one notch or multi-level landing 61 for proper positioning of a resilient member 19 (not shown), said needle trap 41 having a lead in section 33 also for locating said resilient member 19 in a compressed and/or extendible position, said needle guard 22 having a protrusion 44 a for maintaining a releasable hold on said needle guard 22 when said needle guard 22 is retained adjacent to said hub portion 15 by said latching arm 26 and hook 21 , said needle trap having a different, or brightly colored indicator 64 which is visible only when the resilient member is retained in a compressed positioned on said needle guard 22 before the needle guard 22 is activated. The resilient member covers said indicator 64 shielding said indicator 64 from view when the needle guard 22 is activated and said resilient member 19 is extended around said needle guard 22 and the movable needle trap 41 . Said resilient member 19 maintains said needle trap 41 in a protective position on said needle guard 22 . Said indicator 64 could easily be located anywhere on said needle guard 22 where the advancing resilient member 19 hides the indicator 64 from view alerting the user that the device is safely shielding the sharpened needle tip 11 thus preventing an unintentional percutaneous needlestick injury.
FIG. 69 is a full, outside, top view of the needle guard assembly 22 shown in its molded configuration comprising a foldable, open-faced needle guard 22 having a hinge section 28 , with adjacent lands 39 which create an aperture when said needle guard assembly 22 is coupled together, a front section 62 , at least one fin 63 for allowing adequate clearance for a latching arm to freely be urged from a releasably holding position on said needle guard 22 when the invention is activated during use. A slot or void 25 is created when the needle guard 22 sections are joined together. A retaining protrusion 44 b is located adjacent to said slot 25 , said retaining protrusion 44 b interfaces with the hook of a latching arm (not shown), a notch 60 for positioning and maintaining the extending force of a resilient member on said needle guard 22 when said guard 22 is in a retained and extending mode, a tapered or reduced proximal end 45 for eliminating any binding effect caused when the resilient member moves around or about the proximal end of said needle guard 22 , said needle guard 22 having a movable needle trap 41 being hingedly attached to said needle guard by the hinge 40 , said needle trap 41 having at least one notch or multi-level landing 61 for proper positioning of a resilient member said needle trap 41 having a lead in section 33 also for locating said resilient member in a compressed and/or extendible position. Said needle trap 22 being fixedly attached to a tether 24 , said tether having at least one protrusion 20 for fixedly attaching said tether 24 to said hub portion 15 or hub 12 , or flange 16 .
FIG. 70 is a view of the proximal end of the tether 24 having a plurality of protrusions 20 a for fixedly attaching said tether 24 to said hub portion 15 or hub 12 , or flange 16 .
FIG. 71 is a is a full, inside face view of the needle guard assembly 22 shown in its molded configuration comprising a foldable, open-faced needle guard 22 having a hinge section 28 , with adjacent lands 39 which create an aperture when said needle guard assembly 22 is coupled together, a slot or void 25 is created when the needle guard 22 sections are joined together, a distal guide section 47 is also created when the needle guard 22 sections are joined together, a retaining protrusion ramp 44 c is located adjacent to said slot 25 , said retaining protrusion interfaces with the hook 21 of the latching arm 26 (both shown in other drawings in this application), said needle guard 22 having a movable needle trap 41 being hingedly attached to said needle guard by the hinge 40 , said needle trap 41 having at least one skirt or fin 46 for entrapping said sharpened needle tip 11 (see FIG. 75 ), said needle guard having a corresponding slot or opening 31 for receiving said needle trap 41 , said needle guard 22 having at least one pin 36 and a corresponding opening 37 for frictionally engaging said needle guard 22 sections together about a hypodermic needle, said pin 36 and slot 37 can be positioned on either side of needle guard 22 sections, said needle guard 22 having an internal guide section 35 and a proximal guide section 34 with a void or space 38 between said guides 34 and 35 , said needle trap having an internal landing 52 located between said internal guide 35 , with said landing 52 having an adjacent landing 53 which serves to guide the hypodermic needle during assembly, storage and use, said landing 53 also houses said sharpened needle tip within said needle guard 22 . Said needle guard 22 being fixedly attached to a tether 24 . Said tether 24 having at least one protrusion 20 for fixedly attaching said tether 24 to said hub portion 15 or hub 12 , or flange 16 .
FIG. 72 is a full front view of the needle guard assembly 22 shown in an open-faced configuration comprising a needle guard assembly 22 having an internal guide section 35 , a hinge section 28 with a plurality of needle guard 22 sections connected adjacent to said hinge section 28 , said hinge section 28 having an adequate area for insert molding a separate tether or fixedly attaching a separate tether, said hinge section 28 also could have an aperture therethrough for fixedly inserting a separate tether, said needle guard 22 having a split line 43 where the needle guard 22 sections mate or join together, an aperture guide 47 on each section at the distal end, a recess 25 on one section having a protrusion 98 a for joining with the corresponding element 98 b on the other section of said needle guard assembly 22 , and a post 36 for joining the needle, guard assembly 22 sections together. Said post 36 is received by a corresponding slot or opening 37 (shown as a dotted line).
FIG. 73 is a full rear view of the needle guard assembly 22 shown in an open-faced configuration comprising a needle guard assembly 22 having a hinge section 28 joining each section, said hinge section 28 having a slot or recess for inserting a fixedly attached, separate tether (not shown), said hinge section 28 also having a fin 79 being hingedly attached to said hinge section 28 , said fin 79 being bendable over said hinge section 28 for fixedly attaching a separate tether by a heat weld or press means, said needle guard 22 having a split line 43 where the needle guard 22 sections mate or join together, an aperture guide 34 on each needle guard 22 section, a protrusion 98 b for joining with the corresponding element 98 b on the alternate needle guard assembly 22 section, a moveable needle trap 41 , at least one post or protrusion 36 on one needle guard assembly 22 section which enters at least one corresponding slot 37 on the other needle guard assembly 22 section for securing the sections together. Said post 36 is received by a corresponding slot or opening 37 (shown as a dotted line).
FIG. 74 is a full, inside face view of one half of the needle guard assembly 22 containing the elements shown and described in FIG. 71 showing said needle guard 22 in its molded configuration comprising a foldable, open-faced needle guard 22 having a hinge section 28 for attaching a separate tether with adjacent lands 39 which create an aperture when said needle guard assembly 22 is coupled together, a slot or void 25 is created when the needle guard 22 sections are joined together, a distal guide section 47 is also created when the needle guard 22 sections are joined together, said needle guard 22 having a corresponding slot or opening 31 for receiving said needle trap 41 (see FIG. 71 ), said needle trap having at least one pin 36 (see FIG. 71 ) and a corresponding opening 37 for frictionally engaging said needle guard 22 sections together about the hypodermic needle, said pin 36 and slot 37 (see FIG. 71 ) can be positioned on either side of needle guard 22 sections, said needle guard 22 having an internal guide section 35 and a proximal guide section 34 with a void or space 38 between said guides 34 and 35 , said needle trap having an internal landing 52 located between said internal guide 35 , with said landing 52 having an adjacent landing 53 which serves to guide said hypodermic needle during assembly, storage and use, said landing 53 also houses said sharpened needle tip within said needle guard 22 . Said needle guard 22 being fixedly attached to a separate tether (not shown) at hinge section 28 .
FIG. 75 is a cross sectional view of the needle guard 22 in FIG. 71 shown in axis 75 - 75 comprising a needle guard 22 , a movable needle trap 41 and fins or skirts 46 . Said skirts 46 maintain alignment of the trapped sharpened needle tip within said needle trap 41 .
FIG. 76 is a cross sectional view of the needle guard 22 in FIG. 71 shown in axis 76 - 76 comprising a needle guard 22 , a split line 43 , a slot 37 and a landing 53 .
FIG. 77 is a cross sectional view of the needle guard 22 in FIG. 74 shown in axis 77 - 77 comprising a needle guard 22 , a split line 43 , a guide section 35 , said guide section 35 having chamfered or angled ends for aligning a hypodermic needle within said guide section 35 on said needle guard 22 during the assembly procedure, said hypodermic needle 10 (shown in other drawings in this application) resides adjacent to the landing 52 .
FIG. 78 is a cross sectional side view of a hypodermic needle for use on a male luer syringe in a ready for use state in accordance with one embodiment of the present invention. The needle assembly is contained within a protective storage cover 54 and end cap 68 , whereby needle 10 , needle guard 22 , resilient member 19 , tether 24 , hub 12 and flange 16 are held within said cover 54 by a wedging action of said flange 16 with the cover 54 . FIG. 78 further illustrates a hub 12 , a fixedly attached needle 10 , a means for retaining a separate, movable needle guard 22 , said needle guard 22 having an aperture therethrough for said hypodermic needle 10 , whereby the needle guard 22 is retained in a ready to use position on said hub 12 , with said retained needle guard 22 being urged away from said needle hub 12 by a compressed resilient member 19 , said resilient member 19 being located between, among or amid said hub 12 and said needle guard 22 , said resilient member 19 also being located in an annular fashion about or surrounding a portion of said needle guard 22 , said needle guard 22 is fixedly attached to said needle hub portion 15 by means of a limiting tether 24 .
Said hub 12 having an aperture therethrough creating a fluid/gas path to said hypodermic needle 10 , at least one flange 101 for attaching the needle hub 12 to a male luer fitting, a needle nest 4 for fixedly attaching the needle 10 , said needle 10 having a sharpened distal end 11 and an unsharpened proximal end being fixedly attached to said needle nest 4 , and an integral hub portion 15 having a protrusion 5 located at the distal end of said hub portion 15 , said protrusion 5 being connected to the hub portion 15 , said hub portion 15 having a fixedly attached tether 24 , said hub portion 15 also having a section 16 for removably attaching said protective storage cover 54 , a moveable latching arm or lever 26 with a touch pad 27 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasably held position adjacent or on said hub portion 15 , said latching arm 26 also having a protrusion 49 for biasing the latching arm 26 in an outward manner when a compressive force is applied to said releasably held needle guard 22 , said movable needle guard 22 having a proximal guide section 34 , an internal guide section 35 , with a recess or void 38 residing between said proximal guide section 34 and said internal guide section 35 , a distal needle guard guide aperture 47 , a receiving slot 31 to receive the needle trap 41 (not shown) a retaining area 44 a with an aperture 48 to receive said protrusion 21 , said needle guard 22 having a compressed resilient member 19 positioned at the proximal end of said needle guard 22 said with the resilient member 19 exerting an extending force on said needle guard 22 ; with said needle guard 22 being releasable held in a compressed position by the hook 21 of the moveable latching arm 26 on said hub portion 15 , an aperture for orienting said needle guard assembly 22 adjacent to said hub portion 12 , said aperture having the hub protrusion 5 positioned therethrough, said latching arm 26 having a protrusion 49 for engaging said needle guard assembly 22 when said needle guard 22 is urged toward said hub portion 12 , said needle guard 22 engages protrusion 49 and mechanically urges said latching arm 26 in an outward manner ensuring said latching arm 26 moves outwardly releasing the hold on the needle guard assembly 22 .
Said cover 54 having at least one internal projection 56 , said projection holding said needle guard 22 and resilient member 19 in a retracted state during storage and prior to use, said cover 54 having a projection 55 for biasly holding or wedging said latching arm 26 in a retaining manner, said latching arm 26 releasably holding said needle guard 22 and said resilient member 19 in a retained position prior to use. The diameter of said cover 54 could also be sized to biasly hold said latching arm 26 in a retaining manner, therefore, eliminating the need for said projection 55 .
A cap 68 is removably placed into or on said cover 54 to contain said needle assembly within said cover 54 and said cap 68 , said cap 68 having a plurality of square shoulders 69 , and a wall section 70 removably sealing said cover 54 and said cap 68 together at the tortuous path interface 71 maintaining a sterile field within said cover 54 and cap 68 . Said projection 56 relieves the extending force of said resilient member 19 on said releasably held needle guard 22 , said retaining latching arm 26 and said hinge 23 of said latching arm 26 , by slightly compressing said resilient member 19 , while said projection 55 holds said latching arm 26 in a wedged or confined position whereby said needle guard 22 is releasably held by said latching arm 26 when said cover 54 is removed from said needle assembly.
FIG. 79 is a cross sectional side view of the invention comprising a hypodermic needle for use on a pre-filled syringe or pre-filled cartridge syringe in a ready for use state having a needle guard 22 and hypodermic needle 10 being stored and retained in a protective storage cover 54 , showing a full view of said hypodermic needle 10 , said cover 54 having a means for retaining a separate, movable needle guard 22 , said needle guard 22 having an aperture therethrough for said hypodermic needle 10 , said needle 10 having a distal sharpened end 11 , whereby the needle guard 22 is retained in a ready to use position, with said retained needle guard 22 being urged away from said prefilled syringe by a compressed resilient member 19 , said resilient member 19 being located between, among or amid said prefilled syringe and said needle guard 22 , said resilient member also being located in an annular fashion about or surrounding a portion of said needle guard 22 , said needle guard 22 is fixedly attached to said needle hub portion 15 by means of a limiting tether 24 .
Said integral hub portion 15 having a protrusion 5 located at the distal end of said hub portion 15 , a moveable latching arm or lever 26 with a touch pad 27 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasably held position adjacent to or on said hub portion 15 , said latching arm 26 also having a protrusion 49 for urging said latching arm 26 in an outward manner when a compressive force is applied to said releasably held needle guard 22 , said movable needle guard 22 having a proximal guide section 34 , an internal guide section 35 , a space or recess 38 between said proximal guide 34 and internal guide 35 , a distal needle guard guide aperture 47 , a receiving slot 31 to receive a needle trap 41 (not shown), a retaining area 44 a with an aperture 48 to receive said protrusion 21 , said needle guard 22 having a compressed resilient member 19 positioned at the proximal end of said needle guard 22 said with the resilient member 19 exerting an extending force on said needle guard 22 ; with said needle guard 22 being releasable held in a compressed position by the hook 21 of said moveable latching arm 26 on said hub portion 15 , an aperture for orienting said needle guard assembly 22 adjacent to said hub portion 12 , said aperture having the hub protrusion 5 positioned therethrough, said latching arm 26 having a protrusion 49 for engaging said needle guard assembly 22 when said needle guard 22 is urged toward said pre-filled syringe, said needle guard 22 engages protrusion 49 and mechanically urges said latching arm 26 in an outward manner ensuring said latching arm 26 moves outwardly releasing the hold on the needle guard assembly 22 .
Said cover 54 having a soft elastomeric or rubber seal 72 inside or within the closed end of said cover 54 which sealingly engages said sharpened tip 11 and said needle 10 of a pre-filled syringe or pre-filled cartridge against leakage.
FIG. 80 is a cross sectional view of the hub 12 contained within a storage cover 54 in axis 80 - 80 of FIG. 78 and comprising a hub section 12 , a storage cover 54 having at least one vane 57 for gripping a flange shoulder of said hub 12 so the needle 10 , said hub 12 and said needle guard 22 can be safely turned or twistedly attached with the cover 54 on or off a medical device.
FIG. 81 is a cross sectional view of the needle 10 contained within a cover 54 in axis 81 - 81 of FIG. 79 . Cover 54 includes at least one, or a plurality of internal projections 73 , said projections 73 relieve the extending force of said resilient member 19 on said releasably held needle guard 22 , said retaining latching arm 26 and said hinge 23 of said latching arm 26 , by slightly compressing said resilient member 19 during storage.
FIG. 82 is a full front view of an open collar or washer 30 used with the indwelling I.V. catheter embodiment of the invention, said washer 30 retaining the resilient member 19 on the proximal end of the needle guard 22 a on said catheter assembly shown in FIGS. 62 , 63 , and 64 . Said washer having an angled entrance 63 for engaging said washer onto said needle guard 22 a . Said washer 30 could comprise a flat configuration and be inserted into a corresponding slot on said needle guard 22 a to hold said resilient member 19 on said needle guard 22 a.
FIG. 83 is a cross sectional view of the washer 30 shown in along axis 83 - 83 in FIG. 82 .
FIG. 84 is a cross sectional top view of the invention containing the elements shown and described in FIG. 64 having a movable metal needle trap 41 used to trap the sharpened needle tip 11 within said needle guard 22 , comprising a hub 12 at least one proximal flange 101 , a hub portion 15 and a flange 16 for wedgedly and removably attaching a protective cover, a releasably held needle guard assembly 22 being releasably held adjacent to said hub portion 15 , said guard assembly 22 being movable by the stored energy present in the compressed resilient member 19 , said resilient member 19 being slidably retained on said needle guard 22 by the notch or indentation 60 , said metal needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 into notches 60 and/or 61 , said needle trap 41 also having at least one notch or indentation 61 for releasably retaining said end coils of said resilient member 19 , said needle guard 22 having a proximal guide section 34 , a distal needle guide aperture 47 , a metal needle trap 41 biasly contacting said hypodermic needle 10 by the inherent memory of the metal configuration of said needle trap 41 and/or the extending force of the surrounding resilient member 19 , whereby the advancing movement of said needle guard 22 is limited by a fixedly attached tether (not shown), said needle 10 having a sharpened distal end 11 and an unsharpened proximal end being fixedly attached to said hub 12 . Said needle trap 41 being hingedly inserted to said needle guard 22 at a hinge slot 40 , said needle guard 22 having a receiving slot 31 to receive the needle trap 41 , a distal needle guide aperture 47 , said needle trap 41 having skirts 46 (shown in FIG. 75 ) to retain said sharpened needle end 11 within said metal needle trap 41 .
Said needle trap 41 being insertable onto said needle guard 22 from the outside of said needle guard, allowing said needle trap 41 to be inserted onto said needle guard 22 either before or after said needle guard 22 is clasped around said hypodermic needle 10 from the side during assembly procedures.
FIG. 85 is a cross sectional top view of the invention containing the elements shown and described in FIGS. 64 and 84 having a movable metal needle trap 41 used to trap the sharpened needle tip 11 within said needle guard 22 , comprising a hub 12 at least one proximal flange 101 , a hub portion 15 and a flange 16 for wedgedly and removably attaching a protective cover, a releasably held needle guard assembly 22 being releasably held adjacent to said hub portion 15 , said guard assembly 22 being movable by the stored energy present in the compressed resilient member 19 , said resilient member 19 being slidably retained on said needle guard 22 by the notch or indentation 60 , said metal needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 into notches 60 and/or 61 , said needle trap 41 also having at least one notch or indentation 61 for releasably retaining said end coils of said resilient member 19 , said needle guard 22 having a proximal guide section 34 , a distal needle guide aperture 47 , a metal needle trap 41 biasly contacting said hypodermic needle 10 by the inherent memory of the metal configuration of said needle trap 41 and/or the extending force of the surrounding resilient member 19 , whereby the advancing movement of said needle guard 22 is limited by a fixedly attached tether (not shown), said needle 10 having a sharpened distal end 11 and an unsharpened proximal end being fixedly attached to said hub 12 . Said needle trap 41 being hingedly inserted to said needle guard 22 at a hinge slot 40 d , said needle guard 22 having a receiving slot 31 to receive the needle trap 41 , a distal needle guide aperture 47 , a receiving slot 31 to receive the metal needle trap 41 , said needle trap 41 having skirts 46 (shown in FIG. 75 ) to retain said sharpened needle end 11 within said metal needle trap 41 .
Said needle trap 41 being insertable onto said needle guard 22 from the inside of said needle guard, allowing said needle trap 41 to be inserted onto said needle guard 22 before said needle guard 22 is clasped around said hypodermic needle 10 from the side during assembly procedures.
FIG. 86 is a graph depicting the interaction of a resilient member and a sliding member, said sliding member being on an elongated shaft, said sliding member having a movable arm being urged away from said resilient member by an extending force, said moveable arm being movably wedged between the diameter of said resilient member and said shaft, said arm slidably contacting said shaft, and where another area of said resilient member is positioned around said sliding member, said resilient member being releasably retained by said movable arm on said sliding member, said resilient member having a portion of said sliding member within said resilient member's inside diameter, whereby the binding force of said resilient member on said sliding member and said movable arm eventually exceeds the extending force of said resilient member as said resilient member extends. Said extending force of said resilient member is greatest when said resilient member is completely compressed, and conversely, said extending force of said resilient member is weakest when said resilient member is completely elongated. The binding force of said resilient member on said movable arm is greatest when said resilient member is compressed.
FIG. 87 is a graph depicting the interaction of a resilient member and a sliding member, said sliding member being on an elongated shaft, said sliding member having a movable arm being urged away from said resilient member by an extending force, said moveable arm being movably wedged between the diameter of said resilient member and said shaft, said arm slidably contacting said shaft, and where another area of said resilient member is positioned in a notch or recess on said sliding member, said resilient member being releasably retained by said movable arm and said notch on said sliding member, said resilient member having a portion of said sliding member within said resilient member's inside diameter, whereby the binding force of said resilient member on said sliding member and said movable arm is always less than the extending force of said resilient member as said resilient member extends. Said extending force of said resilient member is exerted in the land created by said notch, maintaining a greater extending force on said sliding member and said movable arm than said binding force of said resilient member. Said movable arm is urged inwardly from a retaining position when said sliding member advances beyond the end of said shaft, thereby releasing the hold on said resilient member.
FIG. 88 is a cross-sectional side view of the present invention ready for use on a male luer syringe showing a full view of the hypodermic needle 10 , and a cross sectional view of the releasing means shown and described in FIG. 48A comprising a hub 412 with a fixedly attached needle 10 , a means for retaining a separate, movable needle guard 22 , said needle guard 22 having an aperture therethrough for said hypodermic needle 10 , whereby the needle guard 22 is retained in a ready to use position on said hub 412 , with said retained needle guard 22 being urged away from said needle hub 412 by a compressed resilient member 19 , said resilient member 19 being located between, among or amid said hub 412 and said needle guard 22 , said resilient member 19 also being located in an annular fashion surrounding a portion of said needle guard 22 , said needle guard 22 is fixedly attached to said needle hub portion 215 by means of a limiting tether 24 .
Said needle guard 22 having a retaining means 77 , said retaining means having an aperture 78 for releasably holding said needle guard 22 in a retained position adjacent to said hub portion 215 , said needle guard 22 having a latching arm 81 being hingedly attached to said needle guard 22 at a hinge section 23 , a protrusion 49 for urging said arm 81 from a releasably held position adjacent to said hub portion 215 when a compressive force is applied to said needle guard 22 and said protrusion 49 engages said retaining means 77 and mechanically releases said hold on said needle guard 22 , said arm 81 having a protrusion 21 for releasably holding said arm 81 in said aperture 78 of said retaining means 77 , said arm 81 having a finger pad 27 with projections which do not impede the movement of said pad 27 and said protrusion 21 through said aperture 78 as said needle guard 22 is urged away from said hub portion 215 .
Said hub 412 having an aperture therethrough creating a fluid/gas path to said hypodermic needle 10 , at least one flange 101 for attaching the hub 412 to a male luer fitting, a needle nest 4 for fixedly attaching the needle 10 , said needle 10 a sharpened distal end 11 and an unsharpened proximal end being fixedly attached to said hub 412 and an integral hub portion 215 having a protrusion 5 located at the distal end of said hub portion 215 , said protrusion 5 being connected to the hub portion 215 , said protrusion 5 having a fixedly attached tether 24 , said hub portion 215 also having a section 16 for removably attaching a protective storage cover said movable needle guard 22 having a proximal guide section 34 , an internal guide section 35 , with a recess or void 38 residing between said proximal guide section 34 and said internal guide section 35 , a distal needle guide aperture 47 , a receiving slot 31 to receive the needle trap 41 said needle guard 22 having a compressed resilient member 19 positioned at the proximal end of said needle guard 22 said with the resilient member 19 exerting an extending force on said needle guard 22 ; with said needle guard 22 being releasably held in a compressed position by the hook 21 of the moveable latching arm 81 on said needle guard 22 , an aperture for orienting said needle guard assembly 22 adjacent to said hub portion 215 , said aperture having the hub protrusion 5 positioned therethrough, said latching arm 81 having a protrusion 49 for engaging said retaining means 77 when said needle guard 22 is urged toward said hub portion 215 , said needle guard 22 engages protrusion 49 and manually moves said latching arm 81 in an outward manner ensuring said latching arm 81 moves inwardly releasing the hold on the needle guard assembly 22 .
FIGS. 89 , 90 and 91 show a cross-section view of the invention described in FIGS. 84 , 85 and 88 , respectively, wherein hub 212 includes a threaded section 74 for attaching the hub to a blood collection device. (See FIG. 25 .)
FIGS. 92 , 93 and 94 show a cross-section view of the invention described in FIGS. 84 , 85 and 88 , respectively, being fixedly attached to a prefilled syringe.
FIG. 95 is a full side view drawing of the disclosed invention hub component 12 , comprising a hypodermic needle hub 12 with a flange 101 for attaching the needle hub 12 to a male luer fitting, a needle nest 4 , a section 16 for removably holding a protective storage cover over a hypodermic needle (not shown) a protrusion 5 located at the distal end of the hub portion 15 , said hub portion 15 having at least one aperture 89 for inserting a glue carrying fixture or the like to apply glue to the needle during assembly, said aperture 89 also being a venting means to allow pneumatic pressure to escape during insertion of needle 10 with glue into said needle nest 4 , said protrusion 5 being connected to the hub portion 15 at the distal end of the hub portion 15 , said section 16 having a shoulder 14 for twistedly attaching said invention to a storage cover, and a moveable latching arm 26 with a finger pad 27 , attached to the hub portion 15 by a hinge section 23 , said finger pad 27 having at least one protrusion for creating a more positive grip or contact with said finger pad 27 , said finger pad 27 also comprising a different, or bright color, which serves as a visual indicator for the user to easily locate the finger pad 27 for manual release of a needle guard assembly or the like, with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position adjacent to said hub portion 15 , said moveable latching arm 26 shown in the preferred molded position.
FIG. 96 is a full side view drawing of the disclosed invention hub component 12 , comprising a hypodermic needle hub 12 with a flange 101 for attaching the needle hub 12 to a male luer fitting, a needle nest 4 , a section 16 for removably holding a protective storage cover over the hypodermic needle (not shown), a protrusion 5 located at the distal end of the hub portion 15 , said hub portion 15 having at least one aperture 89 for inserting a glue carrying fixture or the like to apply glue to said needle 10 during assembly, said aperture 89 also being a vent to allow pneumatic pressure to escape during insertion of needle 10 into said needle nest 4 , said protrusion 5 being connected to the hub portion 15 at the distal end of the hub portion 15 , said section 16 having a shoulder 14 for twistedly attaching said invention to a storage cover, and a moveable latching arm 26 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position adjacent to said hub portion 15 , said moveable latching arm 26 shown in the preferred molded position.
FIG. 97 is a cross-sectional side view of the invention attached to a prior art glass pre-filled syringe 6 having a nest bead 7 and a hypodermic needle 10 with a distal sharpened end 11 , said needle 10 having a change in profile 3 near the distal end for limiting axial movement of a slidable needle guard 22 relative to the needle tip 11 after positioning the needle guard at the distal end of the needle 10 . FIG. 97 further shows a hub body 15 being fixedly attached to said syringe 6 at the nest bead 7 by the attaching section 65 ; said hub body 15 having a protrusion 5 located at the distal end of said hub portion 15 , said protrusion 5 being connected at the distal end of the hub portion 15 , said hub body 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 attached to the hub body 15 by a hinge section 23 , said lever 26 having a touch pad 27 , a protrusion 21 for retaining a component in a releasable position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging said latching arm 26 in an outward manner when a compressive force is applied to the releasably held needle guard 22 (shown in other drawings in this application), with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub portion 15 .
FIG. 98 is a cross-sectional side view of the invention integrally molded to a pre-filled cartridge syringe hub 8 b having a fixedly attached needle 10 with a sharpened proximal end 111 and a sharpened distal end 11 , said needle 10 having a change in profile 3 near the distal end for limiting axial movement of a slidable needle guard relative to the needle tip 11 after positioning said needle guard at the distal end of the needle 10 , said sharpened proximal end 111 is for piercing the stopper of a medicine or fluid cartridge. The invention includes an integral hub portion 15 , having a needle nest 4 ; said hub portion 15 having a protrusion 5 located on said hub portion 15 , said hub portion 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging the latching arm 26 in an outward manner when a compressive force is applied to the releasably held needle guard 22 with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub portion.
FIG. 99 is a cross-sectional side view of the invention attached to a prior art pre-filled cartridge syringe hub 8 a having a fixedly attached needle 10 with a sharpened proximal end 111 and a sharpened distal end 11 , said needle 10 having a change in profile 3 near the distal end for limiting axial movement of a slidable needle guard (not shown) relative to the needle tip 11 after positioning a needle guard at the distal end of the needle 10 , said sharpened proximal end 111 for piercing the stopper of a medicine or fluid cartridge. The invention includes a hub portion 15 being fixedly attached to said syringe hub 8 a at the needle nest 4 ; said hub portion 15 having a protrusion 5 located on said hub portion 15 , said hub portion 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 with a touch pad 27 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasably held position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging the latching arm 26 in an outward manner when a compressive force is applied to a releasably held needle guard, with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub body 15 .
FIG. 100A is a cross-sectional side view an I.V. catheter introducer having a hub section 9 , having a fixedly attached needle 10 with a sharpened distal end, said needle 10 having a change in profile 3 near the distal end for limiting axial movement of a slidable needle guard (not shown) relative to the needle tip 11 after positioning said needle guard 22 at the distal end of the needle 10 , a section 18 for removably attaching a protective storage cover, a hypodermic needle 10 being fixedly attached to a needle nest 4 ; said catheter mounting section 9 being retrofitted with the present invention, wherein hub portion 15 is fixedly attached to said catheter mounting section 9 at the nest 4 by the attaching section 66 , said hub portion 15 also having a section 16 for removably attaching a protective storage cover.
FIG. 100B is a cross-sectional side view of the present invention integrally molded to an I.V. catheter introducer comprising a hub 9 , a hypodermic needle 10 being fixedly attached to a needle nest 4 said needle 10 having a sharpened distal end 11 , said needle 10 having a change in profile 3 near the distal end for limiting axial movement of a slidable needle guard (not shown) relative to the needle tip 11 after positioning said needle guard 22 at the distal end of the needle 10 , a hub portion 15 , said hub portion 15 having a protrusion 5 located on said hub portion 15 , said hub body 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging said latching arm 26 in an outward manner when a compressive force is applied to the releasably held needle guard with said moveable latching arm shown in the preferred position for retaining at least one component in a retained position on the hub portion 15 .
FIG. 101 is a cross sectional side view of the invention being threadedly attached to a glass cartridge hub 68 , said glass cartridge hub 68 being fixedly attached to a glass cartridge 6 , said hub 68 having a needle nest 4 for fixedly attaching a needle 10 , said needle 10 having a sharpened distal end 11 , said needle 10 having a change in profile 3 near the distal end for limiting axial movement of a slidable needle guard relative to the needle tip 11 after positioning said needle guard 22 at the distal end of the needle 10 , said hub 68 also having a threaded section 67 fixedly attaching hub body is to said glass cartridge hub 68 by the threaded section 67 ; said hub body 15 having a protrusion 5 located at the distal end of said hub portion 15 , said protrusion 5 being connected at the distal end of the hub portion 15 , said hub body 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 with a touch pad 27 attached to the hub body 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging said latching arm 26 in an outward manner when a compressive force is applied to the releasably held needle guard 22 (shown in other drawings in this application), with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub body 15 .
FIG. 102 is a cross sectional side view of the invention being fixedly attached to a glass cartridge 6 , comprising a hub 68 having a needle nest 4 for fixedly attaching a needle 10 , said needle 10 having a sharpened distal end 11 , said needle 10 having a change in profile 3 near the distal end for limiting axial movement of a slidable needle guard relative to the needle tip 11 after positioning said needle guard 22 at the distal end of the needle 10 , a hub portion 15 being integrally molded to said glass cartridge hub 69 ; said hub portion 15 having a protrusion 5 located at the distal end of said hub portion 15 , said protrusion 5 being connected at the distal end of the hub portion 15 , said hub body 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasable position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for urging said latching arm 26 in an outward manner when a compressive force is applied to the releasably held needle guard 22 (shown in other drawings in this application), with said moveable latching arm 26 shown in the preferred position for retaining at least one component in a retained position on the hub body 15 .
FIG. 103 is a cross sectional top view of the invention shown on an indwelling catheter 29 embodiment, having a movable needle guard 22 a and a separable indwelling I.V. catheter 29 , said catheter 29 being fixedly attached to a catheter hub 13 ; a hub 9 having a fixedly attached hollow bore hypodermic needle 10 having a sharpened distal end 11 , said needle 10 being fixedly attached to a hub portion 15 having a section 16 for removably attaching a protective storage cover, a slidable needle guard 22 a being fixedly attached to said hub portion 15 by means of a limiting tether 24 , said tether 24 being slidably disposed through an aperture on said hub 9 , said needle guard 22 a having a projection or finger post 80 for advancing said separable catheter 29 and said needle guard 22 a along said hypodermic needle 10 so said catheter 29 may be inserted into a blood vessel, said hypodermic needle 10 being slidable through a guide aperture in said movable needle guard 22 a , said needle guard 22 a having a movable needle trap 41 with a corresponding slot 31 for receiving the needle trap 41 when said trap 41 moves beyond the needle tip 11 , said needle guard 22 a having an open collar or washer 30 for retaining the resilient member 19 on the proximal end of said needle guard 22 a , said resilient member 19 being slidably held on said needle guard 22 a by the notch or indentation 60 , said movable needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 a into notches 60 and/or 61 , said needle trap 41 also having a notch or indentation 61 for retaining said end coils of said resilient member 19 , with the distal end of said needle guard 22 a having a male section 78 for removably attaching an indwelling I.V. catheter hub 13 , said needle trap 41 having a movable arm 45 and projection 42 for releasably retaining a catheter hub 13 from said male section 78 after insertion of the catheter 29 into a patient. Said catheter hub 13 having at least one flange 301 and an inner channel, recess, slot or undercut 32 for being releasably held by said movable arm 42 . Said movable arm 42 could also comprise a metal component which is inserted during or after said male section 78 is manufactured. Said channel 32 can comprise an annular, or segmented configuration.
Said hub portion 15 could also comprise the latching arm 26 shown in other drawings in this application, otherwise said needle guard 22 a would be releasably held adjacent to said hub portion 15 prior to use by a frictional or wedged means. The disclosed invention is shown in a ready to use state in FIG. 103 .
FIG. 104 is a cross sectional top view of the invention shown showing the catheter introducer needle tip 11 being withdrawn into the needle guard 22 a . The catheter 29 and catheter hub 13 remain releasably held adjacent to said needle guard 22 a as the needle 10 is being withdrawn from the catheter insertion site through the distal guide 47 of said needle guard 22 a . This drawing shows said needle guard 22 a being held within a housing or shroud 85 . Said housing 85 having an inner chamber for receiving a resilient member 19 and a slidable needle guard 22 a , said housing 85 also having exterior projections 86 serving as a non-slip gripping means, said projections 86 can be longitudinal, radial or the like, and may comprise any surface or contour which improves the hold by the user on said housing 85 . Said housing 85 may also have an internal projection 88 for fixedly attaching said needle guard 22 a within said housing 85 , and internal fins 97 to concentrically locate said resilient member 19 within said housing 85 . Said needle guard 22 a being held within said housing 85 by a snap-fit means created by the wedge 66 a and slot 66 b at the proximal end of said needle guard 22 a . Said housing 85 having a corresponding aperture to receive said wedge 66 a and slot 66 b , said aperture having a “lead-in” 96 for easy assembly of said guard 22 a into said housing 85 . Said housing also may have an internal ring or at least one projection 88 which correspondingly is received by a slot 89 in said needle guard 22 a . Said slot 89 and projection 88 may be placed either on the guard 22 a or housing 85 .
Said slidable needle guard 22 a being fixedly attached to a hub portion by means of a limiting tether 24 , said hypodermic needle 10 being slidable through a proximal guide aperture 34 in said movable needle guard 22 a , said needle guard 22 a having a movable needle trap 41 with a corresponding slot 31 for receiving the needle trap 41 when said trap 41 moves beyond the needle tip 11 , said needle guard 22 a having a notch or indentation 60 for releasably holding said resilient member 19 on said needle guard 22 a , said movable needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 a into notches 60 and/or 61 , said needle trap 41 also having a notch or indentation 61 for retaining said end coils of said resilient member 19 , with the distal end of said needle guard 22 a having a male section 78 for removably attaching an indwelling I.V. catheter hub 13 , said needle trap 41 having a movable arm 45 and projection 42 for releasably retaining a catheter hub 13 from said male section 78 after insertion of the catheter 29 into a patient. Said catheter hub 13 having at least one flange 301 and an inner channel, recess, slot or undercut 32 for being releasably held by said movable arm 45 and said projection 42 . Said movable arm 45 could also comprise a metal component which is inserted during or after said male section 78 is manufactured.
Said hub portion 15 could also comprise the latching arm 26 shown in other drawings in this application, otherwise said needle guard 22 a would be releasably held adjacent to said hub portion prior to use by a frictional or wedged means.
FIG. 105 is a cross sectional and cut away top view of the movable needle guard 22 a on an indwelling catheter 29 embodiment containing the elements shown and described in FIG. 104 , showing the needle tip 11 being safely contained within the needle guard 22 a with the arm 45 and projection 42 correspondingly moved inwardly and activated with the needle trap 41 , including a few different versions of the components: said tether 24 being fixedly attached to the housing 85 , said housing 85 having at least one longitudinal nonslip projection 86 , said housing having a distal projection 90 which may snap over said needle guard 22 a when said needle guard 22 a is contained within said housing 85 , said needle guard 22 a having a split line 43 , said projection 42 having a “v” shape. The shape of the projection 42 is not limited to a singular or double faced surface, but might be oval, round, radial, smooth or rough or a combination of any surfaces described herein.
FIG. 106 is a cross-sectional and cut away side view of the present invention ready for use on a male luer syringe shows a full view of the hypodermic needle 10 having a change in profile 3 near the distal end for limiting axially movement of a slidable needle guard 22 relative to the needle tip 11 after positioning said needle guard 22 at the distal end of the needle 10 comprising: a hub 12 with a fixedly attached needle 10 , a means for retaining a separate, movable needle guard 22 , said needle guard 22 having an aperture therethrough for said hypodermic needle 10 , whereby the needle guard 22 is retained in a ready to use position on said hub 12 , with said retained needle guard 22 being urged away from said needle hub 12 by a compressed resilient member 19 , said resilient member 19 being located between, among or amid said hub 12 and said needle guard 22 , said resilient member 19 also being located in an annular fashion surrounding a portion of said needle guard 22 .
Said hub 12 having an aperture therethrough creating a fluid/gas path to said hypodermic needle 10 , at least one flange 101 for attaching the needle hub 12 to a male luer fitting, a needle nest 4 for fixedly attaching the needle 10 , said needle 10 a sharpened distal end 11 and an unsharpened proximal end being fixedly attached to said hub 12 and an integral hub portion 15 having a protrusion 5 located at the distal end of said hub body 15 , said protrusion 5 being connected to the hub portion 15 , said hub portion 15 also having a section 16 for removably attaching a protective storage cover, a moveable latching arm or lever 26 with a touch pad 27 attached to the hub portion 15 by a hinge section 23 , with the moveable latching arm 26 having a protrusion 21 for retaining a component in a releasably retained position on the hub portion 15 , said latching arm 26 also having a protrusion 49 for biasing the latching arm 26 in an outward manner when a compressive force is applied to the releasably held needle guard 22 ; and a movable needle guard 22 having a proximal guide section 34 , a distal needle guide section 47 and a movable needle trap 41 (not shown in this view), a receiving slot 31 to receive the needle trap, a retaining area 44 a with an aperture 48 to receive said protrusion 21 , said needle guard 22 having a compressed resilient member 19 positioned at the proximal end of said needle guard 22 said with the resilient member 19 exerting an extending force on said needle guard 22 ; with said needle guard 22 being releasably held in a compressed position by the hook 21 of the moveable latching arm 26 on said hub portion 15 , an aperture for orienting said needle guard assembly 22 adjacent to said hub portion 12 , said aperture having the hub protrusion 5 positioned therethrough, said latching arm 26 having a protrusion 49 for engaging said needle guard 22 when said needle guard 22 is urged toward said hub portion 12 , said needle guard 22 engages protrusion 49 and manually moves said latching arm 26 in an outward manner ensuring said latching arm 26 moves outwardly releasing the hold on the needle guard 22 .
FIG. 107 is a cross sectional and cut away top view of FIG. 106 containing the elements shown and described in FIG. 106 with the releasably held needle guard assembly 22 (shown in a partial cut away view) being releasably held adjacent to said hub portion 15 , said guard assembly 22 being movable by the stored energy present in the compressed resilient member 19 , said resilient member 19 being slidably retained on said needle guard 22 by the notch or indentation 60 , said movable needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 into notches 60 and/or 61 , said needle trap 41 also having at least one notch or indentation 61 for releasably retaining said end coils of said resilient member 19 , said needle guard 22 having a proximal guide section 34 , a distal needle guide aperture 47 , a needle trap 41 biasly contacting said hypodermic needle 10 by the inherent memory of the molded configuration of said needle trap 41 and/or the extending force of the surrounding resilient member 19 , whereby the advancing movement of said needle guard 22 is limited by a change in profile 3 of said needle 10 , said needle 10 having a sharpened distal end 11 and an unsharpened proximal end being fixedly attached to said hub 12 .
Said needle 10 being fixedly attached to hub 12 in a needle nest 4 , said hub 12 having a flange 16 for removably attaching a protective cover, and at least one flange 101 . Said needle trap 41 being hingedly attached to said needle guard 22 by a hinge section 40 , said needle guard 22 having a receiving slot 31 to receive the needle trap 41 .
FIG. 108 is a cross sectional and cut away top view FIGS. 106 and 107 showing the needle tip 11 being trapped within the needle guard 22 by the movable needle guard 41 , comprising a hypodermic needle 10 having a sharpened tip 11 , said needle guard 22 being limited in its axial movement by means of a change in profile 3 near the distal end of said needle 10 , with the resilient member 19 extended and maintaining an extending force on the needle guard assembly 22 , said needle guard 22 is prevented from advancing further by the limiting feature of said change in profile 3 , said resilient member 19 being slidably retained on said needle guard 22 by the notch or indentation 60 , said movable needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 into notches 60 and/or 61 , said needle trap 41 also having at least one notch or indentation 61 for releasably retaining said end coils of said resilient member 19 , said needle guard 22 having a proximal guide section 34 , a distal needle guide aperture 47 , a needle trap 41 biasly contacting said hypodermic needle 10 by the inherent memory of the molded configuration of said needle trap 41 and/or the extending force of the surrounding resilient member 19 , whereby the advancing movement of said needle guard 22 is limited by a change in profile 3 of said needle 10 , said needle 10 having a sharpened distal end 11 and an unsharpened proximal end being fixedly attached to said hub 12 . Said needle 10 being fixedly attached to hub 12 in a needle nest 4 , said hub 12 having a flange 16 for removably attaching a protective cover, and at least one flange 101 . Said needle trap 41 being hingedly attached to said needle guard 22 by a hinge section 40 , said needle guard 22 having a receiving slot 31 to receive the needle trap 41 .
Said proximal guide 34 is shown here maintaining the needle guard 22 in a substantially concentric manner on said hypodermic needle 10 . Said needle guard 41 also having a tapered or reducing proximal section 304 for non-binding access by the movable resilient member 19 .
FIG. 109 is a full top view of a needle guard 22 having a proximal guide section 34 , a reducing section 304 , a longitudinally shaped chamber 94 , a projection 63 to allow free movement of a movable latch, and a distal guide section 47 . This embodiment utilizes a separate needle guard component.
FIG. 110 is a full front view of a needle guard 22 shown in FIG. 109 , having a longitudinal chamber 94 , a slot 25 to accept a latching means, a distal guide section 47 , and an aperture.
FIG. 111 is a cross sectional view of the needle guard 22 shown in FIG. 109 along axis 111 - 111 showing the slotted configuration, of chamber 94 .
FIG. 112 is a full bottom view of a needle guard 22 shown in FIG. 109 having a notch 60 , a reducing section 304 and a projection 63 to allow free movement of a movable latch.
FIG. 113 is a full rear view of the movable needle guard 22 shown in FIG. 112 having a chamber 94 , an aperture, a notch 60 and a proximal guide section 34 .
FIG. 114 is a full top view of the needle guard 220 for a catheter introducer having an inner chamber 94 , a proximal guide section 34 , a recess 31 to receive a movable needle trap, a middle guide section 93 for locating a needle 10 during assembly procedures, a slot 80 for receiving the proximal end of a separate needle trap 41 , a slotted catheter adapter 78 , a distal guide section 92 , and a projection 91 for releasably holding a catheter hub 13 in a specific orientation on said needle guard 220 .
FIG. 115 is a full front view of the needle guard 220 for a catheter introducer shown in FIG. 114 having a middle guide section 93 for locating a needle 10 during assembly procedures, a slotted catheter adapter 78 , a distal guide section 92 , and a projection 91 for releasably holding a catheter hub 13 in a specific orientation on said needle guard 220 . Said needle guard 220 having a needle 10 therethrough, said needle being contained through said needle guard 220 by the separately attached needle trap 41 . Said needle 10 being concentrically located through said needle guard 220 located by the needle trap 41 .
FIG. 116 is a cross sectional and cut away side view of a separate needle trap 41 having a proximal side 82 which inserts into a slot within a slidable needle guard. Needle trap 41 includes a least one projection 83 for fixedly attaching said needle trap in a needle guard, a lead in side 33 for locating a resilient member during assembly procedures, a notch 61 for maintaining an extending force of said resilient member on said trap 41 , and a plurality of sides or skirts 46 to contain a sharpened tip 11 of a needle 10 within said trap 41 . Said needle trap 41 can comprise plastic, metal, or any other substantially impenetrable material.
FIG. 117 is a full top view of the housing 85 having a lip 90 and internal fins 97 . Said fins 97 can be eliminated by shaping the cross section of said housing 85 to match the housing shape shown in FIG. 120 .
FIG. 118 is a cross sectional and cut away top view of a catheter introducer comprising the components shown and described in FIG. 114 , having a needle 10 with one sharpened distal end 11 , said needle 10 having a change in profile 3 near the distal end of said needle 10 , said needle 10 being fixedly attached to a hub 9 by a needle nest 4 , said hub 9 having a flange or plurality of projections 16 to accept a removable storage cover, said needle 10 having a needle guard 220 being slidably disposed about said needle 10 and initially positioned adjacent to the proximal end of said needle 10 . Said needle guard 220 having a receiving slot 31 for a movable needle trap 41 , a slot 80 for fixedly attaching a separate needle trap 41 , a catheter adapter 78 , and a proximal guide section 34 . Said needle trap 41 having a proximal side 82 which is received in said slot 80 , a plurality of sharp projections 83 for fixedly attaching said needle trap 41 on said needle guard 220 into slot 80 , an extending arm 45 and a projection 42 for releasably holding a catheter hub 13 adjacent to said needle guard 220 , said side 82 having a guide section 84 for locating said needle centrally through said guard 220 . Said separable catheter 29 having a hub 13 and an inner channel, recess, slot or undercut 32 for being releasably held by said movable arm 42 . This embodiment still side loads onto a needle, leaving the delicate tip untouched and sharp.
FIG. 119 is a full top view of the separate needle trap 41 for a syringe or blood collecting assembly, comprising a needle trap 41 , a plurality of skirts 46 , each created by a fold, a notch 61 , a lead in section 33 , a proximal side 82 , created by a fold, having a plurality of sharp projections 83 and a guide section 84 . Notch 61 and lead in section 33 are optional.
FIG. 120 is a cross sectional and cut away top view of a catheter introducer ready for use comprising the components shown and described throughout this application, having a needle 10 with one sharpened distal end 11 , said needle 10 being fixedly attached to a hub 9 by a needle nest, said hub 9 having a lead in area 38 for concentrically locating a movable housing 85 onto said needle 10 , a flange or plurality of projections 16 to accept a removable storage cover, said needle 10 having a needle guard 22 a being slidably disposed about said needle 10 and initially positioned adjacent to the proximal end of said needle 10 . Said hub 9 also having a distal hub section 15 and a flashback chamber located at the distal end of said hub 9 . Said flashback chamber being closed by means of a removable plug 100 .
This drawing shows said needle guard 22 a being held within a housing or shroud 85 , said housing having a tapered configuration, allowing for concentric placement of said resilient member within said housing and an improved gripping means by the user. Said housing 85 having an inner chamber for receiving a resilient member 19 and a slidable needle guard 22 a , said housing 85 may also have exterior serrations or channels serving as a non-slip gripping means. Said needle guard 22 a being held within said housing 85 by a snap-fit means created by the wedge 66 a and slot 66 b at the proximal end of said needle guard 22 a . Said housing 85 having a curb 90 serving as a gripping means, and a corresponding, proximal aperture to receive said wedge 66 a and slot 66 b , said aperture having a “lead-in” 96 for easy assembly of said guard 22 a into said housing 85 .
Said housing 85 and resilient member 19 are assembled onto the needle 10 by an over the needle 10 procedure. The proximal aperture of said housing 85 is substantially larger than the needle 10 diameter, allowing the housing 85 to easily be assembled onto the needle 10 without touching the delicate tip 11 . A means to automatically and concentrically locate the housing 85 on the needle 10 is described in this application. The proximal guide section 34 of the needle guard 22 a is only slightly larger than the needle 10 diameter, allowing a close, concentric fit necessary for the invention to function properly. The needle guard 22 a is loaded onto the needle 10 from the side and once the clam shell guard 22 a is closed, the concentrically located needle guard 22 a slides down the needle 10 shaft and snap fits into the concentrically located housing 85 and resilient member 19 . The side load guard 22 a also works in the same concentric manner once the separate needle trap 41 is fixedly attached to the needle guard 22 a once the guard 22 a and trap 41 are concentrically located on the needle 10 shaft.
Said needle guard 22 a comprising a clam-shell design having a split line 43 , a receiving slot 31 for a movable needle trap 41 , a distal catheter adapter 78 , and a proximal guide section 34 (shown in other drawings in this application). Said needle trap 41 having an extending arm 45 and a projection 42 for releasably holding a catheter hub 13 adjacent to said needle guard 22 a . Said separable catheter 29 having a hub 13 , an inner channel, recess, slot or undercut 32 for being releasably held by said movable arm 45 and projection 42 , and a plurality of flanges 301 to twistedly attach said hub 13 to a luer fitting.
Said slidable needle guard 22 a being fixedly attached to a hub portion 9 by means of a limiting tether 24 , said tether 24 being fixedly attached to said needle guard 22 a by means of an extension 28 . Said needle guard 22 a having a notch or indentation 60 for releasably holding said resilient member 19 on said needle guard 22 a , said movable needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 a into notches 60 and/or 61 , said needle trap 41 also having a notch or indentation 61 for retaining said end coils of said resilient member 19 , with the distal end of said needle guard 22 a having a male section 78 for removably attaching an indwelling I.V. catheter hub 13 , said needle trap 41 having a movable arm 45 and projection 42 for releasably retaining a catheter hub 13 from said adapter section 78 after insertion of the catheter 29 into a patient. Said catheter hub 13 having at least one flange 301 and an inner channel, recess, slot or undercut 32 for being releasably held by said movable arm 45 and said projection 42 .
Said needle guard lead in 33 section on said needle trap 41 could also comprise longitudinal channels to reduce the contact surface area of said resilient member, reducing frictional contact and reducing the amount of material used to manufacture the component.
FIG. 121 is a cross sectional and cut away top view of a catheter introducer safely trapping the needle tip 11 after the catheter 29 has been inserted into a patient, comprising a needle 10 with one sharpened distal end 11 , said needle 10 being fixedly attached to a hub 9 by a needle nest 4 , a flange of plurality of projections 16 to accept a removable storage cover, said needle 10 having a needle guard 22 a being slidably disposed about said needle 10 and said needle tip 11 being safely positioned within said needle guard 22 a . Said hub 9 also having a distal hub section 15 and a flashback chamber located at the distal end of said hub 9 . Said flashback chamber being closed by means of a removable plug 100 . Said hub 15 having a lead in area 38 for concentrically locating a movable housing 85 onto said needle 10 .
FIG. 121 shows needle guard 22 a being held within a housing or shroud 85 having an integral resilient member 19 . Said housing 85 having an inner diameter which locates the compressed resilient member 19 on the notches 60 and/or 61 on said needle guard 22 a , said housing 85 may also have exterior serrations or exterior channels serving as a non-slip gripping means, and a proximal skirt 99 which contacts said hub 15 during assembly, allowing said needle guard 22 a to be pressed into said housing 85 .
Said needle guard 22 a being held within said housing 85 by a snapfit means created by the wedge 66 a and slot 66 b at the proximal end of said needle guard 22 a . Said wedges 66 a may have a longitudinal opening 81 at the split line 43 to allow said wedges 66 a to compress as said needle guard 22 a is snap fit into said housing 85 . Said housing 85 may also have a distal curb 90 , described in FIG. 105 , serving as a gripping means, and a corresponding proximal aperture to receive said wedge 66 a and slot 66 b , said proximal aperture having a “lead-in” 96 for easy assembly of said guard 22 a into said housing 85 . Said housing 85 is centrally located onto said needle 10 by an over the needle procedure. Said housing 85 having a proximal skirt 99 with an internal annular chamfer for concentrically locating said housing 85 onto said needle 10 and hub 9 by means of chambered configuration of said needle nest 4 . Said skirt 99 is not necessarily needed to implement the present invention.
Said needle guard 22 a comprising a clam-shell configuration having a split line 43 , a receiving slot 31 for a movable needle trap 41 , a distal catheter adapter 78 , and a proximal guide section 34 (shown in other drawings in this application). Said needle trap 41 having an extending arm 45 and a projection 42 for releasably holding a catheter hub 13 adjacent to said needle guard 22 a . Said separable catheter 29 having a hub 13 , undercut 32 for being releasably held by said movable arm 45 and projection 42 , and a plurality of flanges 301 to attach said hub 13 to a luer fitting.
Said undercut 32 can be annular or segmented and still provide a holding means to keep said catheter hub 13 adjacent to said needle guard 22 a until said needle tip 11 is fully contained within said needle guard 22 a.
Said slidable needle guard 22 a being fixedly attached to a hub portion 9 by means of a limiting tether 24 , said tether 24 being fixedly attached to said needle guard 22 a by means of a extension 28 or the like. Said needle guard 22 a having a notch or indentation 60 for releasably holding said resilient member 19 on said needle guard 22 a , said movable needle trap 41 having a lead-in area 33 for locating said resilient member 19 on said needle guard 22 a into notches 60 and/or 61 , said needle trap 41 also having a notch or indentation 61 for retaining said end coils of said resilient member 19 , with the distal end of said needle guard 22 a having a male section 78 for removably attaching an indwelling I.V. catheter hub 13 , said needle trap 41 having a movable arm 45 and projection 42 for releasably retaining a catheter hub 13 from said adapter section 78 after insertion of the catheter 29 into a patient. Said catheter hub 13 having at least one flange 301 and an undercut 32 for being releasably held by said movable arm 45 and said projection 42 .
FIGS. 122A , 122 B and 122 C show an isometric view of the catheter described in FIGS. 120 and 121 as the catheter adapter 9 is separated from catheter 29 .
FIG. 123 is a full top view of the separate needle trap 41 for the indwelling catheter invention, comprising a needle trap 41 , a plurality of skirts 46 , each created by a fold or bend, a notch 61 , a lead in section 33 , a proximal side 82 , created by a fold or bend, having a plurality of sharp projections 83 and a guide section 84 , a ledge, or retainer 27 created by at least one fold or bend, an extending arm 45 , created by a fold or bend, and a projection 42 , created by a fold or bend.
FIG. 124 is a full and cut away view of FIG. 123 comprising a separate needle trap 41 for the indwelling catheter invention, comprising a needle trap 41 , a plurality of skirts 46 , each created by a fold or bend, a notch 61 , a lead in section 33 , a proximal side 82 , created by a fold or bend, having a plurality of sharp projections 83 , a ledge, or retainer 27 created by a fold or bend, an extending arm 45 , created by a fold or bend, and a projection 42 , created by a fold or bend.
FIG. 125 is a is a full, outside, top view of the needle guard assembly 22 a for an indwelling catheter shown in its molded configuration comprising a foldable, open-faced needle guard 22 a having an extended mounting section 28 , a catheter adapter 78 , a notch 60 for positioning and maintaining the extending force of a resilient member 19 (not shown) on said needle guard 22 a when said guard 22 a is in a retained and extending mode, and a wedge 66 a and slot 66 b at the proximal end of said needle guard 22 a . Said needle guard 22 a having a movable needle trap 41 being hingedly attached to said needle guard 22 a by a hinge 40 , said needle trap 41 having an extended arm 45 and projection 42 for releasably retaining a catheter hub from said adapter 78 after insertion of the catheter 29 into a patient. Said needle trap 41 also having at least one notch or multi-level landing 61 for proper positioning of a resilient member 19 (shown in other drawings in this application), said needle trap 41 having a lead in area 33 also for locating said resilient member 19 in a compressed and/or extendible position. Said needle guard 22 a being fixedly attached to a tether 24 , said tether 24 having at least one protrusion 20 for fixedly attaching said tether 24 to said hub portion 15 or hub 12 , or flange 16 .
FIG. 126 is a is a full, inside face view of the needle guard assembly 22 a for an indwelling catheter shown in its molded configuration comprising a foldable, open-faced needle guard 22 a having an extended hinge section 28 , a wedge 66 a and slot 66 b located at the proximal end of said needle guard 22 a , said needle guard 22 a having a movable needle trap 41 being hingedly attached to said needle guard 22 a by a hinge 40 , said needle trap 41 having an extended arm 45 and projection 42 for releasably retaining a catheter hub from said adapter 78 after insertion of the catheter into a patient. Said needle guard 22 a also having a proximal guide section 34 and a distal guide section 47 , which are created when the needle guard 22 a sections are joined together, said needle guard 22 a also having a middle guide section 93 . Said needle guard 22 a having a movable needle trap 41 being hingedly attached by the hinge 40 , said needle trap 41 having at least one skirt or fin 46 for entrapping said sharpened needle tip 11 (shown in other drawings in this application), said needle guard 22 a having a corresponding slot or opening 31 for receiving said needle trap 41 , said needle guard 22 a having at least one pin 36 and a corresponding opening 37 for frictionally engaging or snap fitting said needle guard 22 a sections together about the hypodermic needle 10 (as shown in previous drawings) said pin 36 and slot 37 can be positioned on either side of needle guard 22 a sections, said needle guard 22 a having an internal guide section 35 and a proximal guide section 34 , said needle guard 22 a having an internal landing 52 located between said internal guide 35 , with said landing 52 having an adjacent landing 53 which serves to guide said hypodermic needle 10 (shown in other drawings in this application) during assembly, storage and use, said landing 53 also houses said sharpened needle tip 11 (shown in other drawings in this application) within said needle guard 22 a.
Said needle guard 22 a being fixedly attached to an integral, or separate, tether 24 . Said tether 24 connects to a hub 15 (not shown).
FIG. 127 is a full front view of the clam shell needle guard assembly 22 a for an indwelling catheter shown in an open-faced configuration comprising a needle guard assembly 22 a having a movable needle trap 41 , said needle trap 41 having an extended arm 45 and a projection 42 , an internal guide section 35 , a distal catheter adapter 78 , an extended hinge section 28 , with a plurality of needle guard 22 a sections connected adjacent to said hinge section 28 , said hinge section 28 having an adequate area for insert molding a separate tether or fixedly attaching said separate tether 24 , said hinge section 28 also could have an aperture therethrough for fixedly inserting a separate tether 24 . Said needle guard 22 a having a split line 43 where the needle guard 22 a sections mate or join together, an aperture guide 47 on each section at the distal end, and a post 36 for joining the needle guard assembly 22 a sections together. Said post 36 is received by a corresponding slot or opening 37 on the adjacent half of said needle guard 22 a.
FIG. 128 is a full rear view of the needle guard assembly 22 a for an indwelling catheter shown in an open-faced configuration comprising a needle guard assembly 22 a having an extended hinge 28 for joining each needle guard 22 a section together, said extended hinge section 28 having a slot or recess for inserting a fixedly attached, or separate tether (not shown). Said needle guard 22 a also having an internal guide section 35 , a split line 43 where the needle guard 22 a sections mate or join together, a proximal guide 34 and proximal wedge projection 66 a located on each needle guard 22 a section, a moveable needle trap 41 , at least one post or protrusion 36 on one needle guard assembly 22 a section which enters at least one corresponding slot 37 on the other needle guard assembly 22 a section for securing the sections together. Said post 36 is received by a corresponding slot or opening 37 .
FIG. 129 is a cross sectional view of the needle guard 22 a in FIG. 126 shown along axis 129 - 129 and comprising a needle guard section 22 a , an internal guide section 35 having an angled face to concentrically locate said hypodermic needle through said needle guard 22 a , a landing 52 and a split line 43 .
FIG. 130 is a cross sectional view of the disclosed needle guard 22 a in FIG. 126 shown along axis 130 - 130 and comprising a needle guard section 22 a , and a needle trap 41 having a plurality of skirts or wall sections 46 .
FIG. 131 is a full side view of the hollow bore needle 10 of the present invention having an expanded change in profile 3 and a sharpened, distal tip 11 .
FIG. 132 is a full top view of the disclosed hollow bore needle 10 having a reduced change in profile 3 a and a sharpened, distal tip 11 .
FIG. 133 is a full side view of the disclosed hollow bore needle 10 in FIG. 131 having an expanded change in profile 3 and a sharpened, distal tip 11 and a slidable washer or bushing 130 adjacent to said expanded change in profile 3 . Washer 130 is limited in axial movement by larger size of expanded change in profile 3 .
FIG. 134 is a cross sectional side view of FIG. 133 comprising a hollow bore needle 10 having an expanded change in profile 3 and a sharpened, distal tip 11 with a slidable washer or bushing 130 having an aperture 131 sized to allow washer 130 to slide axially on needle 10 , but axial movement of washer 130 on needle 10 is limited by the expanded change in profile 3 because the aperture 131 is smaller than the change in profile 3 .
FIG. 135 is s full front view of washer or bushing 130 having an aperture 131 .
FIG. 136 is a cross sectional and cut away side view of the needle guard assembly of the present invention showing the needle tip 11 being trapped within the needle guard 22 by the movable needle guard 41 , comprising a hypodermic needle 10 having an expanded change in profile 3 and sharpened tip 11 , said needle guard 22 being limited in its axial movement by engagement of bushing or washer 130 with expanded change in profile 3 near the distal end of said needle 10 , said washer being retained by slot 132 in needle guard 22 , with the resilient member 19 extended over movable needle trap 41 and maintaining said needle trap 41 in a locked position. Said needle trap 41 being hingedly attached to said needle guard 22 by a hinge section 40 , said needle guard 22 having a receiving slot or nest 31 to receive the needle trap 41 .
Said proximal guide 34 and washer 130 are shown here maintaining the needle guard 22 in a substantially concentric manner on said hypodermic needle 10 . Said needle guard 41 also having a tapered or reducing proximal section 304 for non-binding access by the movable resilient member 19 .
FIG. 137 is a cross sectional and cut away side view of the needle guard assembly 22 shown in FIG. 136 showing the needle tip 11 being trapped within the needle guard 22 by the movable needle trap 41 , said needle trap having a rib or protrusion 133 to closely contain said needle 10 within needle guard assembly 22 , comprising a hypodermic needle 10 having an expanded change in profile 3 and sharpened tip 11 , said needle guard 22 being limited in its axial movement by engagement of bushing or washer 130 with expanded change in profile 3 near the distal end of said needle 10 , said washer being retained by slot 132 in needle guard 22 , with the resilient member 19 extended over movable needle trap 41 and maintaining said needle trap 41 in a locked position. Said needle trap 41 being hingedly attached to said needle guard 22 by a hinge section 40 , said needle guard 22 having a receiving slot or nest 31 to receive the needle trap 41 .
FIG. 138 is a cross sectional front view of the needle guard assembly 22 shown in axis 138 - 138 of FIG. 137 showing the needle 10 being trapped within the needle guard 22 by the movable needle trap 41 , said needle trap having a rib or protrusion 133 to closely contain said needle 10 within needle guard assembly 22 .
FIG. 139 is a full front view of the needle guard assembly 222 comprising an off set split line 143 creating aperture 147 that needle 10 can slide through, and a corresponding needle guard section 223 .
FIG. 140 is a full side view of a prior art needle 310 having an anti-coring tip 311 and a bend, or change in axis, 303 on needle shaft 310 .
FIG. 141 is a cross sectional side view of needle 310 being covered with slidable housing 322 , said needle 310 having an anti-coring tip 311 and a bend, or change in axis, 303 at a position on the needle shaft 310 that limits axial movement of housing 322 on shaft 310 , said housing 322 having a distal opening 347 , a proximal guide shaft 334 that is sized to slide on shaft 310 , said housing 322 is limited in axial movement on shaft 310 by proximal guide 334 engaging bend 303 . Said proximal guide 334 being sufficient to limit axial movement of housing 322 on needle 310 .
FIG. 142 is a cross sectional side view of needle 310 having an anti-coring tip 311 and a bend, or change in axis, 303 in the needle shaft 310 that limits axial movement of bushing 313 on shaft 310 . A needle guard assembly as shown in FIGS. 136 and 137 may include bushing 313 to limit axial movement of a needle guard assembly on shaft 310 .
FIG. 143 is a cross-sectional side view of the needle guard assembly of the present invention showing the interaction of the needle guard assembly 322 and resilient member 319 , said hypodermic needle 310 having an anti-coring sharpened needle tip 311 and a change in axis 303 , comprising a slidable needle guard assembly 322 with a hypodermic needle 310 therethrough, with resilient member 319 urging the needle guard assembly 322 toward the distal end of the hypodermic needle 310 . The needle guard assembly 322 having proximal guide section 334 , a movable needle tip guard 341 with a hinge section 340 , said needle tip guard 341 is molded in a manner whereby the needle tip guard 341 comprises an inherent biasing force toward the hypodermic needle 310 , another biasing force is exerted on the needle tip guard 341 by the extending force of the resilient member 319 , said needle tip guard 341 enters the corresponding recess 331 when said needle tip guard 341 advances beyond the sharpened needle tip 311 , said needle tip guard 341 slidably contacts said hypodermic needle 310 .
FIG. 144 is cross-sectional side view of the needle guard assembly shown in FIG. 143 showing containment of the sharpened needle tip 311 within the needle guard assembly 322 comprising a needle guard assembly 322 with a hypodermic needle 310 therethrough, said needle guard assembly 322 being urged beyond the distal end of the hypodermic needle 310 and sharpened needle tip 311 by the extending force of a resilient member 319 whereby the moveable, self-biasing needle tip guard 341 of the needle guard assembly 322 moves in front of the sharpened needle tip 311 , containing the sharpened needle tip 311 within the needle guard assembly 322 and behind the substantially impenetrable needle tip guard 341 having a hinge section 340 . The needle guard assembly 322 having proximal guide section 334 that engages bend in needle 303 to limit axial movement of needle guard 322 on needle 310 .
Additionally, the extending force of the resilient member 319 urges the needle tip guard 341 inwardly to a covering position, said resilient member 319 surrounds both the needle guard assembly 322 and the outer wall of the needle tip guard 341 holding the needle tip guard 341 in a closed, protective position by a radially confining force. In the protected, closed position, the needle tip guard 341 enters the corresponding recess 331 of the needle guard assembly 322 , preventing movement and ensuring safe containment of the sharpened needle tip 311 within the needle guard assembly 322 .
FIG. 145 is a full side view and cut away drawing of the needle hub of the present invention comprising a hypodermic needle hub 612 with at least one flange 601 for attaching the needle hub 612 to a luer fitting, a needle nest 604 (not shown in this view) for fixedly attaching the needle (not shown in this view), an inner aperture 616 (not shown in this view) creating a fluid/gaseous path between needle hub 612 and needle 610 (not shown in this view), at least one aperture 644 located at the distal end of a deformable housing 615 for receiving a protrusion for releasably retaining a member on needle hub 612 , said housing 615 having an inner cavity or chamber 617 and deformable wall section 650 .
FIG. 146 is a full front view drawing of the needle hub of FIG. 145 comprising a deformable housing 615 having an inner aperture 616 for creating a fluid/gaseous path between hub 612 (not shown in this view) and a hypodermic needle 610 (not shown in this view), said housing 615 having an inner cavity or chamber 617 and deformable wall section 650 .
FIG. 147 is a full top view drawing of the needle hub of FIG. 145 comprising a hypodermic needle hub 612 with at least one flange 601 for attaching the needle hub 612 to a luer fitting, at least one aperture 644 located at the distal end of a deformable housing 615 for receiving a protrusion for releasably retaining a member on needle hub 612 .
FIG. 148 is a full top view drawing of a ready to use needle apparatus of the present invention showing needle guard 622 being releasably retained in deformable housing 615 by engagement of protrusion 645 of needle guard 622 into aperture 644 of deformable member or housing 615 , comprising a hypodermic needle hub 612 with at least one flange 601 for attaching the needle hub 612 to a luer fitting. Said needle guard 622 may include a resilient member (not shown in this view) to propel needle guard 622 to the distal end of needle 610 .
FIG. 149 is a full front view of the needle guard assembly 622 of FIG. 148 comprising at least one protrusion 645 , an off set split line 643 creating aperture 647 and a corresponding needle guard section 623 .
FIG. 150 is a full front view of the needle guard apparatus of the present invention comprising needle guard assembly 622 being releasably retained within deformable member or housing 615 , said housing having a cavity or chamber 617 for accepting a member or guard, said needle guard assembly 622 comprising a passageway for needle 610 , at least one protrusion 645 , an off set split line 643 creating aperture 647 and a corresponding needle guard section 623 , said deformable housing 615 having at least one aperture 644 located at the distal end for receiving and releasably retaining protrusion 645 of needle guard assembly 623 within cavity 617 of housing 615 .
FIG. 151 is a full front view of the needle apparatus of FIG. 150 showing the needle guard assembly 622 being selectively released when a compressive force “F” is exerted on deformable housing 615 , said needle guard assembly 622 comprising a passageway for needle 610 , at least one protrusion 645 that is released from aperture 644 (not shown in this view) when deformable housing 615 is squeezed. Said needle guard assembly having an off set split line 643 creating aperture 647 creating a passageway for needle 610 , and a corresponding needle guard section 623 , said deformable housing 615 having at least one aperture 644 located at the distal end for releasably retaining protrusion 645 of needle guard assembly 623 within cavity 617 of housing 615 .
FIG. 152 is an isometric view of the needle guard assembly 622 ready to usereleasably being retained within deformable housing 615 having a deformable wall section 650 , said housing 615 being selectively attachable to hub 602 having a luer end 601 , said needle guard assembly 622 comprising a movable trap 641 , a passageway for needle 610 with a sharpened tip 611 and a change in profile 603 , at least one protrusion 645 (shown retained within aperture 644 of housing) on section 623 , an off set split line 643 creating aperture 647 and corresponding needle guard section 623 , said deformable housing 615 having at least one aperture 644 located at the distal end for receiving said protrusion 645 of corresponding needle guard assembly 623 . Said housing 615 having an inner guide or rib 651 to properly position needle guard 622 within hub 615 , said housing 615 being selectively attached to hub 602 by a retaining means or hook 613 and may include at least one rib 625 for gripping said housing 615 . Needle guard 622 is released from a retained position by squeezing deformable housing 615 and guard 622 is propelled along the needle 610 by resilient member 619 .
FIG. 153 is an isometric view of the needle guard assembly of FIG. 152 showing containment of the sharpened needle tip 611 within the needle guard assembly 622 , said needle guard assembly 622 comprising a movable trap 641 that is locked in a protective position on needle tip 611 , needle guard is limited in axial movement by engagement of needle guard 622 with change in profile 603 of needle 610 . Additionally, when the needle guard assembly 622 is disposed within the housing 615 , the movable trap 641 is interposed between two posts 642 a and 642 b . The interposition of the moveable trap between the two posts 642 a and 642 b limits the rotational movement of the needle guard assembly 622 when the needle guard assembly 622 is disposed within the housing 615 .
A number of embodiments have been disclosed herein as they relate to the needle protective device of the present invention. It is important to understand that many of the elements described herein may be interchangeable. It is also important to note that the invention can comprise a variety of embodiments, ranging from a single piece, injection molded part, where the components are manufactured unitarily, to a plurality of components, all which achieve the desired result of safely capturing the sharpened needle tip.
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A needle tip protective device for use with percutaneous entry needles. In one embodiment, the needle tip protective device includes a needle guard slidably mounted on a hypodermic needle, the latter having a needle tip located at the distal end thereof, and a change of profile formed medially there along. The needle guard is movable along the hypodermic needle and engageable with the change in profile formed thereon. The engagement with the change in profile is configured to correspond with the ability of the needle trap to entrap the needle tip once the needle trap has advanced the sufficient distance distally along the hypodermic needle. In further refinements, the needle trap may be biased toward the distal needle tip of the needle.
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BACKGROUND
1. Field of the Invention
This invention relates generally to the field of image analysis methods and more particularly to methods of creating a mask surrounding an area of interest in an image, such that when the mask is applied to the image (e.g., though a summation operation) only the area of interest remains. The invention is applicable to digital images generally. One area where it is of particular utility is analysis of images of biological specimens. For example, the mask can serve to isolate and highlight areas of interest, such as cancerous cells, in a magnified image of a cellular or tissue specimen.
2. Description of Related Art
In the biology fields, including cytology, histology, and pathology, digital images of tissue and cellular specimens are typically obtained from a microscope equipped with a color camera which records red, green, and blue planes for these images. Frequently, the objects in the specimen can fall into two general types: normal cells and abnormal cells. The abnormal cells may for example be cells which have indicia of cancer, due to their size, shape and/or color.
It is also common practice to apply one or more stains to the specimen on the slide so that the objects of interest have a contrasting color from background objects or objects of less interest so that they are more readily identified and observed. For example, normal cells are often stained (or, counterstained as is usually said) with a stain such Hematoxylin and appear light blue, while abnormal cells (i.e. positive cells) are stained with a different stain, such as 3-amino 9-ethylcarbazol (AEC) so that the abnormal cells have a different color, e.g. reddish brown. Other color combinations are possible and known in the art.
A quantitative analysis of a limited region of interest in an image is performed in some image processing procedures. For example, image analysis techniques may be applied to a limited region of interest in order to quantify the amount of DNA or a protein present in a region of interest. The algorithms used in such techniques are easier to execute if the unwanted areas in the image, i.e., those area extraneous to the area of interest, are eliminated. Hence, masking techniques are used to isolate the region of interest. In known masking techniques, the region of interest in the image is undisturbed, but image information in the peripheral areas outside the perimeter of the region of interest is deleted, e.g., converted to black. To achieve this, a mask is created that is basically black outside of the region of interest and white (pixel values of 255) in the region of interest. The mask is applied to the image using a logical product operation, e.g., AND, wherein 255 operated by AND with any pixel value yields the pixel value and 0 operated by AND with any pixel value yields 0.
The prior art has had difficulty in easily, reliably and automatically creating a mask for a region of interest that is bounded by closed curve. The hard part is telling what “inside” is, i.e., defining the portion of the image comprising the region of interest that is interior of the closed curve. This is particularly so if the closed curve is essentially any arbitrary closed curve. Given that the region of interest in biological specimens can take virtually any conceivable shape, the algorithms have to be able to create a mask for a region of interest that is bounded by any valid closed curve. An arbitrary closed curve is reducible to a complex polygon in a digital image in which the pixels are arranged in rows and columns. Solution of the problem of whether a particular appoint in the image is inside or within any arbitrary closed curve (complex polygon) is a non-trivial problem. There are heuristics approaches that work some but not all the time, but that is not satisfactory if the image analysis procedures are to work reliably and automatically. Other solutions to the problem are more reliable than heuristics methods, but they are exceedingly complex to implement.
The present invention provides a method of creating a mask for a portion of interest in an image that is very easy to understand conceptually and code in software, very rapid to execute in a computer, and works reliably all the time. As such, it presents a useful contribution to the art. The present invention takes advantage of the insight and discovery of a way to define the area outside of the area of interest and create a mask based on the territory peripheral to the closed curve, rather than attempting to find the interior of the region of interest specified by the closed curve.
SUMMARY
In a first aspect, a method is provided for creating a mask isolating a region of interest in an image. The mask serves to delete information in the image that is peripheral to the region of interest. The method includes the step of obtaining a digital image containing the region of interest. For example, this first image may be a magnified color image of a cellular specimen, however the invention is applicable generally. The region of interest is represented by pixels having pixel values. This image is typically displayed on a computer display and a first closed curve is defined in the image, forming a perimeter around the region of interest. The step of defining the closed curve or perimeter will typically be performed by a user on the display of a workstation (e.g., using a mouse to outline the closed curve). If there are any gaps in the curve, the gaps are closed through appropriate algorithms so as to form a single closed curve.
The method includes a step of creating a second image comprising a plurality of pixels. This second image, occasionally referred to herein as an underlay image, is used to create the mask. The second image has a boundary (e.g., a rectangular boundary) corresponding to at least a portion of the first or original image. The first closed curve around the region of interest in the first image is represented in the second image as a matching second closed curve. The second closed curve in the underlay image is contained within the boundary of the underlay image. In one possible embodiment, a software tool is used such that when the user draws the perimeter of the region of interest in the first or original image, the matching closed curve is created simultaneously in the underlay image.
As noted above, the present invention makes use of the insight that it is easier to recognize the areas outside of the closed curve than it is to identify the areas inside of the closed curve. The invention carries this out by assigning all pixels on the boundary of the underlay image with a first pixel value, e.g., the minimum pixel value, e.g., 0 in an 8 bit quantization scheme (black) and similarly assigning the first (minimum) pixel values to all the other pixels peripheral to the second closed curve, e.g., by flood filling techniques. Additionally, all pixels in the underlay image within the region bounded by the second closed curve are assigned a second pixel value, e.g., 255 (white). This can be achieved by initializing the underlay image such that all pixels in the underlay image have pixel values of 255, creating the closed curve in the underlay image as a black line, and flood filling the peripheral pixels with minimum values (black).
The underlay image with the pixel values assigned as recited is then saved in memory as a mask. Application of the mask to the first image (e.g., by a logical AND operation) deletes image information for areas peripheral to the region of interest and leaves pixel values for the region of interest undisturbed. The areas peripheral to the region of interest appear black, whereas the region of interest pixels appear as in the original. Alternatively, after the mask has been applied to the original image, the resulting image can be reversed such that the peripheral areas appear white and the region of interest appears as in a negative.
In a related aspect, a workstation for creating a mask for a digital image composed of pixels having pixel values is provided. The mask isolates a region of interest in the image and deletes information in the image peripheral to the region of interest. The workstation comprises a processing unit, a user interface including a display and a pointing device associated with the display, and a memory storing the image. The workstation further includes machine-readable instructions for execution by the processing unit. The machine-readable instructions comprising instructions for:
1) displaying the image on the display; 2) providing the user the ability to define with the pointing device and the display a first closed curve forming a perimeter around the region of interest; 3) creating a second (underlay) image comprising a plurality of pixels, the second image having a boundary corresponding to at least a portion of the image encompassing and enclosing the region of interest, 4) creating in the second image a second closed curve within the boundary matching the first closed curve; 5) assigning all pixels in the second image on the boundary and peripheral to the second closed curve with a first pixel value (e.g., 0) and assigning all pixels in the second image within the region bounded by the second closed curve a second pixel value, e.g., 255 (white) and 6) applying the mask to the image and thereby deleting information peripheral to the region of interest and leaving pixel values for the region of interest undisturbed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is diagram on biological image environment in which the invention can be employed.
FIG. 2 is a magnified image of a tissue sample that may contain one or more regions of interest shown displayed on the user interface of the general-purpose computer of FIG. 1 .
FIG. 3 is a further magnified portion of the image of FIG. 2 , shown displayed on the user interface of the general-purpose computer, showing the user tracing a closed curve forming the perimeter of a region of interest with a mouse.
FIG. 4 is an illustration of a second or underlay image initialized to all pixel values equal to a maximum value, showing the outline of a closed curve in black that matches the closed curve drawn by the user in FIG. 3 .
FIG. 5 is an illustration of the underlay image of FIG. 4 which forms a mask after a flood-fill operation has been performed to assign pixel values for the perimeter pixels and all pixels outside of the closed curve a minimum value (e.g., 0 in an 8 bit gray scale system). The area within the closed curve is white (pixels values equal to 255 in an 8 bit system).
FIG. 6 shows the result of application of the mask of FIG. 5 to the image of FIG. 3 in the region surrounding the area of interest. The area peripheral to the region of interest are black (contain no image information), whereas the pixels in the region of interest are undisturbed.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
While the present image mask invention is applicable generally to digital images containing a region of interest, a presently preferred embodiment is in the field of imaging of biological samples and the invention will therefore be described in this context. FIG. 1 is an illustration of digital image acquisition apparatus that includes a microscope 10 , X-Y stage 12 for holding a slide 14 containing a biological specimen, and a plurality of objective lenses for focusing a magnified image of the specimen on the slide 14 onto a charge-coupled device color imaging camera (not shown). The apparatus of FIG. 1 is conventional and known in the art. An image acquired by the camera in the microscope 10 is captured and stored in digital form and therefore can be sent over a communications link to any general-purpose computer 20 . The computer 20 includes a central processing unit (CPU 22 ), a hard disk memory (not shown) for storing the image captured by the microscope, and a user interface including as screen display 24 , computer keyboard 26 and mouse 28 . The computer 20 is conventional and may be any off-the-shelf general-purpose computer. The memory of the computer 20 includes standard image processing and display software, which may consists of a package or suite of such software, for displaying images on the display 24 of the computer 20 . Such software packages are known in the art and commercially available or may be standard equipment with the computer 20 . In FIG. 1 , the display 24 includes a display of the magnified image 30 of the specimen on the slide.
FIG. 2 is another view of the screen display 24 , showing the magnified image 30 of a tissue sample on the slide 24 . The image 30 may contain one or more regions of interest to a user (e.g., pathologist or cytotechnician) operating the computer. The entire slide does not fit into the window shown in FIG. 24 , therefore the image display software includes tools 32 and 34 allowing the user to scroll up or down or from side to side so as to be able to view the entire region of the slide.
FIG. 3 is a further magnified portion of the image 30 of FIG. 2 . The user may access this more magnified view of the slide by activating a suitable icon or entering commands via the keyboard. The user has now identified a region of interest 40 in the slide. The present invention provides a method for providing a mask around the region of interest 40 such that areas peripheral to the region 40 are black (contain no image information) but the region of interest 40 remains undisturbed. Rather than masking the entire slide except for the region of interest, a preferred embodiment masks only a rectangular area surrounding the region of interest 40 .
The user marks the perimeter of the region of interest 40 by using the mouse pointing device 38 , for example clicking the mouse while moving the cursor 38 around the periphery of the region of interest. This action identifies particular pixel addresses that create a closed curve 36 defining the region of interest 40 . In the event that the user accidentally created gaps in the curve 36 , the gaps are closed by constructing lines connecting the end points of defining the gap. This could be done by a suitable algorithm in the software or by prompting the user to click again on the image and close any gaps.
The present invention creates the mask by using a second or underlay image 50 , shown in FIG. 4 . The underlay image in the illustrated embodiment is a rectangular image, comprised of individual pixels 52 (shown greatly enlarged in FIG. 4 ), that corresponds to at least a portion of the original image 30 . In one possible embodiment, the underlay image 50 could have the same number of pixels and be the same size as the original image. In other embodiments, for example where multiple areas of interest may be present in the original image, the underlay image 50 only corresponds to a portion of the original image that immediately surrounds the region of interest designated by the user as in FIG. 3 . In the embodiment of FIG. 4 , as the user draws the closed curve in FIG. 3 , the same closed curve 54 is created in the underlay image 50 . The underlay image size may be dynamically adjusted. The boundary 62 of the underlay image 50 may be dynamically varied substantially simultaneous with the defining of the closed curve 36 , to thereby insure that the underlay image completely encompasses the closed curve 36 (curve 54 in the underlay image). This is the embodiment shown in FIG. 4 . This closed curve 54 is separated from the boundary 62 of the underlay image, as indicated by the gaps 56 between the closed curve 54 and the boundary 62 . The gaps can be created by adding an arbitrary number of rows and columns to the row and column pixel coordinates defining the upper, lower, left hand and right hand bounds of the closed curve. The closed curve 54 separates the interior 60 of the closed curve from the periphery 58 of the closed curve.
The underlay image of FIG. 4 is not necessarily displayed to the user and can simply exist as a file in the memory of the computer. When the underlay image is initially created, the pixel values for all pixels in the underlay image are initialized to a maximum value (white). When the closed curve 36 is drawn as shown in FIG. 3 , the pixels coordinates assigned by the user with their mouse are carried over to the pixel coordinates in the underlay image and each of these pixels are assigned a minimum pixel value (0) corresponding to black.
With the underlay image created as shown in FIG. 4 , the mask is created by flood filling the pixel values for all the pixels in the peripheral region 58 to black ( 0 ). The algorithm automatically knows the pixel coordinates for the boundary of the underlay image, and by definition the boundary is exterior of the closed curve 54 since the boundary was created by adding some positive integer number of pixels to the row and column pixel coordinates of the upper, lower, left hand and right hand extremes of the closed curve. Consequently a simple flood fill algorithm changes all pixel values for the boundary pixels and all pixels exterior of the pixels defining the closed curve 54 . The result is the underlay image forming a mask shown in FIG. 5 , showing interior region 60 , and black pixels in the peripheral region 58 .
The mask is applied to the original image (or a portion thereof) in a logical product operation, wherein 255 ANDed with any pixel value x returns x, and 0 ANDed with any pixel value x returns 0. The result is shown in FIG. 6 . All pixels exterior of the closed curve are black (maximum pixel value) and contain no image information. The interior points containing the region of interest 46 are undisturbed.
Thus, from the above description I have described a method for creating a mask ( FIG. 5 ) isolating a region of interest in an image, as shown in FIG. 6 . The mask serves to delete information in the image that is peripheral to the region of interest, as shown in FIG. 6 . The method includes the step of obtaining a digital image containing the region of interest. For example, this first image may be a magnified color image of a cellular specimen, acquired using the apparatus of FIG. 1 , however the invention is applicable generally. The region of interest 40 ( FIG. 3 ) is represented by pixels in the original image. This image is typically displayed on a computer display. A first closed curve 36 is defined in the image, forming a perimeter around the region of interest. The step of defining the closed curve or perimeter will typically be performed by a user on the display of a workstation (e.g., using a mouse to outline the closed curve), as explained above. If there are any gaps in the curve, the gaps are closed through appropriate algorithms so as to form a single closed curve.
The method includes a step of creating a second image ( FIG. 4 ) comprising a plurality of pixels. This second or underlay image, is used to create the mask. The second image has a boundary 62 (e.g., a rectangular boundary) corresponding to at least a portion of the first or original image. The first closed curve 40 around the region of interest in the first image is represented in the second image as a matching second closed curve 54 . The second closed curve in the second or underlay image is contained within the boundary of the second image. In one possible embodiment, a software tool is used such that when the user draws the perimeter of the region of interest in the first or original image, the matching closed curve 54 is created simultaneously in the second or underlay image of FIG. 4 .
As noted above, the present invention makes use of the insight that it is easier to recognize the areas outside of the closed curve than it is to identify the areas inside of the closed curve. The invention carries this out by assigning all pixels on the boundary of the second image with a first pixel value, e.g., minimum pixel value, e.g., 0 in an 8 bit quantization scheme (black) and similarly assigning the same pixel value to all the other pixels peripheral to the second closed curve, e.g., by flood filling techniques. Any point in the first row (y=0), the first column (x=0), the last row (y=imageheight −1), or the last column (x=image width −1) can be chosen as a starting point for the flood fill algorithm. Once chosen, a floodfill is performed of all pixels of that color (in this case black) to convert them to black (the color of the perimeter line 54 ).
Additionally, all pixels in the second image within the region 60 bounded by the second closed curve are assigned a second pixel value, e.g., 255 (white). This can be achieved by initializing the second image such that all pixels in the second image have pixel values of 255, creating the closed curve in the underlay image as a black line, and flood filling the peripheral pixels with minimum values (black).
The second image with the pixel values assigned as recited is shown in FIG. 5 and then can saved in memory or a buffer as a mask.
Application of the mask of FIG. 5 to the first image (e.g., by a logical AND operation) deletes image information for areas peripheral to the region of interest and leaves pixel values for the region of interest undisturbed. See FIG. 6 . The areas 58 peripheral to the region of interest appear black, whereas the region of interest 40 pixels appear as in the original. Alternatively, after the mask has been applied to the original image, the resulting image can be reversed such that the peripheral areas appear white and the region of interest appears as in a negative.
It will also be appreciated that I have described a workstation or computer 20 for creating a mask for a digital image. The workstation comprises a processing unit 22 , a user interface including a display 24 and a pointing device 28 / 38 associated with the display 24 , and a memory storing the image. The workstation further includes machine readable instructions for execution by the processing unit. The machine-readable instructions comprising instructions for:
1) displaying the image on the display, as shown in FIGS. 2 and 3 ; 2) providing the user the ability to define with the pointing device and the display a first closed curve 36 forming a perimeter around the region of interest, as shown in FIG. 3 ; 3) creating a second (underlay) image ( FIG. 4 ) comprising a plurality of pixels 52 , the second image having a boundary 62 corresponding to at least a portion of the image, 4) creating in the second image a second closed curve 54 within the boundary matching the first closed curve (as shown in FIG. 4 ); 5) assigning all pixels in the second image on the boundary and peripheral to the second closed curve with a first pixel value corresponding and assigning all pixels in the second image within the region bounded by said second closed curve a second pixel value, as shown in FIG. 5 , and 6) applying the mask to the image as shown in FIG. 6 , e.g., through a logical AND operation, thereby deleting information peripheral to the region of interest and leaving pixel values for the region of interest undisturbed.
While presently preferred embodiments have been described with particularity, variation from the details of the preferred embodiment are contemplated without departure from the true scope and spirit of the invention. For example, the nature of the original image, and the means by which the image is acquired and stored is unimportant. The method works with any arbitrary user-defined closed curve or polygon. Additionally, other pixel values could be chosen, or the black and white pixel values for the masks could be reversed and a different logical or summation operation used to apply the mask to the original image to thereby delete the information exterior to the region of interest.
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A method and system is described for creating a mask that isolates a region of interest in a digital image. The mask is created using a second underlay image that is initialized to 255 pixel values (white). A user identifies a region of interest in the digital image by drawing a closed curve around the region of interest. The same closed curve is created automatically on the underlay image with black pixel values for the curve. The pixels in the underlay image in the area between the closed curve and the border of the underlay image are assigned pixel values equal to minimum pixel value (black). The pixels in the interior of the underlay image have 255 pixel values (white), due to the initialization of the underlay image. The mask is applied to the original image by a summing operation. Image details peripheral to the region of interest are removed, while the region of interest pixels remain undisturbed.
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BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a pull tab assembly removably mounted on and adapted to manipulate a slider in opening and closing a slide fastener.
Related Invention
The present invention is an improvement in and relating to the invention disclosed in U.S. Pat. No. 4,920,615 to the same assignee, Yoshida Kogyo K. K., Tokyo, Japan.
Prior Art
A slider pull tab disclosed in U.S. Pat. No. 4,920,615 is represented in FIGS. 6-8 inclusive of the accompanying drawings and shown comprising a clamper 100 pivotally connected to a trunnion 101 on a slider body 102, a hook 103 extending from one end of the clamper 100 and having an aperture 104, a resilient member 105 disposed at the lower portion of the hook 103 and normally closing off the aperture 104 of the hook 103 and a pull tab 106 having an annular link 107 for connecting the pull tab 106 to the clamper 100. While this prior pull tab device has many of its inherent advantages, it has now been found that the resilient member 105 is susceptible to deformation leading to loss of its elastic action, if not to physical damage, when subjected to pressure exerted by the annular link 107 rotating in contact with the resilient member 105 as for example in the case of ironing the garment to which the slide fastener is attached.
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide an improved pull tab assembly for slide fastener slider which incorporates structural features tailored to eliminate the foregoing drawbacks of the prior art.
More specifically, the pull tab assembly according to the invention includes means of maintaining a pull tab out of contact with a resilient member even when the pull tab is oriented to underlie a clamper.
The pull tab assembly according to the invention further includes means of facilitating connection and disconnection of the pull tab with respect to a clamper.
The pull tab assembly of the invention also includes means of preventing undue lateral rocking movement of the pull tab.
According to the ivnention, there is provided a pull tab assembly for slide fastener slider which comprises a clamper including an arcuate peripheral wall defining therein an aperture and a transverse bridge linking the confronting ends of the peripheral wall, a hook extending from the confronting ends and having its distal end terminating short of the bridge so as to define an opening, a resilient member supported in the hook, and a pull tab provided at one end with a pair of spaced ears interconnected by a pin, each of the ears having side peripheral walls and an end surface merging through corners with the side walls, and each of the ears having a geometry such that a distance as measured between the end surface and a tangent line of the pin extending in parallel with the end surface is smaller than the width of the opening of the hook and that a distance as measured between the side wall adjoining the corner and a tangent line of the pin extending at right angles to the end surface is larger than the width of the opening.
The above and other features and advantages of the present invention will appear clear from the following detailed description taken in conjunction with the accompanying drawings which illustrate by way of example a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a pull tab assembly embodying the invention;
FIG. 2 is an exploded, perspective view on enlarged scale of the assembly;
FIG. 3 is a cross-sectional view of part of the assembly shown in one operative position;
FIG. 4 is a view similar to FIG. 3 but showing the assembly in another operative position;
FIG. 5 is a plan view on further enlarged scale of the pull tab assembly shown in fully assembled condition; and
FIGS. 6, 7 and 8 inclusive are views utilized to explain the construction and operation of a prior art pull tab assembly.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and firstly FIG. 1, there is shown a pull tab assembly 10 which comprises a clamper 11 and a pull tab 12 releasably connected thereto by a hook 20, the clamper 11 being pivotally connected to a connecting lug or trunnion 14 on a slider body 15 in a well known manner.
As better shown in FIG. 2, the clamper 11 includes an arcuate peripheral wall 16 defining therein an aperture 17 through which the trunnion 14 of the slider body 15 is loosely fitted for pivotal connection of the clamper 11 and a transverse bridge 18 linking the confronting ends 16', 16' of the arcute peripheral wall 16, at which ends are formed shoulders 19, 19 having respective tapered guide surfaces 19', 19'. A hook 20 formed integral with the arcuate peripheral wall 16 has an upper straight wall 21 extending integrally from the confronting ends 16', 16' of the arcuate peripheral wall 16, a lower straight wall 22 and an arcuate wall 23 integrally interconnecting the upper and lower walls 21 and 22 and defining therewith a substantially U-shaped aperture 24 extending transversely of the pull tab body 12. The lower wall 22 of the hook 20 has its distal end terminating short of the transverse bridge 18 so as to define an opening 25 communicating with the aperture 24 and adapted to bring the clamper 11 into and out of engagement with the hook 20. The upper wall 21 of the hook 20 is raised above the level of the arcuate peripheral wall 16 so as to define an opening 26 through which a resilient member 27 is mounted in place in a manner hereafter described.
The hook 20 has a first recess 28 formed in the inner surface of the upper wall 21 and a second recess 29 formed in the distal end of the lower wall 22 for receptive engagement with the resilient member 27 as better shown in FIGS. 3 and 4.
The resilient member 27 thus supported in the hook 20 is in the form of a substantially U-shaped leaf spring which has an upper arm 30 and a lower arm 31 merged together by an arcuate joint 32. The upper arm 30 is provided at its distal end with an upwardly projecting claw 30', and the lower arm 31 is provided at its distal end with a downwardly slanted finger 31'.
The claw 30' and the finger 31' are snappingly received in and retained at the first recess 28 and the second recess 29, respectively, of the hook 20, with the arcuate joint 32 held in surrounding relation to the transverse bridge 18 of the clamper 11 as better shown in FIGS. 3 and 4.
The pull tab body 12 is in the form of a rod provided at one end 12' with a pair of ears 33, 33 diverging toward the clamper 11 and interconnected by a transverse pin 34 with which to displace the lower arm 31 of the resilient member 27 inwardly out of engagement with the second recess 29 of the hook 20 so as to engage the pull tab 12 with the clamper 11 as shown in FIGS. 3 and 4. The ears 33, 33 each have side peripheral walls 33a, 33a tapering off toward the pull tab end 12' and a substantially straight end surface 33b merging through rounded corners 33c, 33c with the side walls 33a, 33a. The ears 33, 33 are spaced apart by a distance substantially corresponding to the width of the hook 20 such that the pull tab 12 once connected to the clamper 11 is retained in place against lateral displacement.
The provision of the guide surfaces 19', 19' being tapered facilitates smooth sliding movement therealong of the ears 33, 33 of the pull tab 12 into the aperture 24 of the hook 20.
According to an important aspect of the invention, each of the ears 33, 33 has a geometry such that a distance B as measured between the end surface 33b and a tangent line 34a of the pin 34 extending in parallel with the end surface 33b is smaller than the width A of the opening 25 of the hook 20 and that a distance C as measured between the side peripheral wall 33a adjoining the corner 33c and a tangent line 34b of the pin 34 extending at right angles to the end surface 33b is larger than the width A of the opening 25 of the hook 20, as depicted in FIGS. 3 and 4. This geometric concept contributes to a maximum of ease with which to mount and dismount the pull tab 12 with respect to the clamper 11 and at the same time precludes the possibility of the pin 34 of the pull tab 12 jamming against and injuring the resilient member 27 even in the event the pull tab 12 is flipped down to undlie the clamper 11 as shown in FIG. 4.
Obviously, various modifications and variations of the present invention are possible in the light of the above teaching. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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A pull tab assembly for slide fastener slider is disclosed, which comprises a clamper having at one of its ends a hook, a resilient member supported in the hook and a pull tab having a pair of ears which each have such a geometry that can facilitate mounting and dismounting of the pull tab with respect to the clamper and further protect the resilient member against deformation or damage.
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FIELD OF THE INVENTION
This invention relates to a gear crank for a bicycle, and more particularly to a gear crank comprising a one-piece crank which integrates a crank shaft with a pair of crank arms, and a chain gear fixed to the crank.
BACKGROUND OF THE INVENTION
Conventionally, a gear crank of the type described above and, as shown in FIG. 5, has a pair of crank arms b and c connected integrally with both axial ends of a crank shaft a so as to form a one-piece crank d. A flange e is provided at an end of one crank arm b at one axial end side of crank shaft a, a chain gear f is fitted onto the end of crank shaft a, and a ball holder g is screwed therewith, the ball holder g and flange e holding therebetween the chain gear f. A ball race i is mounted on one axial end of a bottom bracket h of a bicycle. The one-piece crank d is inserted through bottom bracket h from the other crank arm c and balls k are interposed between the ball holder g and the ball race i, so that crank shaft a is supported at its one axial end rotatably to bottom bracket h, At the other axial ends of bottom bracket h and crank shaft a are provided a ball race l and a ball holder m, and balls n are interposed therebetween, so that crank shaft a is supported at the other axial end thereof rotatably to bottom bracket h. A nut o is screwably tightened to crank shaft a outside ball holder m.
With this construction if a tooth breaks on the chain gear f, it needs to be exchanged, and the nut o, ball holder m and ball race l, must be removed following which the, one-piece crank d is drawn out of bottom bracket h, and thereafter chain gear f is removed from crank shaft a by unscrewing ball holder g. A new chain gear is mounted on crank shaft a and the one-piece crank d is reset to bottom bracket h. This exchange of chain gear f is very troublesome and impracticle for a user.
SUMMARY OF THE INVENTION
An object of the invention is to provide a gear crank very simple procedure to exchange a chain gear without requiring this dismounting of a one-piece crank from a bottom bracket of the bicycle.
The gear crank of the invention is so constructed that a crank shaft of a one-piece crank is provided at the axially outer surface of one axial end of the crank shaft with a face perpendicular to the axis of the crank shaft for receiving the chain gear. The receiving face is provided with a threaded portion extending axially of the crank shaft and the chain gear is provided with a first through bore through which a screw member is inserted to fix therewith the chain gear to the crank and a second through bore through which one crank arm is inserted, so that the chain gear is seated on the receiving face and the screw member screws with the threaded portion, whereby the chain gear is detachably fixed outside of the crank.
Therefore, the gear crank of the invention need not dismount the one-piece crank from the bottom bracket for renewing the chain gear when its tooth is broken. In other words, even an expert user can readily exchange the chain gear keeping the one-piece crank set to the bottom bracket.
These and other objects of the invention will become more apparent in the detailed description and example which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially omitted longitudinal sectional view of an embodiment of a gear crank of the invention,
FIG. 2 is a partially omitted perspective view of the FIG. 1, embodiment,
FIG. 3 is a perspective view of the gear crank in FIG. 2, from which a chain gear is removed,
FIG. 4 is a partially cutaway front view only of a principal portion of a modified embodiment of the invention, and
FIG. 5 is a partially omitted longitudinal sectional view of an exemplary conventional gear crank.
DETAILED DESCRIPTION OF THE INVENTION
A gear crank of the invention comprises a one-piece crank 1, a chain gear 2 and a screw member 3 for fixing chain gear 2 to crank 1. The crank 1 comprises a crank shaft 4 and a pair of crank arms 5 and 6 fixed to both axial ends of crank shaft 4, the crank shaft 4 being provided at the outer peripheries of both axial ends thereof with screw threads 7 and 8 respectively, the crank arms 5 and 6 being integral with crank shaft 4 at a phase difference of 180°.
Referring to FIG. 1, the one-piece crank 1, like the conventional one piece crank shown in FIG. 5, is supported rotatably to a cylindrical bottom bracket 10 of the bicycle through ball races 11 and 12 provided at the inner peripheries of both axial ends of bottom bracket 10, ball holders 13 and 14 screwed with screw threads 7 and 8 at crank shaft 4, and balls 15 and 16 interposed between the ball races 11 and 12 and the ball holders 13 and 14 respectively. In addition, reference numeral 18 designates a lock nut and 19 designates a sealing member.
A face 20 for receiving chain gear 2 is formed at the axially outer surface of one axial end of crank shaft 4 and at the root of one crank arm 5, and a threaded bore 21 extending axially inwardly of crank shaft 4 is provided at the center of receiving face 20.
At the center of chain gear 2 is provided a first through bore 22 through which the screw member 3 passes, and at a position radially outward from the center of bore 22 is provided a second through bore 23 through which one crank arm 5 passes.
The chain gear 2 is fitted onto crank arm 5 from the utmost end thereof through the second through bore 23 and seated at receiving face 20, and a headed screw member 3 is inserted through the first through bore 22 from its outside and screws with threaded bore 21 at crank shaft 4, thereby fixing chain gear 2 to one-piece crank 1.
In addition, a projection 24 is provided at the inner surface of crank arm 5 and an engaging bore 25 is provided at chain gear 2 opposite to projection 24, so that projection 24 engages with engaging bore 25 so that chain gear 2 integrally rotates with crank arm 5.
The gear crank of the invention constructed as described above is mounted on bottom bracket 10 in the following manner. Ball holder 13 screws with screw thread 7 of crank shaft 4 at the crank arm 5 side (the left-hand side in FIG. 1) and balls 15 are placed on ball race 11, and then one-piece crank 1 is inserted through bottom bracket 10 from crank arm 6 and balls 15 are interposed between the ball race 11 and the ball holder 13, thereby rotatably supporting crank shaft 4 at one axial end thereof; and ball holder 14 is inserted onto crank arm 6 from the utmost end thereof and screwed with screw thread 8 of crank shaft 4 at the right-hand side in FIG. 1 and balls 16 are interposed between the ball holder 14 and the ball race 12 mounted on the other axial end of bottom bracket 10, so that crank shaft 4 is supported at the other axial end thereof rotatably to bottom bracket 10, and lock nut 18 is screwed with crank shaft 4 outside of ball holder 14, thus fixing one-piece crank 1 to bottom bracket 10.
The chain gear 2 is inserted through its second through bore 23 onto crank arm 5 and seated on receiving face 20 and then screw member 3 is inserted through the first through bore 22 and screws with threaded bore 21, thereby fixing chain gear 2 to one-piece crank 1.
The chain gear 2, if its tooth is broken, is drawn out of crank arm 5 after removing screw member 3 and a new chain gear is fixed to one-piece crank 1 in the same steps as abovementioned. Therefore, when chain gear 2 is exchanged, there is no need of dismounting one-piece crank 1 from bottom bracket 10 as conventional, whereby chain gear 2 is very readily exchangable while crank 1 remains set to bottom bracket 10, enabling even an inexperienced user to replace it by himself.
Alternatively, a screw bolt 31, as shown in FIG. 4, may be formed at receiving face 20 and a nut 30 may be used as the screw member for fixing chain gear 2 to crank 1.
While an embodiment of the invention has been shown and described, the invention is not limited to the specific construction thereof, which is merely exemplary of the invention. Accordingly, the invention is not limited by the specification description or drawings, but is only limited by the scope of the claims appended hereto.
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A gear crank comprising a one-piece crank and a chain gear, said crank having a vertical chain gear receiving face formed at the axially outer surface thereof at the one axial end side thereof, so that the chain gear is detachably mounted on the receiving face.
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FIELD OF THE INVENTION
This invention relates generally to virtual reality models, and more particularly to decorating virtual models derived from physical models.
BACKGROUND OF THE INVENTION
In U.S. Pat. No. 4,275,449 “Modeling Arrangements,” Aish describes a set of building blocks as a computer input device for architectural applications. The blocks were geometric solids with connectors on some of the faces, and could be changeably interconnected to form different modeling arrangements whose geometric structure could be read by a computer. Each block had an identifier, which when used as an index into a file of information about the blocks, permitted 3-D renderings to be made of the physical model. Aish devised an approach to reading out the structure of a modeling arrangement that kept the circuitry in each block to a minimum. A host computer directed a search of the structure, selecting one block at a time. That block's identity was read, then neighbors detected and control passed from that block to a neighbor, and so on, until an exhaustive search of the structure had been completed.
Evans, in “Intelligent Building Blocks,” Architect's Journal, Jan. 30, 1985, pp. 47-54, mentions that other information, such as material properties and costs, could also be associated with such blocks, permitting the computer to prepare various architectural analyses and reports about the modeled structures. Frazer, in “An Evolutionary Architecture,” Architectural Association, 1995, describes a more ambitious series of prototypes of machine-readable modeling tools. In general their approach to reading the modeling structure followed Aish's, although they tried several different kinds of building elements, and used them for a variety of applications. In one embodiment, each of Frazer's blocks had eight bits of state reflected in eight LEDs that could be controlled by a host computer. One of the blocks was equipped with six mercury tilt-switches to determine the orientation of the entire model. Another block had magnet-sensitive reed-switches embedded in external cladding panels. As the computer came to poll that block for its identify, the state of these switches could affect the result in a way that would in turn affect the virtual model's rendered appearance.
Frazer also developed a modeling kit whose elements corresponded to the components used in kits for building actual modular homes. The miniature modeling kit included a variety of elements such as wall panels, doors and windows. Software on the computer drew plans, gave feedback on planning errors, estimated costs and energy consumption, etc.
Dewey et al., in “Geometry-Defining Processors for Partial Differential Equations,” B. J. Alder (ed.) “Special Purpose Computers,” Academic Press, 1988, pp. 67-96, describe a set of 3-D blocks similar to some of those built by Frazer's group, but with a different application in mind. The motivation for their geometry-defining processors was to build a re-configurable parallel computer for finite-element simulations of systems studied in mechanical engineering. Thus, the connection geometry of the parallel processing elements could match the geometry of the underlying physical system being modeled, and thereby use the available communications bandwidth more efficiently. Because the principal goal was engineering computation, each building element contained a commercially available microprocessor.
Other related work is described by Gorbet et al. in “Triangles: A Physical-Digital Construction Kit,” Proceedings of Designing Interactive Systems: Processes, Practices Methods and Techniques, August 1997, pp. 125-128, and in “Triangles: Tangible Interface for Manipulation and Exploration of Digital Information Topography,” Proceedings of CHI 98, April 1998, pp. 49-6. In the “Triangles” system, the basic building elements are triangles. Each triangle is a planar, plastic equilateral triangle with an embedded microprocessor. The triangles connect to each other physically and digitally with magnetic, electrically conducting connectors. When connected to each other, the triangles can be tiled on a flat surface, or folded over into more complex surface topologies. When the triangles are connected, information about their identities is exchanged, and messages can be relayed to a host computer. In this way, an application running on the host can determine relationships between the connected pieces, and specific connections can trigger specific digital events. Typical applications include visual programming, visual scripting, and pattern formation.
Key attributes desired of self-describing construction kits include: scalability—the ability to build large structures containing hundreds of building elements, configurability—the ability to connect building elements in rich and varied ways, interactivity—the ability to interact physically and electrically with a constructed artifact, and presentation—the ability to design customized and stylized visual and physical interpretations of constructed artifacts. Known prior art building block systems lack integrated solutions that address these key attributes.
SUMMARY OF THE INVENTION
Only skilled people know how to use graphics modeling packages, such as a CAD/CAM system, but everyone can build things out of blocks. Starting from this premise, and with the goal of developing accessible modeling tools for building and populating virtual worlds, the invention provides a novel object-modeling system. The system includes building blocks that self-describe the geometric structures into which they are assembled. Each building block contains a microcontroller, and can communicate with the other blocks to which it is physically connected.
The invention provides a novel architecture for a distributed computer system comprising self-describing building blocks with embedded microprocessors (microcontrollers). Each self-describing building block is formed of an enclosure having a top surface and a bottom surface. An array of m by n radially symmetric connectors are arranged on the top surface and on the bottom surface of the enclosure, wherein both m and n are greater than one if a rigid structure is required. The connectors are configured to carry power and data signals. A microcontroller, including a memory, is mounted in the enclosure. The microcontroller is coupled to each of the connectors. The microcontroller includes communication means for exchanging data messages using any of the connectors.
The connectors enable a plurality of the blocks to be arranged in a rigid three-dimensional structure. This structure can be recovered by a distributed computation performed by the blocks, and passed to a host computer. The host computer can make the structure available for various applications, including virtual-reality computer games, information management for buildings, and artistic expression.
From the collected block connectivity data, and presorted or editable block attributes, the host can recover the geometric structure of the assembled blocks. The structure can then be rendered in various styles, ranging from a literal rendition, to decorative interpretations in which structural elements are identified automatically and augmented appropriately. After being rendered, the virtual models are available for viewing and manipulation by the user. The automatically decorated models can also be “replicated” using 3D. stereolithography.
After the block connectivity data has been collected, each block can communicate with the host, and with the other blocks. Sensors in the blocks can report their status, and transducers such as lights, speakers, motors, etc., can be controlled. For example, the blocks can be assembled into a model of an actual building, with sensors in the model being used to control the lighting in the building, and sensors in the building being used to control the corresponding lights in the model.
The geometric arrangement of the blocks, as well as sensor data, and transducer controls can also be shared over a network, e.g., the Internet, permitting collaborative design, remote monitoring, and multi-user game playing, for example.
In contrast to the prior art, our system concurrently achieves scalability, configurability, and interactivity, as well as a unique capability to enhance constructed artifacts through automatic, intelligent decoration. This is accomplished using a physical form factor that allows a rich and varied connectivity of building elements; a microprocessor-based, distributed, packet-switching architecture that facilitates efficient and robust computation of connectivity, and the autonomous operation of building elements during interactive use; and the automatic interpretation of constructed artifacts for the purpose of visual and physical decoration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of a construction element or building block according to the invention;
FIG. 2 is a bottom perspective view of the block of FIG. 1;
FIG. 3 is a side view of a circuit board mounted in the block of FIGS. 1 and 2.
FIG. 4 a is a flow diagram of the process used by the building blocks for determining the connectivity of an arrangement of blocks;
FIG. 4 b is a block diagram of a message routed among the blocks;
FIG. 5 is a perspective view of an arbitrary rigid arrangement of building blocks according to the invention;
FIG. 6 shows a literal graphic rendition of the arrangement of FIG. 5;
FIGS. 7-10 are alternative graphic renditions of the arrangement of FIG. 6;
FIG. 11 illustrates a checkerboard signaling pattern;
FIG. 12 is a flow diagram of a process for determining the connectivity of an arrangement of blocks;
FIG. 13 is a diagram illustrating the interaction among a model world made from the construction elements, a graphic virtual world of the model world, and a physical work represented in the model and virtual worlds;
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Block Structure
FIGS. 1-2 shows a construction element 100 according to our invention. FIG. 1 is a top view, and FIG. 2 is a bottom view. The element 100 is in the form of a 2×4×2 building block. Here, 2×4×2 refers to the arrangement of the sixteen connectors on the top and bottom of each block. It should be noted that in general the invention admits any m×n array of connectors on the top and bottom of the block. However, to form a rigid structure both m and n need to be greater than one.
Each block has a unique block identification number (BID), and each connector has an associated connector identification number (CIN 1 , . . . , CIN 16 ).
The block 100 is a two-part plastic enclosure having a top part 101 and removable bottom part 102 . The parts can be fixed together with screws. Holes are formed in the top and bottom to mount connectors 103 - 104 .
The eight top holes are for plugs 103 (CIN 1 , . . . , CIN 8 ), and the eight bottom holes mount jacks 104 (CIN 9 , . . . , CIN 16 ). To allow the blocks to be connected together in a wide range of orientations, we make the connectors radially symmetric, for example, round.
The dimensions of the blocks (m×n), and the locations of the radially symmetric plugs and jacks are such that multiple blocks can be arranged into the same kind of 3D structures that one could create with LEGO™ building blocks.
Each of the connectors 103 - 104 has two conductors (lines). However, instead of using one conductor for power and one for ground, which is the normal usage for a DC power connector, we use an inner conductor as a signal line 105 for bi-directional data communications, and an outer conductor or sleeve 106 for power distribution. In an alternative embodiment described below, a single conductor is used for both power and data signal. In this case, the power signal is modulated to carry the signal.
The outer conductors 106 are wired so that adjacent connectors alternate power and ground signals on their outer sleeves, in a pattern similar to one described in U.S. Pat. No. 4,883,440 “Electrified Toy Building Block with Zig-Zag Current Carrying Structure” issued to Bolli. Thus, every block will have at least one connection to power and one to ground in any typical structure built with the blocks.
When the blocks are connected, there is no way to tell a priori which sleeves are connected to power and which sleeves are connected to ground. We solve this problem as shown in FIG. 11 . All of the sleeves for one of the polarities 1101 are connected to one of the inputs of a full-wave bridge rectifier 320 , see FIG. 3, and all of the sleeves for the other polarity 1102 to the other input of the rectifier 320 . The output of the bridge rectifier is a supply voltage with a known power and ground polarity. Note that there is a voltage drop as the power passes through the full-wave bridge rectifier 320 and as power passes through the connectors 103 and 104 .
This supply voltage is then fed into a voltage regulator 330 that outputs correctly regulated power for the integrated circuits used within the block's circuitry. The voltage regulator ensures that the correct voltage is supplied to the circuitry independent of the input voltage to the regulator, so long as voltage is sufficiently high. This allows higher voltage, unregulated power to be distributed from block to block. This in turn allows a greater distance from the power source to the power consumer, and thereby enabling the construction of larger structures.
Data communication according to our invention, described in greater detail below, is done without the use of a global communication bus. Instead, we use a message passing protocol via the signal lines 105 .
Two holes 107 are formed in each side of the block. A light emitting diode (LED) is mounted behind each hole so that there is a visual indication of the block's operation.
As shown in a side view in FIG. 3, a circuit board 300 is mounted in the block 100 . The connectors 103 - 104 are fixed to the circuit board, as are the LEDs 301 . The connectors form the physical mounting basis for the circuit board. A microcontroller 310 , the rectifier 320 , and the voltage regulator 330 are mounted on the board. We use a Microchip™ Technology Inc. PIC16C77 microcontroller. The microcontroller includes a random access memory. The board 300 also includes pads for the connector plugs and jacks, and assorted analog elements, i.e., resistors, capacitors, and a crystal to generate the clock for the microcontroller.
Several pads in the periphery of the circuit board are left open to accommodate additional transducers and sensors inside the block, such as a speaker 110 shown in FIG. 2, motors, RF, IR, ultrasound, and microwave transmitters, LED, LCD, CRT, and other display devices, cameras, microphones, proximity, presence, motion, and touch sensors 120 , RF, IR, ultrasound, and microwave receivers, and the like. Alternatively, the current board can be trimmed to fit inside a 2×2×2 building block without affecting its basic functionality.
The microcontroller 310 has thirty-three I/O pins of which sixteen are used for data communication via the signal lines of the connectors. The microcontroller includes an eight-bit RISC CPU, 8K of 14-bit words of read-only program memory (PROM), 368 8-bit bytes of data memory (RAM), a hardware Universal Synchronous/Asynchronous Receiver/Transmitter (USART), and interrupt handling. The data memory is used to store temporary data and connectivity information during operation.
We program the controller in assembly language to achieve execution efficiency, and to save code space. At startup, the program and data in each block's microcontroller are identical other than the block's unique identification number (BID).
Operation of Assembled Structure
The operation of our invention is described with reference to FIG. 4 a . An arbitrary number of blocks are connected to each other to form some three-dimensional structure 400 . Because of the constructive versatility of the blocks having an m×n array of radially symmetric connectors, a pair of 2×4×2 blocks can be connected in 184 different configurations, and one 2×4×2 block can be connected to as many as twelve others.
The geometry of the three-dimensional structure is determined using a message-routing protocol. The low-level details of the protocol are described below. At a high level, the protocol operates in three phases. Phase 1 determines connectivity, Phase 2 determines plug-to-jack correspondences, and in Phase 3 , the connectivity database is sent, or “drained,” to, for example, a host computer 480 . The procedures that comprise the three phases operate in parallel 499 in the various blocks. The host computer can be a PC, workstation, or the like.
After these three phases have completed, the bricks enter a final phase known as Phase R (“R” for Routing). This phase allows the blocks to communicate with each other or with the host, and for the host to communicate with the blocks. The blocks function as general-purpose network routers and are also able to autonomously determine the state of sensors and alter the state of transducers during this phase.
Phase 1
Operation commences when we supply a power and ground signal on lines 401 - 402 to a drain block 403 , described below. From the drain block(s), power is distributed to all of the blocks. When the blocks are powered on, they immediately enter Phase 1 ( 410 ). During Phase 1 , the blocks determine their connectivity 411 in parallel. Lacking a global communication bus, the switching on of power is the only source of synchronization, which is necessarily approximate because of small delays in propagating power throughout the entire structure.
All 16 signal lines of each block, i.e., 8 connectors 103 on top and 8 connectors 104 on the bottom, are normally held high by pull-up resistors. Phase 1 is initiated by having each block pull its top signal lines (those in the plugs) low in response to the power signal.
Each block then tests its bottom signal lines (the lines 105 in the jacks 104 ) to determine and store which have been pulled low by some other connected block. After a short delay, to ensure that the approximately synchronized blocks do not try to drive shared signal lines simultaneously in both directions, this test is repeated with the roles of the top and bottom signal lines reversed.
Thus when Phase 1 completes, each block has identified in parallel which of its signal lines are connected, i.e., which connectors are attached to other blocks, but not to which specific other blocks or connectors.
Phase 2
After another short delay, each block enters Phase 2 ( 420 ). This phase has a first bottom-to-top half, and a second top-to-bottom half. During this phase, blocks communicate with neighboring blocks over the connected signal lines identified in Phase 1 to determine plug-to-jack correspondence information 421 . At the start of the first half of Phase 2 , each block first listens on its connected bottom signal lines for transmitted messages that contain the BID of the transmitting block, BID T , and the connector number (CIN) of the connector over which that block is transmitting, CIN T .
Note, transmitted messages may be missed when the receiving block is busy when transmission commences. Electrical interference, or noise, may also corrupt a message. Therefore, all messages are transmitted using a check-summed, acknowledged protocol, and unacknowledged transmissions are retried a predetermined number of times after appropriate timeouts.
The receiving block stores the message content along with its own BID number, BID R , and the connector number over which it received the transmission, CIN R , in its memory, e.g., (BID T , CIN T , BID R , CIN R ). This dataset forms a complete record of a single connection between two blocks. A database 450 of these records stores the local connectivity information in each block.
After a block has successfully received transmissions on all of its connected bottom lines, it begins transmitting on each of its connected top lines, iterating in order of its connector numbers. Connectivity information therefore flows initially through the block structure from bottom to top, with the potential for significant parallel communication. At the completion of this parallel procedure, each block knows to which connector of which block each of its own bottom connectors is attached.
The procedure is repeated during the second half, but with blocks listening on their top connected lines and transmitting on their bottom connected lines. Thus at the end of Phase 2 , each block has acquired and stored in its memory complete knowledge about all of its connected lines: the BIDs of the connected pair of blocks, and the corresponding connector numbers by which they are attached.
Each connected line that is processed successfully in Phase 2 is designated as valid; unconnected lines are deemed invalid.
Phase 3
In Phase 3 ( 430 ), the connectivity information (BIDs and CINs) is communicated to a host computer via the drain block 403 , which includes a serial communication connection to the host computer. In addition to mediating communication between a block structure and the host, the drain also supplies power to the connected blocks, and may be attached to any part of a block structure. In other words, the drain can be configured as block 100 with a serial connection.
During Phase 3 , all blocks listen on all of their valid lines for messages. When a request-to-drain message is received by a block on a particular connector, that connector is designated a “drain” connector. The request-to-drain message can be generated by the drain block 403 and first sent to some block connected to it, or the request-to-drain message can be generated by the host computer and first sent to the drain block 403 . Beginning with Phase 3 , a drain block functions by reliably forwarding messages to a block connected to it; its existence is transparent to the algorithm. In response to receiving the request-to-drain message, a block transmits connectivity messages containing all stored plug-to-jack correspondence information 421 on its “drain” connector, the one from which it received the request-to-drain message.
After the block has successfully completed transmitting the connectivity messages, the block forwards the request-to-drain message on a valid line with the lowest connector number, and the block enters a message-forwarding mode.
If the block receives a connectivity message in response to forwarding the request-to-drain message, then the block forwards that message on its drain connector. If the block receives any subsequent request-to-drain messages, then the block responds with a done message. If the block receives the done message, then the block forwards the request-to-drain message on a valid line with a higher connector number. If all valid lines have been processed, then the block sends a done message on its drain connector.
As stated above, the first request-to-drain message can be injected into the structure 400 by the drain block 403 . The requests then percolate through the block structure in a preorder, depth-first traversal. Although this traversal is performed sequentially, that is, with only one block draining at any point in time, the forwarding of messages towards the drain is pipelined, thereby achieving parallelism in this phase as well.
At the end of Phase 3 , the host 480 has complete connectivity information for the block structure. In fact, the host has redundant connectivity information, because each connection is reported twice, once by each of the two connected blocks. This redundancy contributes to the robustness of the system, but it can be eliminated for efficiency by eliminating the second half of Phase 2 . Because block structures are rigid, their geometry can be inferred deterministically from complete connectivity data. Using geometrical data so inferred, various renderings of block structures can be computed, as described below.
Phase R
Phase R ( 440 ) implements a scalable and responsive approach to providing interactivity. Blocks autonomously report events, rather than being polled for state changes. Using the route-to-drain found in Phase 3 , messages about events are communicated in a store-and-forward fashion through a chain of blocks to the drain block, and on to the host.
In Phase R 440 , blocks listen for general-purpose messages. Each message is check-summed, and successfully received messages are acknowledged. After a timeout, an unacknowledged message is retransmitted until successfully acknowledged.
As shown in FIG. 4 b , messages 460 are composed of a sequence of packets 461 . Each packet contains a prefix 462 which includes a packet sequence number 466 and an optional route-to-drain indication 467 . The packet-sequence number is used to guarantee that packets are received successfully and in the correct order. If the route-to-drain indication is present, then the packet is forwarded to the receiving block's drain connector without further processing. Each packet also includes a header 463 , content 464 , and a checksum 465 .
Phase-R packets are identified by packet type 468 in the header. The header also stores the length 469 of the packet. The accepted packet types include: (1) a Read/Write-RAM/registers packet, (2) a RAM/registers-contents packet, (3) an Alter-LEDs packet, (4) a Play-music packet, (5) a Route-packet-following-specified-path packet. This last packet type allows other packets to be sent to any other block.
The specified path is determined by listing a sequence of Connector Identification Numbers (CIN) over which the packet should be forwarded. Using a form of “worm-hole” routing, each block sets up a forwarding path to the first CIN specified in the list and then removes that CIN from the list that is forwarded to the next block.
Phase R monitors the state of attached sensors, and upon determining a change, autonomously sends a RAM/registers-contents packet to the host, using the route-to-drain indicator, to notify the host of the change. Thus, the host is made aware of the state of all sensors on all of the blocks all of the time. The host may send packets to specified blocks, using the Route-packet type, to cause the blocks to change the state of attached transducers. Thus, the host is able to control accessories attached to the blocks.
As shown in FIG. 4 b , a message 460 is composed of one or more packets 461 . Packets are composed of a sequence of separately synchronized bytes. Each packet contains an optional prefix byte 462 , a message header 463 , message-contents bytes 464 , and a checksum 465 . The prefix stores a sequence number 466 and a route-to-drain indication. The header stores a packet type 468 and a packet length 469 . The content 464 can be routing information (CINs), or actual message-specific data.
Packets are acknowledged, and unacknowledged packets are retransmitted using an adaptive timeout algorithm. Packets are transmitted in a pipelined fashion. Thus, the system using the protocol, as described herein, emulates a self-configuring, store-and-forward computer network. This form of architecture facilitates transducers that require active control, such as speakers or motors, and sensors that require data buffering, such as microphones and cameras.
Graphic Rendering of Structure
As shown in FIG. 4 a , the host 480 has access to a database (DB) 490 . The database stores the BID 491 and attributes 492 for each block in the structure 400 . The attributes can include shape, size, color, texture, and other physical or graphic information associated with the identified block. In other words, the attributes 492 can give the blocks additional characteristics. The attributes can be assigned when the blocks are given their unique BIDs. The database can be edited. This process is illustrated in FIG. 12 .
In FIG. 12, a database 1200 stores the brick specific information. Connectivity information 1210 is received from Phase 3 as described above. Step 1220 infers the placement of the individual blocks. At this point, files 1231 - 1233 , in various standard formats, describing the structure 400 can be generated.
A graphics-rendering application 481 executing on the host can now graphically render 1240 the 3-D geometry 500 of the structure on an output device 485 , and a user can perform Phase R interactions 1250 via a user interface. The application 481 can be any common 3D modeling system. For example, FIG. 6 shows a graphic 600 generated by the host from the physical block structure 500 shown in FIG. 5 . Note, that the rendered shape of the blocks can be different from the physical shape of blocks 100 . For example in FIG. 6, the blocks are made to look like LEGO™ blocks.
In FIG. 10 the same structure 500 has been incorporated as a building 1000 in the well-known Quake™ game. In this rendition, it actually becomes possible to “navigate” through the structure in a virtual-reality environment. In this case, the attributes given to the blocks include game effects, such as explosive walls, trap doors, electrified walls, etc.
Decorative Rendering
In addition, we generate a description of the block structure as a set of logical axioms 493 stored in the database 490 of FIG. 4 a , one axiom to assert the location, orientation, and identification ( 494 ) of each block. These axioms can serve as input to a logic-program application written in, for example, the Prolog language, to identify larger scale structural elements of a block structure through unification-driven pattern matching, e.g., the walls and roof of the structure 500 when the structure is to be interpreted as a building, see Appendix A and B for detailed examples.
Other structural elements identified include windows, doors, corners, roof apexes, etc. Recognized structural elements can then be colored and textured distinctively, and decorated with additional ornamental geometry, to enhance the visual appearance of the rendered model.
In FIG. 7, the graphic 700 shows the identical physical structure rendered as a thatched roof cottage: note the brick texture, roof blocks modified to slope smoothly, and rendered with a mottled texture, and the additional fascia around the base of the roof.
In FIG. 8, the same blocks are rendered as a castle 800 . The crenellated walls are built out of randomly-shaped, colored blocks of stone to create a hand-made appearance. Bars have been placed in the windows. A flagpole has been placed at the apex of the roof, and red turrets have been added at the outside corners.
In FIG. 9, the same blocks 400 or 500 become a wooden fort 900 .
The pattern-matching rules can be expanded to recognize more structural elements of buildings, and to support additional rendering styles. In addition, interpretive and decorative rules for other modeled artifacts, such as vehicles or organic forms, can be devised.
Once rendered in a decorative fashion, the augmented geometry of a structure can be transformed into an appropriate format for 3-D printing, e.g., via stereo lithography. Thus multiple decorative versions of a block structure can be realized physically.
Multi-World Interactivity
The blocks 100 can be equipped with proximity and touch sensors so that the user can interact with the blocks in real-time. Sensor data is conveyed to the host computer via the Phase-R protocol described above. Transducers in the blocks are also controlled via Phase-R messages.
As shown in FIG. 13, these features make possible several monitoring and control applications that relate the real physical world 1301 , a model world 1302 , and a virtual world 1303 connected by a network 1304 . For example, a block-structure model can be created for a real-world building. Virtual representations of the building can be viewed on a computer display. By manipulating switches or sensors on the block structure, aspects of the real-world building such as lights and thermostats can be controlled. The status of real-world sensors can be reflected in the block model, e.g., by turning on LEDs or activating the speaker. In both instances, state and behavior data can also be depicted in the virtual model. More generally, any change of state in any one of the worlds can be reflected in any other worlds.
Summary
In summary, our invention provides a tangible interface that allows users to fashion and manipulate virtual object models by simply building a physical structure. Object recognition allows a host computer to intelligently manipulate and augment the structures built by the user.
It is to be understood that various other adaptations and modifications may be made within the spirit and scope of the invention. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the true spirit and scope of the invention.
APPENDIX A
% wall/1 finds sets of blocks that form walls. A wall is defined to be
% a contiguous set of blocks that lie flush against some vertical plane,
% and that comprise a given fraction of the structure.
wall(WALL_BLOCKS) :-
structure_bbox(X_MIN, X_MAX, _, _, Z_MIN, Z_MAX),
candidate_planes(X_MIN, X_MAX, Z_MIN, Z_MAX, U, V, W, R),
lies_flush_against(U, V, W, R, PLANE_BLOCKS),
contiguous_subsets(PLANE_BLOCKS, PLANE_BLOCKS_SUBSETS),
member(WALL_BLOCKS, PLANE_BLOCKS, _SUBSETS),
big_enough(WALL_BLOCKS).
% wall_tops/1 finds the blocks that are the tops of walls.
wall_tops(WALL _TOPS) :-
findall (BLOCK,
( wall(WALL_BLOCKS),
member(BLOCK, WALL_BLOCKS),
not _overhung(BLOCK, WALL_BLOCKS)),
WALL_TOPS).
APPENDIX B
% roof_blocks/1 computes the set of blocks comprising the roof, which is
% defined to be those blocks that rest directly or indirectly on the tops of
% walls. The indirectly resting blocks are computed by grow _roof/2.
roof_blocks(ROOF_BLOCKS) :-
findall(=BLOCK1,
(=wall_tops(WT_BLOCKS),
member(WT_BLOCK, WT_BLOCKS),
on_top_of(BLOCK1, WT_BLOCK)),
BASE_BLOCKS_BAG),
setof(=BLOCK2,
member(BLOCK2, BASE_BLOCKS_BAG),
BASE_BLOCKS),
grow_roof(BASE_BLOCKS, ROOF_BLOCKS).
grow_roof(NASCENT_ROOF_BLOCKS, FINAL_ROOF_BLOCKS) :-
member(BLOCK1, NASCENT_ROOF_BLOCKS),
on_top_of(BLOCK2, BLOCK1),
not member(BLOCK2, NASCENT_ROOF_BLOCKS),
grow_roof([BLOCK2|NASCENT_ROOF_BLOCKS], FINAL_ROOF
_BLOCKS),
!.
grow_roof(ROOF_BLOCKS, ROOF_BLOCKS).
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A method for decorating a virtual world model first builds a physical model from a plurality of building blocks. Each building block includes a microcontroller coupled to a plurality of connectors. The connectros are for physically and electronically connecting the blocks in a three-dimensional structure to form the model. An arrangement of the blocks in the model is derived by connecting the model to a host computer. The arrangement is expressed as a set of logical axioms. The set of logical axioms is processed by a logic program to identify large scale structural elements of the model, and decorative attributes are assigned to the large. scale structural elements.
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FIELD OF THE INVENTION
The present invention relates to a desensitizing gum for lithographic printing plates.
BACKGROUND OF THE INVENTION
In making lithographic printing plates, a step of coating a desensitizing gum, called a gumming-up step, is provided as a final step for protecting non-image areas (areas which retain water to repel a printing ink).
The desensitizing gum is applied to non-image areas to protect the hydrophilicity of the non-image areas as well as to protect the areas from being stained or flawed by adhesion of fingerprints, fats and oils, dusts, etc. upon correction of image areas such as retouching or deletion, during storage before printing and after plate making or storage before reuse, or upon handling to mount the printing plate on a press and, in addition, to prevent oxidative stains. Known gum compositions for lithographic printing plates which include compositions comprising an aqueous solution of gum arabic, cellulose gum or a water-soluble high molecular substance containing carboxy groups in the molecule and optionally containing a pH-adusting agent, an antiseptic, etc, have been popularly used. However, these conventionally known compositions have the following problems. That is, in the final step of finishing a printing plate, a gum solution is applied to the printing plate and spread all over the plate surface a using sponge or a cotton pad, followed by polishing the plate surface with a cotton pad or a cloth wiper until it becomes dry, upon which the water-soluble high molecular substance is thickly coated in part on image areas (areas which receive an ink). The thickly coated image areas have such a poor ink receptivity in printing that many copies must be printed before the image fully accepts ink. This phenomenon is generally called image blinding (so-called blinding). Where the above-described phenomenon takes place, the plate generally must be subjected to a washing step with water or weakly acidic solution to thereby remove the hydrophilic colloid adsorbed on the image areas for reproducing image areas. This washing step consumes much time, and hence there has been developed a removing solution for desensitizing gum as described in U.S. Pat. No. 4,024,085.
The coating of image areas with fats and oils before the gumming-up step has been carried out for the purpose of protecting ink-receptive properties of the image areas. However, this makes the plate-making step complicated and deteriorates workability and, in addition, it is not preferable due to the pollution and health hazard problems. Accordingly, attempts have been made at using a water-soluble organic high molecular compound which does not causing image blinding as a desensitizing gum. For example, U.S. Pat. No. 4,095,525, and British Pat. No. 2,010,298, West German Pat. No. 2,504,594, and Soviet Pat. No. 623,755 disclose dextrin, pullulan and its derivatives, carboxy-containing polyacrylamide derivatives, metyl acrylate (or methacrylate) grafted polyacrylamide copolymor, etc. However, these compounds are not desirable because they exert only a poor desensitizing action on non-image areas.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a desensitizing gum which exerts a desensitizing action on non-image areas of a lithographic printing plate and which does not cause image blinding of image areas even when the plate is stored for a long period of time.
Another object of the present invention is to provide a desensitizing gum which can be easily applied to a printing plate using a sponge, a cotton pad or an automatic gum coater, which can be easily removed from the lithographic printing plate by washing with water or bringing the plate into contact with dampening rollers on a lithographic press, and which makes it possible to maintain the hydrophilicity in non-image areas.
As a result of intensive investigations for attaining the above-described objects, the inventors have achieved the present invention.
That is, the inventors have found that the above-described objects can be attained by using as a desensitizing gum at least one of film-forming starches modified with phosphoric acid or its derivatives (hereinafter referred to as "modified starch").
DETAILED DESCRIPTION OF THE INVENTION
Modified starches used in this invention are obtained by esterification of starches with phosphorus oxychloride, trimetaphosphoric acid salts (e.g. sodium salt), orthophosphoric acid salts, polyphosphoric acid salts, phosphoric acid, organic phosphonic acids, etc. There are two types of esters, i.e., monesters and crosslinked diesters, both of which can be used in this invention but monoesters are preferred because they are low in aging properties which are inherent in starch. As starches, there can be used those obtained from potato, sweet potato, wheat, tapioca, corn, glutinous corn, rice, glutinous rice, etc.
Theoretically maximum degree of esterification of modified starch is 3, wherein all three hydroxyl groups of glucose unit of starch have been esterified. Preferably the degree of esterification is 0.03 to 1.0, and particularly 0.1 to 0.6.
The modified starches used in the invention are esters between glucose constituting starch and phosphoric acid or its derivatives and are high molecular compounds having the repeating unit of the following formula: ##STR1## wherein R 1 , R 2 and R 3 may be the same or different and each represent hydrogen atom or residue of phosphoric acid or its derivatives.
A process for the synthesis of the modified starches is described in "SUIYOSEI-KOBUNSHI, MIZUBUNSANGATA-JYUSHI SOGO-GIJYUTSU SHIRYOSYU (Water-soluble high molecular compounds, water dispersion type resin, General technical data)", published by KEIEI-KAIHATSU CENTER, Jan. 23, 1981, pages 68 to 69. Groups R 1 , R 2 and R 3 in the formula can be selected to obtain various modified starches having desired properties.
The amount of modified starch contained in the desensitizing gum of the invention is preferably 0.1 to 30 wt. %, and particularly 0.3 to 8 wt. %. The modified starch can be dissolved in water at room temperature or elevated temperature (e.g., 70° to 80° C.) to obtain an aqueous solution which is used as a desensitizing gum.
In addition to modified starch, the desensitizing gum of this invention may contain other hydrophilic high molecular compounds.
Such hydrophilic high molecular compounds include cellulose derivative such as methyl cellulose, ethyl cellulose, hydroxyethyl cellulose or carboxymethyl cellulose; starch derivative such as roast starch, enzymatically modified starch, alkyleneoxide modified starch, α-starch, dextrin, or dialdehyde starch; and natural or semi-synthetic high molecular compound such as an alginic salt, locust bean gum, arabogalactan, pullulan, etc. Further, other synthetic high molecular compounds such as polyvinyl alcohol, polyvinyl pyrrolidone, polyacryl amide, polyvinyl methyl ether, polyethylene oxide, a copolymer of vinyl acetate and maleic anhydride, etc. may be used in combination with the modified starch. When gum arabic is used in combination, it can be used in a much smaller amount than usual to attain the object of this invention.
The total amount of hydrophilic high molecular compound (i.e. the amount of the modified starches plus the other hydrophilic high molecular compound.) contained in the desensitizing gum of the invention is 3 to 30 wt. %, preferebly 8 to 25 wt. % based on the total weight of the gum.
Generally, the desensitizing gum is advantageously used in an acidic condition, i.e., pH 2.5 to 6.0. For making the pH of the desensitizing gum 2.5 to 6.0, a mineral acid, an organic acid or an inorganic salt is added to the desensitizing gum in an amount of, usually, 0.01 to 2 wt. %.
Such mineral acids include nitric acid, sulfuric acid, phosphoric acid, etc. Such organic acids include citric acid, acetic acid, oxalic acid, malonic acid, p-toluene sulfonic acid, tartaric acid, malic acid, lactic acid, levulinic acid, organic phosphonic acid and such inorganic salts include magnesium nitrate, monosodium phosphate, disodium phosphate, nickel sulfate, sodium hexametaphosphate, sodium tripolyphosphate, etc. Two or more of the mineral acids, organic acids or inorganic salts can be used in combination.
The desensitizing gum of the invention may contain a surfactant to improve the surface properties of the coating. Such surfactans include those of anionic and nonionic types.
Anionic sufactants include aliphatic alcohol sulfuric ester salts, aliphatic alcohol phosphoric ester salts, sulfonic acid salts of dibasic aliphatic acid esters, aliphatic amide sulfonic acid salts, alkyl aryl sulfonic acid salts, and formaldehyde condensed naphthalenesulfonic acid salts.
Such nonionic surfactants include polyethylene glycol alkyl ethers, polyethylene glycol alkyl esters, sorbitan alkyle esters, and polyoxypropylene polyoxyethylene ethers. These surfactants may be used in combination of two or more. The amount of these surfactants added is not particularly restricted but is preferably 0.01 to 10 wt. % based on the total weight of the desensitizing gum.
In addition to the above components, a lower polyhydric alcohol such as glycerin, ethylene glycol, triethylene glycol may be used as a wetting agent. The amount of the wetting agent contained is suitably 0.1 to 5.0 wt. %, preferably 0.5 to 3.0 wt. %. Further the desensitizing gum of the invention may contain an antiseptics such as benzoic acid or its derivatives, phenol, formalin, sodium dehydroacetate, etc. in an amount of 0.005 to 2.0 wt. %.
The desensitizing gum of the present invention can be applied to various lithographic printing plates. It is particularly preferable to apply it to lithographic printing plates obtained by imagewise exposing and developing presensitized plates (which will be called "PS plate" hereinafter) comprising a support of an aluminum plate having provided thereon a light-sensitive layer. Preferable examples of negative working PS plates such as those comprising an aluminum plate having provided thereon a light-sensitive layer composed of a mixture of diazo resin (salt of a condensate between p-diazodiphenylamine and paraformaldehyde) and shellac as described in British Pat. No. 1,350,521; or those comprising an aluminum support having provided thereon a light-sensitive layer composed of a mixture of diazo resin and a polymer having hydroxyethyl methacrylate units or hydroxyethyl acrylate units as major repeating units, as described in British Pat. Nos. 1,460,978 and 1,505,739; and positive-working PS plates comprising an aluminum plate having provided thereon a light-sensitive layer composed of a mixture of an o-quinonediazide light-sensitive compound and a novalak type phenol resin, as described in U.S. Pat. No. 4,123,279. Further, PS plates comprising an aluminum plate having provided thereon a light-sensitive layer of photo-crosslinkable photopolymer specifically described in U.S. Pat. No. 3,860,426, PS plates comprising an aluminum plate having provided thereon a light-sensitive layer of photopolymerizable photopolymer composition as described in U.S. Pat. Nos. 4,072,528 and 4,072,527, and PS plates comprising an aluminum plate having provided thereon a light-sensitive layer composed of a mixture of an azide and a water-soluble polymer as described in British Pat. Nos. 1,235,281 and 1,495,861 are also preferable.
One embodiment of applying the desensitizing gum of the present invention to a PS plate is described below. However, the invention is not limited thereto.
A PS plate is first imagewise exposed to light, then developed to prepare a lithographic printing plate. This lithographic printing plate is washed with water and, after squeezing away the water on the plate surface, a suitable amount of the desensitizing gum of the present invention is applied to the plate surface, followed by rubbing the surface with a sponge so as to spread the gum solution all over the plate surface and drying. Thus, non-image areas of the printing plate are protected, and the resulting lithographic printing plate can be stored. In order to start printing, the gum on the plate surface is washed away, and subsequent procedure are conducted in a usual manner to print copies. Alternatively, an automatic gum coater may be used to uniformly apply the gum onto the plate surface. Upon printing, sufficiently satisfactory, sharp and clear copies can be obtained immediately after initiations of printing without producing many spoiled copies, which is an important improvement over the prior art.
According to this invention, it is unnecessary to use a protective ink which has been used to hold lipophilic property of image areas in making planographic printing plates.
The invention is illustrated by the following non-limitative examples in which percent (%) and part are by weight unless otherwise indicated.
EXAMPLE 1
60 Parts of phosphoric acid modified starch (degree of esterification: 0.2, viscosity of 40% aqueous solution (25° C.): 300-400 cps) was dissolved in 769.7 parts of pure water at 70° to 80° C. After cooled to 30° C., there were added 150 parts of water-soluble polyoxypropylene modified starch and 10 parts of carboxymethyl cellulose (viscosity of 10% aqueous solution (25° C.): 410 cps). The resulting solution had the viscosity of 17 cps at 25° C. To this solution, there were added 5 parts of polyoxyethylene alkylsulfuric ester salt (anionic surfactant), 0.4 part of sodium dehydroacetate, 0.3 part of ethyl benzoate and 4.6 part of phosphoric acid (85%) to obtain a desensitizing gum of this invention.
A 0.24 mm thick aluminum plate was degreased in 7% trisodium phosphate aqueous solution at 60° C., washed with water and grained by rubbing with a nylon brush while applying pumice-water suspension. After washing with water, the plate was immersed in 5% potassium silicate (SiO 2 /K 2 O molar ratio: 2.0) aqueous solution at 70°C. for 30 to 60 seconds, washed with water and then dried.
To the plate, there was applied a light-sensitive solution consisting of 2.0 parts of 2-hydroxyethyl methacrylate copolymer (prepared by the method described in EXAMPLE 1 of British Pat. No. 1,505,739), 0.12 part of 2-methoxy-4-hydroxy-5-benzoylbenzene sulfonic acid salt of a condensate of p-diazodiphenylamine and paraformaldehyde, 0.03 part of OIL BLUE #603 (produced by ORIENT KAGAKU KOGYO), 15 parts of 2-methoxy ethanol, 10 parts of methanol and 5.0 parts of ethylene chloride so as to obtain 1.8g/m 2 coating after drying. The presensitized plate thus prepared was exposed to light through a half-tone negative transparency developed with an aqueous developer consisting of 3.0 parts of sodium sulfite, 30.0 parts of benzylalcohol, 20.0 parts of triethanolamine, 5 parts of monoethanolamine, 10 parts of sodium t-butylnaphthalene sulfonate and 1000 parts of pure water, washed with water and dried.
The printing plate thus prepared was cut into three pieces. The first one was coated with 7° Be gum arabic aqueous solution (about 15% aqueous solution) and excess gum was wiped off with a cloth to obtain a finished printing plate (Sample A).
The second one was coated with the desensitizing gum of the present invention and excess gum was wiped off with a cloth to obtain a finished printing plate (Sample B).
The third one was not treated and designated as Sample C.
These Samples A, B and C were stored in a chamber maintained at 45° C. and 85% RH for 3 days and then installed in HEIDELBELG KOR-D printing machine. With sample A, more than 100 spoiled copies had to be printed before sharp and clear copies were printed and, with samples B and C, 10 and 8 spoiled copies had to be printed, respectively.
As to stain during printing, samples A and B suffered no stains, whereas sample C was extremely easily stained. Thus, Sample B in which the desensitizing gum of this invention is used is excellent in both lipophilic property in image areas and hydrophilic property in non-image areas.
EXAMPLE 2
20 Parts of phosphoric acid modified starch (degree of esterification: 0.25, viscosity of 20% aqueous solution (25° C.): 450 cps) was dissolved in 786.7 parts of pure water at 70° to 80° C. After cooled to 30° C., there were added 160 parts of CREAM DEXTRIN #3 (produced by MATSUTANI KAGAKU Co.) and 20 parts of carboxy methyl cellulose (viscosity of 10% aqueous solution (25° C.): 250 cps). The resulting solution had a viscosity of 20 cps at 25° C.
In this solution, there were dissolved 0.5 part of dialkylsulfosuccinic ester salt (anionic surfactant) and 5.0 part of 40% aqueous solution of sodium alkyldiphenylether disulfonate (anionic surfactant), 3 parts of magnesium sulfate, and 0.8 part of sodium dehydroacetate, and 4 parts of 85% phosphoric acid was added to adjust the p H to 3.8 to obtain a desensitizing gum.
One part of naphthoquinone-1,2-diazido-5-sulfonic ester of polyhydroxyphenyl prepared by polycondensation of pyrogallol and acetone described in U.S. Pat. No. 3,635,709 and 2 parts of novolak type cresol-formaldehyde resin were dissolved in 40 parts of methyl cellosolve to prepare a light-sensitive solution. A 0.2 mm thick aluminum plate was grained, washed with water and dried. The light-sensitive solution was coated on the aluminum plate using whirler so as to result in a weight of about 2.0 g/m 2 after drying and dried to prepare a positive working presensitized plate. The plate was exposed to light through a half-tone positive transparency, developed with 3% sodium silicate aqueous solution, washed with water and dried.
The resulting printing plate was cut into three pieces. The first one was coated with 14° Be gum arabic aqueous solution (about 27% aqueous solution) and the second one was coated with the desensitizing gum described above and excess gum was wiped off with a cloth to obtain finished plate Samples A and B, respectively. The third one was not coated and designated as Sample C.
These Samples A, B and C were stored in a chamber maintained at 45° C. and 85% RH for 7 days and then installed in HEIDELBELG KOR-D printing machine. Printing was conducted in a conventional manner. Samples A, B and C required 35, 5 and 3 spoiled copies, respectively before sharp and clear copies were printed. Background contamination was not found in Samples A and B but found frequently in Sample C. Thus, Sample B in which the desensitizing gum of this invention is used in excellent in both lipophilic property in image areas and hydrophilic property in non-image areas.
EXAMPLE 3
50 Parts of phosphoric acid modified starch (degree of esterification: 0.1, viscosity of 20% aqueous solution (25° C.): 450 cps), 100 parts of CREAM DEXTRIN, 50 parts of white dextrin (produced by MATSUTANI KAGAKU), 15 parts of polyvinyl pyrrolidone K-30, 2 parts of polyoxyethylene alkylphenolether (EMULGEN #950 (trademark), produced by KAO Corporation), 3 parts of sodium naphtalene sulfonate -formalin condensate (DEMOL P (trademark), produced by KAO Corporation), 5 parts of sodium hexametaphosphate, 0.5 part of ethyl benzoate and 5.0 parts of 85% phosphoric acid were dissolved in 769.5 parts of pure water to prepare a desensitizing gum which had a viscosity of 18 cps at 25° C.
In the same manner as in EXAMPLE 1, a presensitized plate was prepared, exposed to light, developed, washed with water and dried to obtain a printing plate which was cut into three pieces.
The first one was coated with 14° Be gum arabic aqueous solution and the second one with the above desensitizing gum and excess gum was wiped off with a cloth to obtain finished plate Samples A and B, respectively. The third one was not coated and designated as Sample C.
In the same manner as in EXAMPLE 1, these Samples A, B and C were stored in a chamber maintained at 45° C. and 85% RH for 7 days and then installed in HEIDELBELG KOR printing machine. Printing was conducted in a conventional manner. With sample A, more than 100 spoiled copies had to be printed before sharp and clear copies were printed and, with samples B and C, 8 and 5 spoiled copies had to be printed, respectively. Background contamination was not found in Samples A and B but found frequently in Sample C. Thus, Sample B in which the desensitizing gum of this invention is used gave satisfactory results.
EXAMPLE 4
40 Parts of phosphoric acid modified starch (degree of esterification: 0.15, viscosity of 40% aqueous solution (25° C.): 300 to 400 cps), 50 parts of enzymatically hydrolyzed dextrin (AMYCOL 1B (trademark), produced by NICHIDEN KAGAKU Co.) 100 parts of CREAM DEXTRIN, 15 parts of a copolymer of methyl vinyl ether and maleic acid (GANTREZ S-95 (trademark), produced by GAF CORPORATION), 5 parts of glycerin, 4 parts of sodium alkylnaphthalene sulfonate (PELEX NBL (trademark), produced by KAO Corporation), 5 parts of polyoxyethylene alkylphenolether sulfuric acid salt (EMAL NC (trademark), produced by KAO Corporation), 2 parts of magnesium nitrate, 1 part of citric acid, 0.8 part of sodium dehydroacetate and 3.5 parts of 85% phosphoric acid were dissolved in 773.7 parts of water to prepare a desensitizing gum which had a viscosity of 17 cps at 25° C.
The printing plate prepared from the positive working presensitized plate of EXAMPLE 2 was coated with the desensitizing gum and stored at 45° C. and 85% RH for 7 days. Printing was conducted using this plate. Seven spoiled copies were required before sharp and clear copies were printed. No background contamination was observed. Thus, the desensitizing gum gave extremely satisfactory results.
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A desensitizing gum comprising an aqueous solution containing at least one of film-forming starches modified with phosphoric acid or its derivatives. The desensitizing gum has good desensitizing ability and can easily be removed from a printing plate finished therewith after prolonged storage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a liquefied-natural-gas (LNG) gasifier and a method of gasification.
2. Description of the Related Art
A liquefied natural gas (LNG), which is liquid methane, is a liquid having a boiling point of about −165° C. The LNG is transported from a liquefaction station by sea with an LNG ship provided with a cryogenic tank. The LNG is handled at on-shore LNG-receiving terminals (stations) near a port of various places to be supplied to customers.
Such LNG-receiving terminals are provided with, for example, an insulated tank to hold the LNG from a ship, a gasifier (vaporizer) to vaporize the LNG to convert into a natural gas (NG), in other words, a heat exchanger, and a controlling and measuring installation that regulates and measures an amount of the LNG supplied to pipeline of a customer.
To serve the LNG at an area without such LNG-receiving terminal, a floating-production-storage-and-offloading (FPSO) vessel is proposed. The FPSO is provided with a gasifier to convert the LNG into the NG at sea. The NG converted from the LNG at sea, for example, on a ship, is supplied through a pipeline to an on-shore pipeline for NG (Patent Literature 1).
An example of an LNG gasifier on a ship is shown in FIG. 4 . As shown in FIG. 4 , a conventional LNG gasifier includes a pipe 2 to feed the LNG from an LNG storage tank 1 . An outer surface of a pipe 2 a is brought into contact with a heating medium such as seawater 3 . The pipe 2 a is surrounded by a tubular shell 4 . A seawater pump 5 is provided inside the tubular shell 4 to send the seawater 3 through the shell 4 . A motor 6 is provided in a ship 7 to drive the seawater pump 5 . The NG obtained by vaporization is collected in a collection tank 8 and sent to shore by a pipe 9 .
Patent Literature 1: Japanese Patent Publication No. 2003-517545
In the conventional LNG gasifier disclosed in patent literature 1, the seawater pump 5 needs to be provided inside the tubular shell 4 to supply seawater, which is used as a heat source for vaporization. This requires provision of the motor 6 to drive the seawater pump 5 as well as maintenance of the seawater pump 5 .
On the other hand, when, for example an open-rack-type LNG gasifier as shown in FIG. 5 that uses seawater for heat exchange is provided in the FPSO, seawater 103 is brought into a seawater trough 101 from a seawater supply port 102 . The LNG passing through a heat exchanging tube 104 is vaporized by means of the seawater 103 overflowing from the seawater trough 101 . Thus, the open rack type LNG gasifier needs a stable supply of seawater. However, a stable supply of seawater from the seawater trough 101 cannot be maintained due to swaying of the ship.
Providing the FPSO with another type of LNG gasifier such as an LNG gasifier that carries out heat exchange by supplying a gas from a burner to a water cistern requires maintenance of the burner and accompanying combustion facilities. Moreover, this results in a high fuel cost.
Providing the FPSO with still another type of LNG gasifier such as an LNG gasifier that carries out heat exchange by means of an intermediate heating medium requires use of combustible liquefied-petroleum gas (LPG) or chlorofluorocarbon substitute as the intermediate medium. This causes difficult handling, for example, in inspection and maintenance.
SUMMARY OF THE INVENTION
It is an object of the present invention to solve the above problems and to provide an LNG gasifier that is simple in structure and enables stable vaporization of LNG in the FPSO, and a method of gasification.
To solve the above problems, a first aspect of the invention of the present invention includes an LNG gasifier for vaporizing LNG that includes a seawater inlet passage that is provided in a main unit and into which seawater flows; a heat exchanging tube for causing heat exchange between the seawater and the LNG, the heat exchanging tube provided inside the seawater inlet passage; a bubbling device for supplying air into the seawater, the bubbling device provided near an inlet port of the seawater inlet passage; an air supplying device configured to supply external air to the bubbling device; and a discharge port for discharging bubbling air, which is generated in the bubbling device, outside the main unit, the discharge port configured to communicate with the seawater inlet passage. The bubbling air generated in the bubbling device brings the seawater inside the inlet passage from the seawater inlet port to vaporize the LNG supplied inside the heat exchanging tube.
In a second aspect of the invention according to the first aspect of the invention, the seawater inlet passage opens in a vertical axial direction.
In a third aspect of the invention according to the first aspect of the invention, the heat exchanging tube includes a spiral shaped tube.
In a fourth aspect of the invention according to the first aspect of the invention, the heat exchanging tube includes a flange joint so that the heat exchanging tube is configured to separate into multiple parts.
In a fifth aspect of the invention according to the first aspect of the invention, the seawater inlet port is located below the discharge port.
A sixth aspect of the invention according to the present invention includes a ship that includes the LNG gasifier according to any one of the first to the fifth aspect the invention.
A seventh aspect of the invention according to the present invention includes an offshore structure that includes the LNG gasifier according to any one of the first to the fifth aspect of the invention.
An eighth aspect of the invention according to the present invention includes a method of gasification of LNG that includes causing bubbles with air inside a seawater inlet passage provided in a main unit to take in seawater inside the seawater inlet passage; and supplying LNG into a heat exchanging tube provided inside the seawater inlet passage to vaporize the LNG.
According to the present invention, it is possible to realize stable gasification of an LNG on an FPSO and an LNG gasifier having a simple structure in which a seawater pump required in a conventional LNG gasifier for supplying a heat source is not required.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a cross-section of an LNG gasifier according to a first embodiment of the present invention;
FIG. 2 is a plan view of the LNG gasifier according to the first embodiment;
FIG. 3 is a schematic of a ship provided with the LNG gasifier according to a second embodiment of the present invention;
FIG. 4 is a schematic of an LNG gasifier according to a conventional technology; and
FIG. 5 is a schematic of another LNG gasifier according to a conventional technology.
DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments of the present invention are explained in detail below with reference to the accompanying drawings. The present invention is not limited to the embodiments. Structural elements described in the embodiments include all modifications and alternative constructions, which may occur to one skilled in the art.
An LNG gasifier according to a first embodiment of the present invention is explained with reference to the accompanying drawings.
FIG. 1 is a cross-section of the LNG gasifier according to the first embodiment. FIG. 2 is a plan view of the LNG gasifier.
As shown in FIG. 1 and FIG. 2 , an LNG gasifier 10 for vaporizing LNG is provided in a main unit 11 immersed in sea 20 . Seawater 12 A is taken into a seawater inlet passage 13 . A heat exchanging tube 14 is provided along an axial direction of a passage inside the seawater inlet passage 13 to cause heat exchange between the seawater 12 and LNG. A bubbling device 16 provided near a seawater inlet port 13 a of the seawater inlet passage 13 supplies air 15 to the seawater 12 . An air supplying device 17 continuously supplies the air 15 from outside to the bubbling device 16 through a passage 17 a. Through a discharge port 18 communicating with the seawater inlet passage 13 , the air 15 in a form of bubble generated in the bubbling device 16 is discharged out of the main unit 11 together with the seawater 12 . The seawater 12 is forcibly brought inside the seawater inlet passage 13 through the seawater inlet port 13 a collaterally with movement of the air 15 in bubbles generated in the bubbling device 16 . Thus, the LNG supplied inside the heat exchanging tube 14 from an LNG tank is vaporized to an NG.
According to the present embodiment, the seawater inlet passage 13 is formed in such a manner that the seawater inlet passage 13 runs through in a vertical axial direction inside the main unit 11 and has a port 13 b that communicates with the outside.
The discharge port 18 is provided on a sidewall 11 a of the main unit 11 in such a manner that the discharge port 18 communicates with the seawater inlet passage 13 so that the bubbling air 15 is swiftly discharged.
According to the present embodiment, the heat exchanging tube 14 is, for example, a trombone-shaped spiral tube so that heat exchange efficiency is enhanced. However, the present invention is not to be thus limited, and a tube of any shape having high heat exchange efficiency may be applied.
According to the present embodiment, the heat exchanging tube 14 includes a flange joint 19 and is separable into multiple parts. Thus, the heat exchanging tube 14 can be separated or connected when the heat exchanging tube 14 is to be inserted into or removed from the seawater inlet passage 13 , thereby making insertion or removal of the heat exchanging tube easier.
According to the present embodiment, the seawater inlet port 13 a is located below the discharge port 18 , thereby increasing efficiency in supplying seawater and increasing the heat exchange efficiency.
According to the present embodiment, the air supplying device 17 supplies air to the bubbling device 16 , and an airlift force of the bubbling causes the seawater 12 to be brought inside the seawater inlet passage 13 . Then, LNG is supplied into the heat exchanging tube 14 . Thus, heat exchange is caused between the LNG and the seawater 12 to vaporize the LNG into NG.
According to the present embodiment, providing the LNG gasifier, for example, to a ship to be an FPSO, it is possible to realize a stable vaporization of LNG. Thus, an LNG gasifier that has a simple structure in which a seawater pump for supplying a heat source, which is required in a conventional LNG gasifier, is not required can be provided.
According to the present embodiment, the seawater is forcibly brought into the seawater inlet passage by supplying air to the bubbling device. Unlike the conventional technology, a heat source such as a burner is not needed, and use of an intermediate medium (LNG or chlorofluorocarbon substitute) is not required. Thus, inspection and maintenance can be easily carried out, and a stable supply of seawater can be maintained without being affected by swaying of the ship at sea.
Second Embodiment
A ship provided with an LNG gasifier according to a second embodiment of the present invention is explained with reference to the accompanying drawings.
FIG. 3 is a schematic of the ship provided with the LNG gasifier according to the second embodiment.
As shown in FIG. 3 , the LNG gasifier 10 is arranged at a bow of a ship 30 according to the present embodiment. The LNG supplied from an LNG tank 31 via a pipe 32 is vaporized in the LNG gasifier 10 and supplied to an on-shore pipeline 35 via a pipeline 34 .
Thus, LNG can be stably vaporized and supplied as NG even to a place on the shore without an LNG receiving terminal. Moreover, the NG supplied can be directly supplied to the on-shore pipeline.
According to the present embodiment, it is possible to vaporize the LNG with a simple structure using the LNG gasifier arranged at the bow of the ship, and to directly supply the NG obtained by vaporization to the on-shore pipeline.
While in the present embodiment, the LNG gasifier shown in FIG. 1 is provided on the ship, the present invention is not thus limited and the LNG gasifier may also be provided on a marine structure located offshore.
Moreover, while in the present embodiment, the seawater is used to vaporize the LNG, the present invention is not thus limited, and other liquid media, for example, water may be used.
INDUSTRIAL APPLICABILITY
The LNG gasifier and method for LNG gasification according to the present invention can be applied to ships or offshore structures that include an LNG gasifier.
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An LNG gasifier configured to be installed on an offshore structure for vaporizing LNG includes a water passage into which water flows; an LNG passage provided inside the water passage and configured to pass the LNG and that allows heat exchange between the water and the LNG; and a bubble generating unit configured to generate bubbles of air into the water in the water passage. The water passage has an inlet port from where the water is taken in and a discharge port from where air and the water are discharged.
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FIELD OF THE INVENTION
Embodiments of the present invention, generally relate to railing systems and methods, and in particular relate to a rail top attachment clip that facilitates upgradable railing systems and methods to provide a customizable rail topper.
BACKGROUND
Railing systems are used extensively for a variety of functional purposes, e.g., as fencing to secure people, animals, and land, and to prevent entry into a specified area. Railing systems also may have aesthetic purposes, e.g., on decks and around yards, terraces, and gardens, etc. Railing systems often include at least one horizontal rail affixed to at least one vertical post, and optionally a plurality of balusters.
A variety of rail shapes exist to address functional and/or aesthetic preferences, e.g., a flat top, or a shape that includes hand-hold features, etc. In particular, one type of rail shape includes a lateral central crown and lengthwise edges and/or ridges, such that the rail resembles a loaf of some types of bread. Such a type of rail shape may be referred to as a “bread loaf” type shape.
Consumers sometimes want to change the look and feel of an installed railing system. Replacing the railing system or major portions of it is costly, inconvenient and time consuming. Upgrading the railing system (e.g., to change color or shape of rail toppings) is simpler, less costly, and thus more likely to be something that a consumer will do.
Traditionally, one method to upgrade a railing system is to screw a regular deck board onto an existing rail. However, this is not aesthetically pleasing since fasteners are exposed and visible.
Another traditional method to upgrade a railing system is to screw clips on top of a rail, then attach a regular deck board to the clips. However, clips by themselves on a rail have poor structural integrity, resulting in undesirable waving and bowing of the deck board. Any exposed clips will not be aesthetically pleasing.
Another drawback is that traditional upgrade methods require multiple components to change the look and feel of an installed railing system.
Therefore, there is a need for an improved railing system and method is needed to address the drawbacks of the traditional methods and systems.
SUMMARY
Embodiments in accordance with the present disclosure provide a system and method to rigidly but removably attach a rail topper to a guardrail, by use of a railing attachment clip. The railing attachment clip includes left and right portions with respective surfaces contoured to match the guardrail and the rail topper, and a central portion laterally coupled to the left and right portion. The central portion separates the left and right portions by a fixed distance. The matching contoured surfaces determine a position of the railing attachment clip on the guardrail, and determine a position of the rail topper on the railing attachment clip. In some embodiments, the central portion is removed after the railing attachment clip is attached to the guardrail, but before the rail topper is attached to the railing attachment clip.
According to an aspect of the present disclosure, a railing system having customizable rail topper is provided herein. The railing system includes an elongated upper rail, an elongated lower rail, and a plurality of balusters extending between the elongated upper rail and the elongated lower rail. The elongated upper rail includes an elongated core member, an attachment clip, and a rail topper member. The attachment clip includes a left side portion, a right side portion, and a middle portion. The left side portion includes a first concave portion, a first curved portion and a first edge portion. The right side portion includes a second concave portion, a second curved portion and a second edge portion. The middle portion connects the first concave portion of the left side portion with the second concave portion of the right side portion. The rail topper member includes an elongated central body having a pair of opposing side walls defining a channel to receive the elongated core member, the rail topper member having a central ridge portion, at least one left flange on left side wall, and at least one right flange on right side wall. The middle portion of the attachment clip is breakable, and the rail topper member is snap-fitted over the attachment clip after breaking the middle portion of the attachment clip. The central ridge portion of the rail topper member contacts an upper portion of the elongated core member. The left flange of the rail topper member engages with the first edge portion of the attachment clip and the right flange of the rail topper member engages with the second edge portion of the attachment clip to lock the rail topper member over attachment clip and the elongated upper rail.
According to another aspect of the present discourse, the railing system includes an elongated upper rail, an elongated lower rail, and a plurality of balusters extending between the elongated upper rail and the elongated lower rail. The elongated upper rail includes an elongated core member, an attachment clip, and a rail topper member. The attachment clip includes a left side flat portion, a right side flat portion, and a middle flat portion. The middle flat portion is connected to the left side flat portion through a first curved portion and is connected to the right side flat portion through a second curved portion. The rail topper member has an elongated central body having a rectangular top surface and a rectangular bottom surface. Each of the first curved portion and the second curved portion of the attachment clip includes mounting holes to receive fasteners and lock the attachment clip over the elongated upper rail. Each of the left portion and the right portion of the attachment clip includes mounting holes to receive fasteners and lock the rail topper member over attachment clip and the elongated upper rail.
According to another aspect of the present disclosure, a method to assemble a railing system is provided. The method includes fixing an attachment clip over an elongated core member. The attachment clip including a left side portion, a right side portion, and a breakable middle portion. The method further includes breaking the middle portion of the attachment clip, and snap fitting a rail topper member over the attachment clip to lock the rail topper member over the attachment clip and the elongated core member.
The railing system, disclosed by the present invention, can be advantageously combined with the traditional railing system to offer a completely different look to the railing. There is no need to replace the whole bay with a different railing system. It can be added easily to existing railing purchased previously by customers as retro-fit.
Further, the present invention advantageously provides a snug snap fit railing assembly and solves structural integrity issues of conventional railing systems. The attachment clip facilitates self-centering of the rail cover or rail topper onto the attachment clip. Further, the present invention provides contact of the rail topper on the railing system, as the middle portion of the clip is snapped off. The center of gravity of the rail topper is lowered, hence providing a more compact structural integrity, which is more immune to bending, bowing, and weathering.
Further, the present invention advantageously provides completely hidden screws and increases the aesthetic appearance of the railing system. Further, the railing system can be put on different types of railings and provides freedom to the customer in their choice. Furthermore, the rail topper is easily detachable and hence, people can easily upgrade or change their existing rail topper time and again, as per their convenience and choice.
The preceding is a simplified summary to provide an understanding of some aspects of embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
FIG. 1 illustrates an exploded view of a railing system, according to an embodiment of the present invention;
FIG. 2 illustrates a perspective view of a rail topper, according to an embodiment of the present invention;
FIG. 3 and FIG. 4 illustrate perspective views of an attachment clip, according to an embodiment of the present invention;
FIG. 5 illustrates a bottom view of the attachment clip, according to an embodiment of the present invention;
FIG. 6A illustrates a side view of the attachment clip, according to an embodiment of the present invention;
FIG. 6B illustrates a side view of another embodiment of an attachment clip, according to an embodiment of the present invention;
FIG. 7 illustrates a cross-sectional view of railing system after assembly of the rail topper and the attachment clip over elongated rail, according to an embodiment of the present invention;
FIG. 8 illustrates a perspective view of the railing system after assembly of the rail topper and the attachment clip over the elongated rail, according to an embodiment of the present invention;
FIG. 9 illustrates another perspective view of the railing system after assembly of the rail topper and the attachment clip over the elongated rail, according to an embodiment of the present invention;
FIG. 10 illustrates a perspective view of an attachment clip, according to another embodiment of the present invention;
FIG. 11 illustrates a side view of the attachment clip shown in FIG. 10 , according to an embodiment of the present invention;
FIG. 12 illustrates a side view of the railing system after assembly of the rail topper and the attachment clip over the elongated rail, according to an embodiment of the present invention;
FIG. 13 illustrates a side view of the railing system after assembly of the rail topper and the attachment clip over the elongated rail, according to another embodiment of the present invention;
FIG. 14 illustrates a perspective view of the railing system after assembly of the rail topper and the attachment clip over the elongated rail shown in FIG. 13 , according to an embodiment of the present invention; and
FIG. 15 depicts an exemplary flowchart illustrating a method of assembly of a rail topper over the railing system with help of the attachment clip, according to an embodiment of the present invention.
To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.
DETAILED DESCRIPTION
As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to.
The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
The term “automatic” and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material”.
FIG. 1 illustrates an exploded view of railing system 100 . In an embodiment of the present invention, railing system 100 includes an elongated rail 102 extending lengthwise and a plurality of balusters 104 extending vertically. The plurality of balusters 104 are connected to elongated rail 102 and extend downward to connect to another elongated rail (not shown in the FIG. 1 ). Railing system 100 may be installed between a pair of vertical support elements, including but not limited to posts, columns or walls. In one embodiment of the present invention, railing system 100 extends along the periphery of a deck, terrace, or other elevated structure. Those skilled in the art will appreciate that in other embodiments, railing system 100 may be used in any location where a railing installation is desired.
Elongated rail 102 includes an elongated core member. The core member is rigid load bearing component and provides internal strength to elongated rail 102 . The core member may be formed of a material that distributes loads along the length of elongated rail 102 , for example, aluminum, wood, plastic, iron etc. In an embodiment, elongated rail 102 has a shape of a bread loaf. Those skilled in the art will appreciate that in another embodiment of the present invention, elongated rail 102 may have different shape. In an embodiment, elongated rail 102 also couples to a load-bearing post 106 . Post 106 may include a top element to enclose an interior of post 106 , which may give post 106 a T-shape. In another embodiment, elongated rail 102 is free-standing without coupling to post 106 .
Railing system 100 further includes a rail topper 108 and an attachment clip 110 . Attachment clip 110 facilitates the snapping together of rail topper 108 and the elongated rail 102 . Attachment clip 110 also facilitates the detaching of rail topper 108 and the elongated rail 102 , however in some embodiments the detaching intentionally is difficult in order to help prevent an unintentional detachment. Detaching may be made difficult by a combination of stiffness of rail topper 108 , stiffness of attachment clip 110 and an amount of movement needed to disengage them from each other. Attachment clip 110 is fixed over elongated rail 102 and rail topper 108 is snap-fitted over attachment clip 110 .
Railing system 100 further includes a rail mounting bracket 112 and a mounting bracket cover 114 . Rail mounting bracket 112 may be connected to post 106 as well as elongated rail 102 and serves to connect and to support elongated rail 102 with post 106 . Mounting bracket cover 114 is connected to elongated rail 102 . Mounting bracket cover 114 includes one or more inwardly facing ribs configured for connection with the elongated core member in a press fit. Rail mounting bracket 112 and mounting bracket cover 114 include a number of mounting holes and a number of fastener slots that connect them to post 106 and elongated rail 102 .
FIG. 2 illustrates a perspective view of rail topper 108 . In an embodiment of the present invention, the rail topper 108 is formed of a semi-flexible and resilient material (for example, plastic). In another embodiment of the present invention, the rail topper 108 may be formed of a rigid material. Rail topper 108 has a lower portion that detachably engages with the upper portion of attachment clip 110 . Rail topper 108 provides a decorative cover to the railing system, and increases aesthetic appearance of the railing system. Rail topper 108 is detachable from attachment clip 110 . This allows rail topper 108 to be replaced with another rail topper or a decorative cover without disassembling structural elements of the installed railing system (for example, elongated rail 102 or balusters 104 ). Rail topper 108 is removable, and can be replaced at any time with a different rail topper 108 having a different aesthetic appearance, and/or covers having different internal structures that may be specially adapted to house wires, conduits or other desired things being run within the railing. Further, rail topper 108 provides a substantial enclosure to attachment clip 110 and the core member of elongated rail 102 so that the core member and attachment clip 110 are not visible on the exterior of the railing system.
In the context of embodiments of the present invention, a semi-flexible and/or resilient material is a material that, when used for a rail topper 108 and given the dimensions of rail topper 108 (length and/or width), and size of a lip or other feature (e.g., horizontal surface 136 ) on a mounting attachment clip 110 used to secure mounted rail topper 108 , provides enough flexibility to allow rail topper 108 to be manipulated by hand or by simple hand tools (e.g., a prying tool such as a screwdriver) onto and over the lip or similar feature such as horizontal surface 136 . A similar amount of force and flexibility would be used to remove rail topper 108 if so desired. On the other hand, the semi-flexible and/or resilient material should not be so flexible that rail topper 108 would likely be dislodged upon ordinary use or ordinary contact not intended to dislodge rail topper 108 , for example, contact such as placing a relatively small object on rail topper 108 (e.g., a flowerpot, a coffee cup, etc.), a person leaning against rail topper 108 , and so forth.
In an embodiment of the present invention, rail topper 108 has an elongated and substantially inverted U-shaped structure, which includes a pair of opposing sidewalls that define a channel to receive the elongated core member. In an embodiment, rail topper 108 includes a center ridge portion 116 , a left flange 118 on left sidewall, and a right flange 120 on right side wall. In another embodiment, rail topper 108 may have different internal structure. Rail topper 108 is capable of providing a decorative cover to elongated rail 102 and is configured to be fixed over attachment clip 110 . Center ridge portion 116 may touch or contact elongated rail 102 . The left and right flanges of rail topper 108 may engage with attachment clip 110 and facilitate locking of rail topper 108 over elongated rail 102 .
In an embodiment, the left flange and right flange are spaced apart at a distance, which is slightly less than the width of the elongated core member. Further, the internal structure of rail topper 108 and attachment clip 110 is formed with resilient flexible flanges and ridges that snap over the exterior of attachment clip 110 and elongated rail 102 , and firmly hold attachment clip 110 and elongated rail 102 , without the use of fasteners or adhesives. The snapping connection between rail topper 108 and elongated rail 102 allows rail topper 108 to be readily attached and removed.
FIG. 3 and FIG. 4 illustrate perspective views of attachment clip 110 . The XYZ coordinate directions are marked in the figures. Unless otherwise indicated, horizontal refers to a direction or plane parallel to the X-Y plane, and vertical refers to a direction or plane perpendicular to horizontal. In an embodiment of the present invention, attachment clip 110 provides a mounting interface between rail topper 108 and elongated rail 102 . In an embodiment, width of attachment clip 110 is substantially equal to elongated rail 102 . Those skilled in the art will appreciate that any other width of attachment clip 110 is also possible that can provide compact fitting of rail topper 108 and elongated rail 102 .
In an embodiment of the present disclosure, attachment clip 110 includes a left portion 122 , a right portion 124 , and a middle portion 126 that connects left portion 122 with right portion 124 . Middle portion 126 may be breakaway or not breakaway, either of which provides benefits that will be apparent below. In an embodiment, middle portion 126 is connected to left portion 122 and right portion 124 with a narrow physical interface such that it is easily breakable with the help of a screw driver (or any other edged or prying tool). In an embodiment, the width of middle portion 126 is chosen such that it provides desired lateral spacing between left portion 122 and right portion 124 so that the rail topper 108 is automatically self-centered on the elongated rail 102 .
In an embodiment, left portion 122 includes a first planar surface 129 substantially parallel to the X-Y plane, a first inclined surface 130 that extends from first planar surface 129 to a first horizontal surface 136 . First horizontal surface 136 extends from first inclined surface 130 to a first vertical surface 132 . Some embodiments of left portion 122 may include a first cavity 128 , such that first planar surface 129 forms at least a portion of a perimeter around first cavity 128 . Left portion 122 may include a mounting hole 134 to receive a fastener (such as a screw). Mounting hole 134 and its fastener facilitate secure attachment of left portion 122 to elongated rail 102 . In some embodiments, first inclined surface 130 facilitates sliding a portion of rail topper 108 over attachment clip 110 with minimal resistance when rail topper 108 is snapped onto attachment clip 110 . Rail topper 108 may be snapped onto attachment clip 110 when a portion of rail topper 108 (e.g., a left flange) mates with first horizontal surface 136 . In some embodiments, inclined surface 130 may have a curvature in the Y-Z plane.
Right portion 124 of attachment clip 110 is similar to the left portion and includes a second planar surface 129 substantially parallel to the X-Y plane, a second inclined surface 130 that extends from second planar surface 129 to a second horizontal surface 136 . Second horizontal surface 136 extends from second inclined surface 130 to a second vertical surface 132 . Some embodiments of right portion 124 may include a second cavity 128 , such that second planar surface 129 forms at least a portion of a perimeter around second cavity 128 . Right portion 124 may include a mounting hole 134 to receive a fastener (such as a screw). Mounting hole 134 and its fastener facilitate secure attachment of right portion 124 to elongated rail 102 . In some embodiments, second inclined surface 130 facilitates sliding a portion of rail topper 108 over attachment clip 110 with minimal resistance when rail topper 108 is snapped onto attachment clip 110 . Rail topper 108 may be snapped onto attachment clip 110 when a portion of rail topper 108 (e.g., a right flange) mates with second horizontal surface 136 . In some embodiments, inclined surface 130 may have a curvature in the Y-Z plane.
In one embodiment of the present invention, attachment clip 110 is semi-flexible. In another embodiment, the left portion and right portion of attachment clip 110 are rigid and the middle portion is semi-flexible. Middle portion 126 is breakable with help of a screwdriver (or any other tool having edge) and creates space (void or groove) to receive the central ridge portion of rail topper 108 . This allows rail topper 108 to come in direct contact with elongated rail 102 and the center of gravity of the rail topper 108 is lowered. This allows improved structural integrity and stability between elongated rail 102 and rail topper 108 . Further, this allows self-centering of rail topper 108 over elongated rail 102 . Furthermore, this prevents movement (for example, rotational or side movement) of rail topper 108 over elongated rail 102 .
FIG. 5 and FIG. 6A illustrate bottom view and side view of attachment clip 110 for railing assembly, respectively. FIG. 6B illustrates a side view of another attachment clip 150 , in which a central portion of the attachment clip 150 is not designed to be removable. Attachment clip 150 may be a single body such that attachment clip 150 includes a side surface 152 that extends from the left side of attachment clip 150 to the right side of attachment clip 150 .
FIG. 7 illustrates a cross-section view of rail topper 108 snap-fitted over elongated rail 102 with help of attachment clip 110 . As shown in the figure, the central ridge portion of rail topper 108 stays intact with the left portion and the right portion of attachment clip 110 even after installation. Further, top surface of attachment clip 110 is contoured to the bottom surface of the semi-flexible rail topper 108 . As illustrated, the central ridge portion protrudes up, and mates with a depression or void in the bottom surface of the semi-flexible rail topper 108 .
In an embodiment of the present invention, attachment clip 110 includes left portion 122 , right portion 124 , and the middle portion 126 , as described above. In another embodiment of the present invention, attachment clip 110 may include only the left portion 122 or the right portion 124 . In this embodiment, a single-piece clip may be installed on each of the left side and right side of elongated rail 102 . The single-piece clip is equivalent to the left portion 122 or right portion 124 of attachment clip 110 described above, and the single-piece clip does not include the middle portion 126 , and there is no middle portion to be broken. Separate left portions 122 or right portions 124 may be installed independently of each other, e.g., at least one each but in unequal numbers, or at staggered locations along elongated rail 102 , and so forth.
FIG. 8 illustrates perspective view of an assembled railing system 800 . As shown in the figure, attachment clip 110 is not visible as it has been concealed by rail topper 108 and elongated rail 102 . Rail topper 108 has been snap-fitted on top of the elongated rail 102 with support of attachment clip 110 . Rail topper 108 sits on top of elongated rail 102 and substantially encloses elongated rail 102 . As shown in the figure, elongated rail 102 is also connected to a post 106 with support of the side cover and the bracket cover.
FIG. 9 illustrates perspective views of yet another assembled system 900 . As shown in the figure, balusters connect the elongated upper rail with the elongated bottom rail. Rail topper 108 has been snap-fitted over the elongated upper rail with help of attachment clip 110 , and attachment clip 110 is not visible. As shown in the figure, rail topper 108 provides attractive and unique aesthetic appearance to the railing system. Further, rail topper 108 is detachable and a different rail topper 108 having different color or design may be snapped over the upper elongated rail when desired by a user.
FIG. 10 and FIG. 11 illustrate a perspective view and side view of an attachment clip 210 , respectively, according to another embodiment of the present invention. In this embodiment, attachment clip 210 includes a left side flat portion 212 , a middle flat portion 214 , and a right side flat portion 216 . Middle flat portion 214 is connected to left side flat portion 212 through a first curved portion, and to right side flat portion 216 through a second curved portion, as shown in FIGS. 10 and 11 . The first curved portion and the second curved portion may include mounting holes to receive fasteners (for example, screws) to fix attachment clip 210 to elongated rail 102 . In this embodiment of the present invention, attachment clip 210 has an elongated structure, and middle flat portion 214 is not broken or removed after attaching attachment clip 210 to elongated rail 102 (unlike attachment clip 110 ). Flat middle portion 214 may be made of same material as left side flat portion 212 and right side flat portion 216 . Those skilled in the art will appreciate that although attachment clip 210 has been drawn as having a significant length in the X-axis direction, a significant length may be not be necessary in some embodiments.
FIG. 12 illustrates a side view of a rail topper member 218 snapped over attachment clip 210 , in railing system 1200 , according to an embodiment of the present invention. Attachment clip 210 may be screwed to elongated rail 102 by use of screws extending through mounting holes of attachment clip 210 . Further, rail topper member 218 includes a left flange and right flange that engages with the left portion and the right portion of attachment clip 210 , respectively and facilitates locking rail topper member 218 to attachment clip 210 . Rail topper member 218 is locked to attachment clip 210 sufficiently to prevent significant unintended movement of rail topper member 218 either left/right (i.e., +/−Y-axis as illustrated in the figures) or up/down (i.e., +/−Z-axis as illustrated in the figures). A significant movement is at least one that may cause rail topper member 218 to disengage from attachment clip 210 , and the movement is unintended if it is not made for the purpose of removing rail topper member 218 from attachment clip 210 .
FIG. 13 illustrates side view of a railing system 1300 , in accordance with an embodiment of the present disclosure. System 1300 includes rail topper 220 rigidly fixed to attachment clip 210 using fasteners. FIG. 13 illustrates an elongated rail 102 , an attachment clip 210 , and a rail topper member 220 . In this embodiment, rail topper member 220 has a central body elongated along the Z-axis (perpendicular to the plane of FIG. 13 ), having a rectangular top surface and a rectangular bottom surface. Further, rail topper 220 may be a rigid member, or may be a semi-flexible member in other embodiments. To assemble railing system 1300 , attachment clip 210 first is fixed over elongated rail 102 with help of fasteners (such as screws) in mounting holes. In this embodiment, attachment clip 210 also includes mounting holes at each of the left side flat portion and the right side flat portion. Then, rail topper member 220 is coupled over and onto attachment clip 210 with help of fasteners (such as screws) in the mounting holes present on left side flat portion and the right flat portion. FIG. 14 illustrates a perspective view of rail topper 220 fixed over attachment clip 210 using fasteners, in railing system 1300 . Those skilled in the art will appreciate that railing system 1300 is easily detachable as the fasteners can be locked and unlocked any time to change or upgrade rail topper 220 .
FIG. 15 illustrates an exemplary flowchart illustrating a method 1500 for operation of fixing a rail topper member (e.g., 108 ) over the railing system, according to an embodiment of the present disclosure.
Initially, at step 1502 , attachment clip 110 (or 210 ) is placed on the railing system, and a place to drill the railings is marked corresponding to the two holes of attachment clip 110 . The railings are then drilled at two marked places.
At step 1504 , the fasteners (for example, screws) are tightened, which locks attachment clip 110 over and onto the railings. In an embodiment of the present invention, attachment clip 110 is fastened to elongated rail 102 using screws. Those skilled in the art will appreciate that in another embodiment, step 1502 and 1504 may be combined in a single step, where the attachment clip 110 may be fixed over the railing system through any other attachment means.
At optional step 1506 , the middle portion (if provided) of an attachment clip may be broken off or snapped off. A middle portion may not be provided if the attachment clip includes separate, unconnected left and right portions. In an embodiment of the present invention, the middle portion if provided may be snapped off using a screwdriver or device having an edge that can engage with the middle portion and snap it off. Removal of the middle portion creates space (e.g., a void or groove) to receive the central ridge portion of rail topper 108 . Step 1506 may be optional for clips such as attachment clip 210 that do not have a removable middle section.
At step 1508 , rail topper 108 is snapped fit over attachment clip 110 and pushed. Rail topper 108 is pushed over attachment clip 110 so that it encloses the railing system and attachment clip 110 . The central ridge portion of rail topper 108 makes direct contact with the top portion of the railings due to removal of the middle portion of attachment clip 110 in step 1506 . The left side and right side flanges of rail topper 108 engages with edge portion of attachment clip 110 to lock rail topper 108 in a sound fit over elongated rail 102 . The ridge portion of rail topper 108 can make contact more easily with the top portion of the railings when the middle portion of attachment clip 110 is snapped off. Hence, the center of gravity of rail topper 108 is lowered, thus providing improved structural integrity between rail topper 108 and the elongated rail 102 .
The foregoing discussion of the present invention has been presented for illustration and description. It is not intended to limit the present invention to the form or forms disclosed herein. In the foregoing detailed description, for example, various features of the present invention are grouped together in one or more embodiments, configurations, or aspects to streamline the disclosure. The features of the embodiments, configurations, or aspects may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention the present invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this detailed description, with each claim standing on its own as a separate embodiment of the present invention.
Moreover, though the description of the present invention has included description of one or more embodiments, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the present invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments, configurations, or aspects to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
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A railing attachment clip to couple a guardrail to a rail topper, the clip including left and right portions with respective surfaces contoured to match the guardrail and the rail topper, and a central portion laterally coupled to the left and right portion. The central portion separates the left and right portions by a fixed distance. The matching contoured surfaces determine a position of the railing attachment clip on the guardrail, and determine a position of the rail topper on the railing attachment clip. In some embodiments, the central portion is removed after the railing attachment clip is attached to the guardrail, but before the rail topper is attached to the railing attachment clip.
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This is a division of application Ser. No. 17,832, filed Mar. 9, 1970 now U.S. Pat. No. 3,775,520.
BACKGROUND OF THE INVENTION
In the past procedures have been proposed for converting an acrylic fibrous precursor to an amorphous carbon form or to a graphitic carbon form which retains essentially the same fibrous configuration as the starting material. The acrylic fibrous material is first thermally stabilized, and then carbonized.
The thermal stabilization of an acrylic fibrous material in an oxygen-containing atmosphere is well known in the art and involves (1) an oxidative cross-linking reaction of adjoining molecules as well as (2) a cyclization reaction of pendant nitrile groups to a condensed dihydropyridine structure. The cyclization reaction is exothermic in nature and must be controlled if the fibrous configuration of the acrylic material is to be preserved. Accordingly, stabilization procedures commonly proposed are conducted for many hours (e.g. at 220°C. for 3 to 7 hours, or more). During the carbonization reaction elements in the stabilized fibrous material other than carbon, e.g. nitrogen, hydrogen, and oxygen are expelled. The term "carbonized fibrous material" as used herein is defined to be a material consisting of at least about 90 per cent carbon by weight, and preferably at least about 95 per cent carbon by weight. Depending upon the conditions under which the carbonized fibrous product is processed, substantial amounts of graphitic carbon may or may not be present in the same as determined by the characteristic x-ray diffraction pattern of graphite.
The achievement of uniformly superior mechanical properties in carbon fibers, such as tensile strength and initial modulus, has been an elusive goal when employing processes of the prior art. For instance, heretofore, it has been proposed that high longitudinal tensional forces be exerted upon a carbonaceous fibrous material during the formation of graphitic carbon. Unfortunately, such processes which operate under high tensions tend to be unstable and have a tendency to fail because of fiber breakage which may be traced at least in part to incipient flaws or voids present in the fibrous material. For a reliable commercial operation, such process failures cannot be tolerated.
Carbon fibers are being increasingly proposed for utilization as a reinforcing medium when embedded in a suitable matrix to form a strong lightweight structural component. Such composites find particular applicability in aerospace applications. There is accordingly a demand for high strength graphitic fibrous materials having uniform properties which may be reliably looked to for the desired reinforcement.
It is an object of the invention to provide an improved process for the conversion of certain acrylic fibrous materials to high strength graphitic fibrous materials.
It is an object of the invention to provide a process for the production of a graphitic fibrous material possessing essentially uniform mechanical properties, i.e. a high tensile strength and a high initial modulus.
It is another object of the invention to provide a process for the conversion of certain acrylic fibrous materials to graphitic fibrous materials in which the carbonization/graphitization portion of the process may be conducted on a reliable and stable basis wherein the desired tenacity is achieved without the necessity of resorting to the exertion of high longitudinal tensions upon the preoxidized fibrous material undergoing conversion.
It is another object of the invention to provide a process for the production of high tenacity graphitic fibrous materials which is relatively insensitive to variations in longitudinal tension during the carbonization/graphitization portion thereof.
It is a further object of the invention to provide a relatively rapid process for production of graphitic fibrous materials which does not require that the acrylic precursor be water washed to remove residual solvent prior to its utilization.
These and other objects, as well as the scope, nature, and utilization of the invention will be apparent from the following detailed description and appended claims.
SUMMARY OF THE INVENTION
It has been found that an improved process for the conversion of a drawn acrylic fibrous material selected from the group consisting of an acrylonitrile homopolymer and acrylonitrile copolymers which contain at least about 95 mol per cent of acrylonitrile units and up to about 5 mol per cent of one or more monovinyl units copolymerized therewith to a high strength graphitic fibrous material comprises:
a. continuously passing a continuous length of said acrylic fibrous material for a residence time of about 90 to 900 seconds through a pretreatment heating zone provided with a gaseous atmosphere at a temperature of about 170° to 220°C. while under a longitudinal tension sufficient to permit up to about a 20 per cent reduction in length brought about through shrinkage or the maintenance of a constant length,
b. continuously withdrawing said continuous length of the resulting pretreated fibrous material from said heating zone.
c. continuously passing said resulting continuous length of pretreated fibrous material for a residence time of about 90 to 210 minutes through a preoxidation heating zone provided with an oxygen-containing atmosphere at a temperature of about 260° to 290°C., and
d. continuously passing a continuous length of said resulting preoxidized fibrous material while under a longitudinal tension of about 0.05 to 0.8 grams per denier through a carbonization/graphitization heating zone provided with an inert atmosphere and a temperature gradient in which said fibrous material is raised within a period of about 20 to about 300 seconds from about 800°C. to a temperature of about 1600°C. to form a continuous length of carbonized fibrous material, and in which said carbonized fibrous material is subsequently raised from 1600°C. to a temperature within the range of about 2400 to about 3100°C. within a period of about 3 to 300 seconds where it is maintained for about 10 seconds to about 200 seconds to form a continuous length of graphitic fibrous material;
said steps (a) and (c) being conducted in accordance with the formula:
A = 3X.sub.2 (12X.sub.2 + 8X.sub.3 + 7X.sub.4) + 17X.sub.3 + 10X.sub.4.
where ##EQU1## and where A is equal to or less than 111.
The resulting graphitic fibrous materials commonly exhibit a single filament tensile strength of at least about 300,000 psi, and a single filament initial modulus of at least about 75,000,000 psi.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representative response surface map which visually presents those operating areas in terms of A values wherein optimum graphite tensile strengths are achieved when operating at various pretreatment shrinkages and various preoxidation times holding the pretreatment temperature constant at 185°C., the preoxidation temperature constant at 270°C., the graphitization time constant at 48 seconds, and the longitudinal tension exerted upon the fibrous material within the carbonization/graphitization zone constant at 0.34 grams per denier.
FIG. 2 is a response surface map similar to that of FIG. 1 with the exception that the preoxidation temperature is held constant at 285°C., rather than 270°C.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The Starting Material
The acrylic fibrous materials which serve as the starting materials in the present process are formed by conventional solution spinning techniques (i.e. are dry spun or wet spun), and are drawn to increase their orientation. As is known in the art, dry spinning is commonly conducted by dissolving the polymer in an appropriate solvent, such as N,N-dimethyl formamide or N,N-dimethyl acetamide, and passing the solution through an opening of predetermined shape into an evaporative atmosphere (e.g. nitrogen) in which much of the solvent is evaporated. Wet spinning is commonly conducted by passing a solution of the polymer through an opening of predetermined shape into an aqueous coagulation bath.
The acrylic polymer utilized as the starting material is either an acrylonitrile homopolymer or an acrylonitrile copolymer containing at least about 95 mol per cent of acrylonitrile units and up to about 5 mol per cent of one or more units derived from a monovinyl compound which is copolymerizable with acrylonitrile such as styrene, methyl acrylate, methyl methacrylate, vinyl acetate, vinyl chloride, vinylidene chloride, vinyl pyridine, and the like.
The acrylic fibrous materials are provided as continuous lengths and may be in a variety of physical configurations. For instance, the acrylic fibrous materials may be present in the form of continuous lengths of multifilament yarns, tows, strands, cables, tapes, or similar fibrous assemblages.
When the starting material is a continuous multifilament yarn, a twist may be imparted to the same to improve the handling characteristics. For instance, a twist of about 0.1 to 5 tpi, and preferably about 0.3 to 1.0 tpi may be utilized. Also a false twist may be used instead of or in addition to a real twist. Alternatively, one may select bundles of fibrous material which possess essentially no twist.
The starting material is drawn in accordance with conventional techniques in order to improve its orientation. For instance, the starting material may be drawn by stretching while in contact with a hot shoe at a temperature of about 140° to 160°C. Additional representative drawing techniques are disclosed in U.S. Pat. Nos. 2,455,173; 2,948,581; and 3,122,412. It is recommended that the acrylic fibrous materials selected for use in the process be drawn to a single filament tenacity of at least about 3 grams per denier. If desired, however, the starting material may be more highly oriented, e.g. drawn up to a single filament tenacity of about 7.5 to 8 grams per denier, or more.
The acrylic fibrous material which is converted to a graphitic fibrous material in accordance with the present process may or may not contain an appreciable quantity of residual solvent. In a preferred embodiment of the invention the fibrous material is unwashed and contains about 2 to 10 per cent by weight residual solvent. In a particularly preferred embodiment of the invention the fibrous material is dry spun, unwashed, and contains about 2 to 10 per cent by weight of residual N,N-dimethyl formamide or N,N-dimethyl acetamide. Residual N,N-dimethyl formamide or N,N-dimethyl acetamide contents of about 2 to 5 per cent by weight are commonly encountered in such unwashed dry spun fiber. Alternatively, the starting material may have been previously washed and contain essentially no solvent prior to introduction into the heating zone described hereafter. The acrylic fibrous materials treated in the present process commonly have an inherent tendency to shrink in length when heated at about 170° to 220°C. (e.g. at about 185° to 220°C.).
The acrylic fibrous material which serves as the starting material in the present invention has not been previously thermally stabilized, such as by exposure to an oxygen-containing atmosphere at an elevated temperature for an extended period of time. The properties of the acrylic fibrous material as it is withdrawn from the pretreatment heating zone, described hereafter, are dissimilar to those of a thermally stabilized acrylic fibrous material. For instance, during thermal stabilization the bound oxygen content of the acrylic fibrous material increases to at least about 7 per cent by weight and possibly as high as 18 per cent by weight as determined by the Unterzaucher analysis. Not only is the fibrous material upon thermal stabilization rendered black in appearance, and non-burning to a match flame, but its mechanical properties such as tenacity are substantially reduced. The pretreatment heating step described hereafter generally results in no substantial diminution of mechanical properties, such as tenacity. Also, even if the pretreatment heating step, described hereafter, were conducted in an oxygen-containing atmosphere, such as air, no appreciable increase in the bound oxygen content as determined by the Unterzaucher analysis results (i.e. less than a one per cent increase in bound oxygen) during the passage of the fibrous material through the pretreatment heating zone.
The Pretreatment Heating Step
In accordance with the present invention the continuous length of acrylic fibrous material is continuously introduced into a pretreatment heating zone provided with a gaseous atmosphere at the temperature indicated. The nature of the gaseous atmosphere is not critical and may be varied widely. For instance, ordinary air may be utilized, or alternatively the atmosphere may be inert, e.g. nitrogen, argon, etc. The gaseous atmosphere which is selected should not be one which is unduely reactive with the acrylic fibrous material so as to diminsh its mechanical properties under the conditions of the heat treatment.
The gaseous atmosphere of the pretreatment heating zone is provided at a temperature of about 170° to 220°C. In a preferred embodiment of the invention the gaseous atmosphere is at a temperature of about 185° to 220°C. In a particularly preferred embodiment of the invention the gaseous atmosphere is at a temperature of about 190° to 220°C. If the acrylic fibrous material undergoing treatment contains an appreciable quantity of residual solvent, it is recommended that provision be made for circulating the atmosphere or for the withdrawal of solvent generated during the pretreatment heating step.
The equipment utilized to produce the requisite temperatures to carry out the pretreatment heating step may be varied widely as will be apparent to those skilled in the art. For instance, the continuous length of acrylic fibrous material may be passed through a circulating oven, or the tube of a muffle furnace. The speed of movement through the pretreatment heating zone will be determined by the size of the zone and the desired residence as discussed hereafter. Rollers or guides may be provided within the zone to direct the movement of the continuous length of acrylic fibrous material. In a preferred embodiment of the invention the acrylic fibrous material is passed through the pretreatment heating zone in the direction of its length and is substantially suspended therein with minimal contact with guides or rollers. If desired, the continuous length of fibrous material may be passed through the pretreatment heating zone a plurality of passes until the desired residence time is achieved.
The acrylic fibrous material is passed through the pretreatment heating zone for a residence time of about 90 to 900 seconds. If the residence time is much below about 90 seconds then the desired enhancement of fiber properties accomplished in the pretreatment heating zone tends to be insufficiently achieved. If the residence time is much more than about 900 seconds, then the thermal stabilization reaction tends to take over. In a preferred embodiment of the invention the acrylic fibrous material is passed through the pretreatment heating zone for a residence time of about 90 to 500 seconds. Also, it is preferred that the residual solvent content of acrylic fibrous material treated in accordance with the present invention be less than about 0.1 per cent by weight at the time of its withdrawal from the pretreatment heating zone. Such solvent content determinations can be made by conventional gas chromatography techniques.
While passing through the pretreatment heating zone, the longitudinal tension on the continuous length of acrylic fibrous material is adjusted so that it is sufficient to permit up to a 20 per cent reduction in length brought about through shrinkage, or the maintenance of a constant length. In a preferred embodiment of the invention the longitudinal tension on the continuous length of fibrous material is sufficient to permit a reduction in length of about 5 to 15 per cent brought about through shrinkage. The relative tension exerted upon the continuous length of fibrous material may be adjusted through a proper selection of feed and withdrawal rates taking into consideration the inherent tendency of the fibrous material to shrink.
The theory whereby the pretreatment step of the present process enhances the properties of the continuous length of fibrous material is considered complex and incapable of simple explanation. It has been found, however, that a more uniform and more dense microstructure results which is believed to be produced through the healing of voids and the release of internal stress. The more uniform morphology of the pretreated fiber is also believed to be carried over the graphitic fiber ultimately derived therefrom.
The pretreatment heating step of the present process is fully described in our commonly assigned U.S. Ser. No. 17,962 (now abandoned), filed concurrently herewith, which is herein incorporated by reference.
The Preoxidation Heating Step
The continuous length of pretreated fibrous material is next continuously stabilized (i.e. preoxidized) at a relatively severe temperature. The preoxidation heating step may be conducted in accordance with certain embodiments of commonly assigned U.S. Ser. No. 749,957, filed Aug. 5, 1968, (now abandoned) of Dagobert E. Stuetz, which is herein incorporated by reference.
More specifically, the continuous length of pretreated fibrous material is continuously introduced, passed through, and continuously withdrawn from a preoxidation heating zone provided at a temperature of about 260° to 290°C. The pretreated fibrous material is maintained in the preoxidation heating zone for a residence time of about 90 to 210 minutes. The preoxidation heating step is preferably conducted in tandem with the pretreatment heating step with the pretreated fibrous material as it is withdrawn from the pretreatment heating zone being passed directly to the preoxidation heating zone.
It is essential that the heated atmosphere which is provided within the preoxidation heating zone be oxygen-containing so that the desired stabilization reaction brought about by preoxidation is accomplished. The preferred oxygen-containing atmosphere is air.
In a preferred embodiment of the invention a longitudinal tension is exerted upon the continuous length of pretreated fibrous material whereby a constant length is maintained while passing through the preoxidation heating zone.
The fibrous material as it is withdrawn from the preoxidation heating zone (1) retains essentially the same fibrous configuration as the starting material, (2) is capable of undergoing carbonization, (3) is black in appearance, and (4) is non-burning when subjected to an ordinary match flame. Even if the acrylic fibrous material which was originally introduced into the pretreatment heating zone was unwashed and originally contained an appreciable residual solvent content, the fibrous material following treatment in the preoxidation heating zone is essentially non-coalesced. The stabilized fibrous material as it is withdrawn from the preoxidation heating zone commonly exhibits a bound oxygen content of at least about 7 per cent by weight as determined by the Unterzaucher analysis.
The equipment utilized to produce the requisite temperatures to carry out the preoxidation heating step may be varied widely as will be apparent to those skilled in the art. For instance, the continuous length of pretreated fibrous material may be passed through a circulating oven, or the tube of a muffle furnace provided with the requisite oxygen-containing atmosphere, such as air. The speed of movement of the pretreated fibrous material through the preoxidation heating zone will be determined by the size of the heating zone and the desired residence time. Rollers or guides may be provided within the preoxidation heating zone to direct the movement of the continuous length of pretreated fibrous material. In a preferred embodiment of the invention the acrylic fibrous material is passed through the preoxidation heating zone in the direction of its length and is substantially suspended therein with minimal contact with guides or rollers. If desired, the continuous length of fibrous material may be passed through the preoxidation heating zone for a plurality of passes until the desired residence time is achieved.
The Carbonization/Graphitization Heating Step
The continuous length of pretreated and preoxidized fibrous material is next continuously passed through a carbonization/graphitization heating zone provided with a temperature gradient (described hereafter) wherein a high strength graphitic fibrous material is ultimately produced. The carbonization/graphitization step may be connected in accordance with certain embodiments of commonly assigned U.S. Ser. No. 777,275, filed Nov. 20, 1968 (now abandoned) of Charles M. Clarke, which is herein incorporated by reference.
An inert non-oxidizing atmosphere is provided within the carbonization/graphitization heating zone. Representative inert atmospheres for utilization in the zone include nitrogen, argon, and helium. The preferred inert atmospheres are nitrogen and argon.
Since the pretreated and preoxidized fibrous material is generally inherently hygroscopic, it is recommended that it be supplied to the carbonization/graphitization heating zone in an essentially anhydrous form in accordance with the teachings of commonly assigned U.S. Ser. No. 17,780, filed Mar. 9, 1970 (now U.S. Pat. No. 3,677,705), of Charles M. Clarke, Michael J. Ram, and John P. Riggs which is herein incorporated by reference.
The continuous length of pretreated and preoxidized fibrous material is generally provided at a temperature of about 20° to 500°C. at the time it is introduced into the carbonization/graphitization heating zone and is elevated to 800°C. The temperature gradient within the carbonization/graphitization heating zone raises the fibrous material from about 800° to about 1600°C. within about 20 to about 300 seconds to form a continuous length of carbonized fibrous material, and subsequently raises the carbonized fibrous material from about 1600°C. to a temperature within the range of about 2400° to about 3100°C. within a period of about 3 to 300 seconds where it is maintained for about 10 seconds to about 200 seconds to form a continuous length of graphitic fibrous material. In a preferred embodiment of the invention the fibrous material is raised from about 800° to about 1600°C. within about 45 to 300 seconds. A preferred maximum graphitization temperature is about 2900° ± 50°C. where the fiber is maintained for about 20 to 60 seconds. Graphitic carbon in the fibrous product may be determined by the characteristic x-ray diffraction pattern of graphite.
While the continuous length of resulting preoxidized fibrous material is passed through the carbonization/graphitization heating zone, it is placed under a longitudinal tension of about 0.05 to 0.8 grams per denier. In a preferred embodiment of the invention the preoxidized fibrous material is under a longitudinal tension of about 0.3 to 0.5 grams per denier while passing through the carbonization/graphitization heating zone. The longitudinal tension exerted upon the fibrous material may be satisfactorily adjusted by controlling the relative rates of introduction and withdrawal of the fibrous material while passing through the carbonization/graphitization heating zone.
It has been found that when the acrylic fibrous material has been pretreated at a temperature of about 185° to 220°C., and when the temperature gradient within the carbonization/graphitization zone raises the fibrous material from about 800° to a temperature of about 1600°C. within a period of about 45 to about 300 seconds, then the carbonization/graphitization portion of the present process tends to be relatively insensitive to longitudinal tension. Under such conditions a high tenacity product is produced over a wide range of tensions. The exact pretreatment temperature range which is required in order to yield this unexpected tension response has been found to vary somewhat with different precursors, however, the pretreatment temperature range of about 190° to 220°C. tends to be preferred for the most pronounced observance of this response.
The equipment utilized to produce the requisite heating to carry out the carbonization/graphitization heating step of the present process may be varied widely as will be apparent to those skilled in the art. It is essential that the apparatus selected be capable of producing the required temperature while excluding the presence of an oxidizing atmosphere. For instance, suitable apparatus include induction furnaces, tube furnaces in which a hollow graphite susceptor is heated by direct resistance heating, and the like.
In a preferred embodiment of the invention, the continuous length of preoxidized fibrous material is heated by use of an induction furnace. In such a procedure, the continuous length of stabilized material is passed through a hollow graphite tube or susceptor which is situated within the windings of an induction coil. By varying the length of the graphite susceptor, the length of the induction coil, and the rate at which the fibrous material is passed through the susceptor, many apparatus arrangements capable of carrying out the present process may be selected. For large scale production, it is of course preferred that relatively long susceptors and extended heating zones be used so that the continuous length of fibrous material may be passed through the same at a higher rate while still being heated in accordance with the desired temperature gradient.
Study of Process Parameters
Table I presents representative graphite tensile strength values achieved under a variety of conditions in which the pretreatment temperature and shrinkages were varied, as well as the carbonization/graphitization tension and times.
A continuous length of a 1600 fil dry spun acrylonitrile homopolymer continuous filament yarn having a total denier of 1920 was selected as the starting material. The yarn was dry spun from a solution of the same in an N,N-dimethyl formamide solvent into an evaporative atmosphere of nitrogen. The fibrous material was dry spun as a 40 fil bundle, and plied to form the 1600 fil yarn which exhibited a twist of about 0.5 tpi.
The yarn was next drawn at a draw ratio of about 5:1 to a single filament tenacity of about 4 grams per denier by stretching while passing over a hot shoe at a temperature of about 160°C. for a residence time of about 0.5 second. Contrary to standard acrylic fiber technology the acrylic yarn was not washed and contained a residual N,N-dimethyl formamide solvent content of about 4 per cent by weight. The yarn also exhibited an inherent tendency to shrink in length when heated to about 170° to 220°C.
The unwashed acrylonitrile homopolymer yarn was next continuously introduced in the direction of its length into a 50 inch muffle furnace (pretreatment heating zone) having an internal diameter of 1.25 inches. A gaseous atmosphere of air at the temperatures indicated (170° to 215°C.) was provided within the muffle furnace. The yarn was passed through the muffle furnace for 3 passes at a speed of 30 inches per minute for a total residence time of 300 seconds. Roller guides were provided at each end of the muffle furnace to facilitate the multiple passes. While passing through the muffle furnace, the longitudinal tension exerted upon the continuous length of fibrous material was adjusted so that shrinkages of 10 or 15 per cent were recorded at the end of the final pass. The resulting yarn exhibited a residual N,N-dimethyl formamide content of less than 0.1 per cent by weight. Also, the bound oxygen content remained substantially unchanged following the heat treatment.
The resulting pretreated yarn was next passed directly to an adjoining preoxidation heating zone. The preoxidation treatment was conducted while the pretreated yarn was continuously passed in the direction of its length through a multi-wrap skewed roll oven provided with circulating air at 270°C. The residence time within the preoxidation heating zone was constant at 120 minutes in each treatment. While passing through the preoxidation heating zone, a longitudinal tension was exerted upon the treated fibrous material whereby an essentially constant length was maintained. The resulting preoxidized yarn was black in appearance, non-burning when subjected to an ordinary match flame, and had a bound oxygen content of about 10 per cent by weight as determined by the Unterzaucher analysis. Upon withdrawal from the preoxidation zone the continuous lengths of preoxidized fibrous material were wound upon bobbins and stored in a forced air oven at 110°C.
The preoxidized fibrous material was dried in an in line continuous manner immediately prior to its introduction into an induction furnace provided with a nitrogen atmosphere and a temperature gradient wherein both carbonization and substantial graphitization occurred. Drying was conducted by passing the preoxidized yarn in the direction of its length through four 12 inch muffle furnaces placed in an end to end relationship and provided with circulating air at 200°C., 250°C., 300°C., and 340°C., respectively.
The preoxidized yarns were passed through the drying zone and the carbonization/graphitization zone at rates of 10 inches per minute and 30 inches per minute. Various longitudinal tensions of 0.08 to 0.72 grams per denier were exerted upon the fibrous material as it passed through the carbonization/graphitization zone. The induction furnace comprised an Inductotherm model Inducto 50 unit provided with a 50 KW power source, a 12 turn water cooled copper coil having a length of 19 inches, and a hollow graphite tube suspended within the coil having a total length of 55 inches. The copper coil had an inner diameter of 8 inches, and the copper tubing from which it was formed was of 0.75 inch outer diameter with a wall thickness of 0.125 inch. The 55 inch hollow graphite tube was provided in two adjoining sections. The main section was 45 inches in length, and had an outer diameter of 3 inches and an inner diameter of 0.75 inch. The auxiliary section was 10 inches in length and was located at the exit end of the main susceptor and had an outer diameter of 2 inches and an inner diameter of 0.75 inch. The copper coil encompassed the main susceptor and had its end located two inches from the point where the main susceptor and the auxiliary susceptor were joined. Thermal insulation in a depth of 5 inches totally surrounded the graphite tube. Air was substantially excluded from the induction furnace by purging with nitrogen. The yarn was raised to a maximum temperature of about 2900°C. while passing through the carbonization/graphitization zone.
When passing through the carbonization/graphitization heating zone at a rate of 10 inches per minute the yarn was raised to a temperature of 800°C. in approximately 48 seconds after entering the graphite tube, from 800° to 1600°C. in approximately 72 seconds, and from 1600° to 2900°C. in approximately 60 seconds where it was maintained ±50°C. for about 48 seconds. When passing through the carbonization/graphitization heating zone at a rate of 30 inches per minute, the yarn was raised to a temperature of 800°C. in approximately 16 seconds after entering the graphite tube, from 800° to 1600°C. in approximately 24 seconds, from 1600° to 2900°C. in approximately 20 seconds where it was maintained ±50°C. of 2900°C. for about 16 seconds. The resulting graphitic yarns exhibited a specific gravity of about 2.0.
TABLE I__________________________________________________________________________ Pretreatment Carbonization/ Time atPretreatment Pretreatment Longitudinal Preoxidation Preoxidation Graphitization Graphitization Single FilamentTemperature Time Shrinkage* Temperature Time Tension in Temperature Tensile Strengthin °C. in Seconds (Per Cent) in °C. in Minutes Grams per Denier in Seconds in psi**(× 1000)__________________________________________________________________________170 300 10 270 120 0.17 48 403170 300 10 270 120 0.36 48 438185 300 10 270 120 0.09 48 413185 300 10 270 120 0.29 48 352185 300 10 270 120 0.54 48 445185 300 15 270 120 0.08 48 388185 300 15 270 120 0.27 48 413200 300 10 270 120 0.08 48 352200 300 10 270 120 0.18 48 397200 300 10 270 120 0.27 48 445200 300 10 270 120 0.36 48 417200 300 10 270 120 0.45 48 432200 300 10 270 120 0.58 48 414200 300 10 270 120 0.69 48 388200 300 10 270 120 0.80 48 417200 300 15 270 120 0.16 48 378200 300 15 270 120 0.35 48 452200 300 15 270 120 0.55 48 417215 300 10 270 120 0.10 48 350215 300 10 270 120 0.20 48 362215 300 10 270 120 0.32 48 320215 300 10 270 120 0.43 48 285215 300 10 270 120 0.55 48 272215 300 15 270 120 0.08 48 358215 300 15 270 120 0.28 48 282215 300 15 270 120 0.48 48 210170 300 10 270 120 0.18 16 355170 300 10 270 120 0.38 16 405185 300 10 270 120 0.19 16 368185 300 10 270 120 0.40 16 352185 300 15 270 120 0.08 16 352200 300 10 270 120 0.09 16 320200 300 10 270 120 0.17 16 325200 300 10 270 120 0.27 16 338200 300 10 270 120 0.37 16 410200 300 10 270 120 0.46 16 400200 300 10 270 120 0.59 16 380200 300 10 270 120 0.72 16 262200 300 15 270 120 0.17 16 378200 300 15 270 120 0.37 16 440215 300 10 270 120 0.09 16 243215 300 10 270 120 0.20 16 252215 300 10 270 120 0.30 16 260215 300 10 270 120 0.40 16 332215 300 15 270 120 0.17 16 247215 300 15 270 120 0.37 16 260__________________________________________________________________________ *Plus or minus one per cent **Average of five breaks
Table II presents representative graphite tensile strength values achieved under a variety of conditions in which the pretreatment shrinkage and times were varied, the preoxidation temperature and times were varied, and carbonization/graphitization tension and times were varied.
The acrylonitrile homopolymer yarn was substantially identical to that described in connection with the process runs reported in Table I. Also, the same equipment was utilized under the conditions reported in connection with the runs of Table I, except as indicated. More specifically, the longitudinal shrinkage in the pretreatment zone varied from 9.2 to 15.6 per cent, and the pretreatment residence times varied from about 250 to 500 seconds. The preoxidation temperatures were 270° and 285°C., and preoxidation times varied from 88 to 197 minutes. The preoxidized yarn was passed through the induction furnace at rates of 10 and 30 inches per minute, and was exposed to the same temperature gradients as discussed in connection with the runs of Table I. Various longitudinal tensions of 0.08 to 0.76 grams per denier were exerted upon the fibrous material as it passed through the carbonization/graphitization zone. The resulting graphitic yarns exhibited a specific gravity of about 2.0.
TABLE II__________________________________________________________________________ Pretreatment Carbonization/ Time atPretreatment Pretreatment Longitudinal Preoxidation Preoxidation Graphitization Graphitization Single FilamentTemperature Time Shrinkage Temperature Time Tension in Temperature Tensile Strengthin °C. in Seconds (Per Cent) in Minutes Grams per Denier in Seconds in psi**(× 1000)__________________________________________________________________________185 300 9.3 270 116 0.09 48 413185 300 9.3 270 116 0.29 48 352185 300 9.3 270 116 0.54 48 445185 300 15.6 270 119 0.08 48 388185 300 15.6 270 119 0.27 48 413185 400 10.6 270 158 0.09 48 422185 400 10.6 270 158 0.28 48 432185 400 10.6 270 158 0.51 48 417185 400 13.6 270 158 0.09 48 414185 400 13.6 270 158 0.18 48 412185 400 13.6 270 158 0.29 48 380185 400 13.6 270 158 0.55 48 390185 400 13.6 270 158 0.76 48 405185 500 9.2 270 197 0.14 48 355185 500 9.2 270 197 0.30 48 435185 500 9.2 270 197 0.48 48 388185 250 10.7 285 88 0.09 48 364185 250 10.7 285 88 0.28 48 282185 250 10.7 285 88 0.52 48 285185 250 13.9 285 88 0.09 48 362185 250 13.9 285 88 0.28 48 365185 250 13.9 285 88 0.50 48 355185 250 13.9 285 88 0.75 48 395185 300 15.6 285 118 0.21 48 360185 300 15.6 285 118 0.42 48 420185 300 15.6 285 118 0.67 48 427185 400 10.6 285 160 0.16 48 335185 400 10.6 285 160 0.35 48 452185 400 10.6 285 160 0.53 48 410185 400 10.6 285 160 0.15 48 355185 400 10.6 285 160 0.32 48 405185 400 10.6 285 160 0.51 48 410185 400 13.6 285 158 0.23 48 262185 400 13.6 285 158 0.47 48 332185 300 9.3 270 116 0.19 16 368185 300 9.3 270 116 0.40 16 352185 300 15.6 270 116 0.08 16 352185 400 10.6 270 158 0.18 16 385185 400 10.6 270 158 0.40 16 412185 400 13.6 270 158 0.09 16 325185 400 13.6 270 158 0.19 16 420185 400 13.6 270 158 0.29 16 482185 400 13.6 270 158 0.42 16 360185 400 13.6 270 158 0.55 16 383185 400 13.6 270 158 0.29 16 390185 500 9.2 270 197 0.14 16 305185 500 9.2 270 197 0.31 16 378185 500 9.2 270 197 0.47 16 417185 250 10.7 285 88 0.19 16 293185 250 10.7 285 88 0.42 16 313185 250 10.7 285 88 0.64 16 345185 250 13.9 285 88 0.18 16 342185 250 13.9 285 88 0.38 16 410185 250 13.9 285 88 0.64 16 295185 300 9.9 285 120 0.10 16 282185 300 9.9 285 120 0.20 16 390185 300 9.9 285 120 0.30 16 372185 300 9.9 285 120 0.45 16 384185 300 9.9 285 120 0.64 16 325185 300 15.6 285 118 0.21 16 308185 300 15.6 285 118 0.42 16 390185 300 15.6 285 118 0.73 16 398185 400 10.6 285 160 0.16 16 292185 400 10.6 285 160 0.33 16 330185 400 13.6 285 158 0.23 16 238185 400 13.6 285 158 0.45 16 367185 400 13.6 285 158 0.76 16 367__________________________________________________________________________ **Average of five breaks
Having made extensive empirical experimentation and the compilation of substantial experimental data, a mathematical equation was obtained which specifies the general relationship of the variables of the present process for optimum results, and which aids one in selecting a combination of variables wherein a fibrous graphitic material of various high levels of tensile strength may be produced. It was determined that a second order polynomial function would be satisfactory to relate graphite properties to the experimental variables. The form of the second-order polynomial and its use to summarize process data are discussed, for example, in "The Design and Analysis of Industrial Experiments" edited by O. L. Davies, Hafner Publishing Company, New York, 1956, Chapter 11.
The second order polynomial was derived by an analysis of the experimental data by way of least squares calculations. A procedure which uses a digital computer to perform the least squares calculations to derive the parameters of the second-order polynomial, and to present the results in the form of response surface maps is reported by P. A. C. Cook and A. J. Rosenthal in the "Annual Technical Conference Transactions 1969" published by American Society for Quality Control, pages 161-172, May, 1969. Selecting preferred carbonization/graphitization conditions of 48 seconds while at 2900°C. ± 50°C., a longitudinal carbonization/graphitization tension of 0.34 grams per denier, and the carbonization/graphitization temperature gradient heretofore discussed, it was found that the estimated single filament tensile strength of the graphitic fibrous material expressed in thousands of psi could be calculated from the following equation:
Estimated Tensile Strength = 411 - 17X.sub.3 - 10X.sub.4 - 37X.sub.2.sup.2 - 24X.sub.2 X.sub.3 - 21X.sub.2 X.sub.4 (1)
where ##EQU2##
To achieve single filament graphite tensile strengths in excess of 300,000 psi utilizing the process of the present invention it is generally necessary to select conditions wherein the per cent shrinkage in the pretreatment zone, the temperature of the preoxidation zone, and the residence time in the preoxidation zone are such that the right-hand side of the equation (1) is equal to or greater than 300. Inserting 300 for the estimated tensile strength and regrouping the terms, one determines that the desired fiber properties are generally expected if a parameter:
A = 3X.sub.2 (12X.sub.2 + 8X.sub.3 + 7X.sub.4) + 17X.sub.3 + 10X.sub.4
is equal to or less than 111.
It accordingly follows that the estimated single filament tensile strength will generally be in excess of 350,000 psi if A is equal to or less than 61. The estimated single filament tensile strength will generally be in excess of 400,000 psi if A is equal to or less than 11. The estimated single filament tensile strength will generally be in excess of 450,000 psi if A is equal to or less than minus 39. A single filament initial modulus in excess of 75,000,000 psi can generally also be expected when A is equal to or less than 111. The above A values should not be considered as an absolute prediction of tensile strength values. The utilization of the above formula is highly useful, however, in selecting variables to be employed in the process of the present invention.
FIG. 1 is a representative response surface map which visually presents those operating areas in terms of A values wherein optimum graphite tensile strengths are achieved when operating at various pretreatment shrinkages and various preoxidation times holding the pretreatment temperature constant at 185°C., the preoxidation temperature constant at 270°C., the graphitization time constant at 48 seconds while at 2900° ±50°C., and the longitudinal tension exerted upon the fibrous material within the carbonization/graphitization zone constant at 0.34 grams per denier. Line A corresponds to an A value of 111. Line B corresponds to an A value of 61. Line C corresponds to an A value of 11. Line D corresponds to an A value of minus 39.
FIG. 2 is a response surface map similar to that of FIG. 1 with the exception that the preoxidation temperature is held constant at 285°C., rather than 270°C.
The following examples present representative comparisons between calculated A values and tensile strength values determined experimentally when employing the process of the present invention. The runs identified in the examples were selected at random from those previously reported in Table II. It should be understood that the invention is not limited to the specific details set forth in the examples.
EXAMPLE I
The pretreatment was conducted at 185°C. for 300 seconds and at a longitudinal shrinkage of 13.6 per cent, the preoxidation for 158 minutes at 270°C., and the carbonization/graphitization for 48 seconds at 2900° ±50°C. while under a longitudinal tension of 0.09 grams per denier. The calculated A value was -0.7. The single filament tensile strength determined experimentally was 414 thousand psi.
EXAMPLE II
The pretreatment was conducted at 185°C. for 400 seconds and at a longitudinal shrinkage of 10.6 per cent, the preoxidation for 160 minutes at 285°C., and the carbonization/graphitization for 48 seconds at 2900° ±50°C. while under a longitudinal tension of 0.16 grams per denier. The calculated A value was 36. The single filament tensile strength determined experimentally was 335 thousand psi.
EXAMPLE III
The pretreatment was conducted at 185°C. for 400 seconds and at a longitudinal shrinkage of 13.6 per cent, the preoxidation for 158 minutes at 285°C., and the carbonization/graphitization for 48 seconds at 2900° ±50°C. while under a longitudinal tension of 0.47 grams per denier. The calculated A value was 64. The single filament tensile strength determined experimentally was 332 thousand psi.
EXAMPLE IV
The pretreatment was conducted at 185°C. for 400 seconds and at a longitudinal shrinkage of 10.6 per cent, the preoxidation for 158 minutes at 270°C., and the carbonization/graphitization for 16 seconds at 2900° ± 50°C. while under a longitudinal tension of 0.40 grams per denier. The calculated A value was -33. The single filament tensile strength determined experimentally was 412 thousand psi.
Although the invention has been described with preferred embodiments, it is to be understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations are to be considered within the purview and scope of the claims appended hereto.
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A process is provided for the efficient conversion of acrylonitrile homopolymer fibrous materials and closely related acrylonitrile copolymer fibrous materials to graphitic fibrous materials of high tenacity. The process incorporates an initial brief fiber healing step which is conducted at a temperature of about 170° to 220°C., a preoxidation step, and a tandem carbonization/graphitization step as described. The relationship of the various variables required to produce the high tenacity graphitic fibrous product is set forth in the equation provided. In a preferred embodiment of the invention the carbonization/graphitization step of the process is conducted on a reliable and stable basis wherein the desired tenacity is achieved without the necessity of resorting to the exertion of high longitudinal tensions upon the preoxidized acrylic fibrous material.
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BACKGROUND OF THE INVENTION
This invention relates to the sensory evaluation of smoking products containing a body of smokable material. The invention is especially suited to the evaluation of cigarettes, cigarillos and cigars but it may also be used for evaluating smokable materials which are consumed in pipes and similar devices.
In the development of smoking products intended for commercial production, it is customary to conduct sensory evaluations of such products during their development phase to determine whether or not the products possess those attributes which are desired by the consumers of the products. Among the sensory evaluations utilized are those performed by small panels of judges who are trained to characterize the attribute intensities of the products. Such sensory evaluations, known as descriptive testing, require the judges to apply uniform terms to describe the product and to be thoroughly familiar with sensory evaluation techniques.
Descriptive testing has heretofore involved the monadic evaluation of smoking products which are smoked ad libitum by sensory panelists or judges who then indicate the intensity of one or more sensory attributes using a predesignated range of intensity ratings. Such testing, however, does not compensate for variables introduced by the judges or panelists. For example, smokers who base their evaluation of the intensity of a particular attribute on the first few puffs may reach a different conclusion than smokers who base their evaluation on the last few puffs of a smoking product being evaluated. This variable can be minimized by obtaining intensity ratings for a particular attribute at spaced points along a rod of smokable material. Although the technique of obtaining a plurality of intensity ratings for the same attribute during the smoking provides a more accurate sensory evaluation of the smoking product, that technique does not address certain other variables which may influence the sensory evaluations made.
It is known that consumers of smoking products develop personal styles and habits for smoking such products to derive the most satisfaction from the use of the products. Thus, some smokers may take small puffs of short duration while other smokers may take large puffs of long duration. The frequency of the puffs taken as well as the degree of inhalation of smoke into the lungs may also vary. These and other differences in the way smoking products are used by consumers make it difficult to develop smoking products designed to appeal to the greatest number of smokers. The differences in how a product is smoked can also influence sensory evaluations due to the individual smoking styles of the panelists. Ideally, the evaluation of a smoking product would be performed by a group of panelists having very similar smoking styles with such smoking styles being representative of a substantial segment of the smoking population. This would require assembling groups of panelists whose smoking styles coincide generally with defined groups within the consuming public. It is not very practical to pursue this idealistic goal due to the wide variations in smoking styles found among smokers and the difficulty in defining the characteristics which distinguish groups of smokers by their smoking styles. Accordingly, there continues to be a need for a sensory evaluation method which is widely applicable to the evaluation of smoking products but which minimizes the influence of variables relating to individual smoking styles of smokers.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide a sensory evaluation method for smoking products which delivers detailed information on the manner in which a product is smoked while the evaluation of the product is being made by a sensory evaluation panelist.
It is a further object of this invention to provide a sensory evaluation method for smoking products which minimizes interference with the ad libitum smoking of a smoking product by a sensory evaluation panelist.
Another object of this invention is to provide a sensory evaluation method for smoking products which allows objective measures of the smoking process to be related to attribute ratings assigned by a sensory evaluation panelist.
Other objects and advantages of the invention will become apparent from the detailed disclosure which follows.
The present invention is based on the discovery that selected smoking parameters can be monitored precisely while a smoking product is being smoked ad libitum by a sensory evaluation panelist and the monitored parameters can be used to coordinate a sequence of instructions and prompts that is communicated to the sensory evaluation panelist as the product is being smoked by the panelist. This allows the panelist to complete the ad libitum smoking process with the least possible disruption to the panelist's normal smoking patterns and leads, therefore, to a better understanding of the smoking characteristics of the product being evaluated. Thus, the invention provides a means of obtaining specific attribute ratings assigned by a sensory evaluation panelist which are correlated with particular smoking parameters that are determined by that panelist's individual and unique smoking patterns.
A system that can be used for conducting sensory evaluation of a smoking product in accordance with the present invention generally comprises a mouthpiece adapted for contact with the lips of a sensory evaluation panelist and for drawing smoke from a smoking product into the mouth of the panelist, sensing means associated with the mouthpiece for monitoring selected smoking parameters and generating signals corresponding thereto as the product is being smoked, computer means and an associated monitor with display screen for processing the signals generated by said sensing means and for communicating a sequence of instructions and prompts to the sensory evaluation panelist, a computer program for coordinating the sequence of instructions and prompts communicated to the panelist with the smoking process as determined by the smoking parameters being monitored by the sensing means and means for receiving a sensory evaluation rating from the panelist in response to the sequence of instructions and prompts communicated to the panelist.
By information entered into the computer program, the present system can be designed to communicate instructions and prompts to the panelist only after certain events have occurred in the smoking process as determined by the sensing means and computer which measure and store information on selected smoking parameters as the smoking process proceeds. Thus, the present invention also provides a method for effecting sensory evaluation of a smoking product as the product is being smoked ad libitum by a sensory evaluation panelist. This method includes the steps of (a) monitoring selected smoking parameters by sensing means placed in communication with a mouthpiece through which smoke from the smoking product is drawn into the mouth of a sensory evaluation panelist, (b) communicating a sequence of instructions and prompts to the sensory evaluation panelist as the smoking product is being smoked by the panelist, (c) coordinating the sequence of instructions and prompts to the panelist with the ad libitum smoking process as monitored by the sensing means and (d) receiving a sensory evaluation rating from the panelist in response to the sequence of instructions and prompts communicated to the panelist.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a typical arrangement for monitoring selected smoking parameters as a smoking product is being smoked.
FIG. 2 presents a diagrammatic representation of a system for effecting sensory evaluation of a smoking product in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention provides a means for analyzing the smoking characteristics of a smoking product based on evaluations made by sensory evaluation panelists who are allowed to smoke the product as they wish in order to derive the most satisfaction from their use of the product. The only constraints placed on the smoking process are occasional instructions and prompts interjected during the smoking process to obtain attribute ratings and/or other information from the panelists. The instructions and prompts are interjected at points which are determined by the smoking process. The panelists are given no advance warning as to when the instructions and prompts will be presented in order to minimize influencing the smoking process due to panelists' aniticipation of instructions and prompts. Thus, an evaluation of a smoking product can be achieved with this invention under smoking conditions that approximate those under which consumers of smoking products normally smoke.
In order to monitor the smoking process as a smoking product is being evaluated by a sensory evaluation panelist, it is necessary to measure and record certain smoking parameters. Those parameters which are usually determined include puff volume, puff duration, number of puffs, interval between puffs, frequency of puffing and the inhalation pattern. Accurate measurements of the puff parameters can be made by techniques known in the art which are based on measurements of the pressure drop across a small resistance interposed between the smoking product and the mouth of the smoker. A mouthpiece of holder and associated apparatus which can be used for making such pressure drop measurements is described, for example, in SMOKING BEHAVIOR edited by Raymond E. Thornton and published in 1978 by Churchill Livingstone (Edinburgh, London and New York), pages 277-288. The teachings of that publication are incorporated herein by reference. Techniques other than pressure drop measurements across a restriction orifice placed in the path of the smoke may also be used to monitor the smoking process. For example, a temperature sensor positioned in the mouthpiece or holder can be employed to detect temperature changes which indicate the flow of smoke during puffs taken by the smoker. Alternatively, a mouthpiece or holder containing no flow restriction orifice but having a connection port for monitoring pressure fluctuations in the smoke passageway with respect to atmospheric pressure may also be used to monitor puffs being taken by the smoker. The puff parameters derived from such monitoring techniques are preferably processed by computer means programmed to coordinate the communication of instructions and prompts to a sensory evaluation panelist with the smoking parameters as monitored by the selected sensor and associated apparatus.
The computer program used in the practice of this invention may take a variety of forms depending on the results desired. The computer program should be designed to facilitate the introduction of changes into the sensory evaluation format selected by the sensory evaluation analyst. In evaluating a particular smoking product, the computer may be programmed to communicate certain instructions or prompts when predetermined conditions relating to the smoking parameters have been met. For example, a sensory evaluation panelist may be requested to rate menthol flavor after a total smoke volume of 150 cubic centimeters has been drawn from the smoking product as measured by the sensing apparatus. Alternatively, the panelist may be asked to rate menthol flavor after two puffs of at least 30 cubic centimeters each have been taken. Other attributes may be rated in a similar manner with the communication of instructions and prompts to the panelist being triggered by certain events occurring during the smoking process. The techniques for programming computers to perform operations as described herein are well known to those skilled in the computer arts so that further elaboration of such techniques is unnecessary for an understanding of the presently disclosed invention.
The computer means used in the preferred embodiment of this invention includes a monitor with a display screen for visually communicating the various instructions and prompts to the sensory evaluation panelist. The computer is also provided with means for receiving responses from the panelist via suitable devices such as a bit pad with stylus, a keyboard for moving a cursor on the monitor display screen and a touch-sensitive display screen. The touch-sensitive screen is particularly preferred due to the ease with which the panelist may enter a response by moving a finger or other activating means into contact with or close proximity to a specific portion or area of the display screen. The speed and ease with which a response from the panelist can be entered is an important aspect of the evaluation process because it minimizes the unavoidable momentary disruption of the ad libitum smoking process. Panelists are usually asked to refrain from taking a further puff until an appropriate response to an instruction or prompt has been entered by the panelist. It is desirable, therefore, to communicate only such instructions and prompts as are necessary to obtain the desired data for the sensory evaluation being made.
For a better understanding of the present invention, reference will now be made to the accompanying drawings.
FIG. 1 shows a filter cigarette 12 mounted in one end of a mouthpiece or holder 14 with the opposite end being adapted for contact with the lips of a sensory evaluation panelist. The wall of mouthpiece 14 is provided with connector tubes 16 and 17 spaced a short distance apart and which are in communication with the internal passageway of mouthpiece 14. A disc with orifice means formed therein is transversely positioned in the internal passageway of mouthpiece 14 at a point intermediate between the points where connector tubes 16 and 17 are attached. Transducers 21, 22 and 23 are connected in series by tubes 25 and 26 which are in pneumatic communication with connector tubes 16 and 17, respectively, via flexible conduits 28 and 29. The remaining inlets 19 and 20 of transducers 21 and 23 are open to the atmosphere. Transducer 21 acts as a "dummy" transducer and contributes stability to the operation of the transducer arrangement. The output voltages from transducers 22 and 23 are transmitted to demodulator 31 where they are processed and sent as a composite signal to computer 33. Mouthpiece 14 may assume different forms such as a one piece unit as depicted in FIG. 1 or as a pressure drop sensor with detachable paper tubes for completing the passageway between the smoking product and the smoker's lips.
Shown in FIG. 2 is a schematic representation of a system for conducting sensory evaluation of a smoking product in accordance with this invention. An appropriate computer program 41 is entered into computer 42 for effecting sensory evaluation of smoking product 46. Sensory evaluation panelist 45 is given smoking product 46 with pressure drop sensor 48 affixed thereto. The pressure drop signals from sensor 48 are converted by transducer array 49 and demodulator 50 into a composite signal reflecting specific smoking parameters that is transmitted to computer 42 for processing in accordance with the routines specified by the computer program. At particular points during the ad libitum smoking of product 46, computer 42 communicates certain instructions and prompts to panelist 45 via monitor display screen 52 as certain smoking parameter signals are processed by computer 42. Sensory evaluation panelist 45 enters on monitor display screen 52 a response to the instructions and prompts communicated to the panelist by computer 42. This response is stored by computer 42 along with other responses made by panelist 45 during the smoking of product 46. This procedure is repeated for other sensory evaluation panelists who are participating in the evaluation of product 46. Computer 42 may be programmed to process further the smoking parameter data and the panelist responses correlated therewith for display on the monitor screen or, alternatively, for hard copy produced by printer 55. The computer program may also be designed to manipulate the processed data in various ways in order to facilitate analysis of the smoking and sensory data.
Typical components which have been found to be useful in the arrangement shown in FIG. 1 include a cylindrically-shaped sensor probe fabricated from low density polyethylene with an internal smoke passageway extending through the body of the probe, an orifice plate disposed in the passageway and an array of three Validyne DP-15 differential pressure transducers arranged so that one transducer monitors the pressure differential between atmosphere and the internal smoke passageway on the mouthend side of the orifice plate. A second transducer monitors the pressure differential across the orifice plate and the third transducer serves as "ballast" to stabilize the signals from the two signal-producing transducers. The sensor probe is connected to the transducer array by means of 1/16 inch (outside diameter) polyethylene hose and the two signal-producing transducers are connected to a Validyne model MC1-10-1924 demodulator (available from Validyne Engineering Corporation of Northridge, Calif.) capable of producing up to a 10 volt positive or negative signal that is proportional to each pressure differential being monitored. The analog voltage outputs from the demodulator are connected to analog-to-digital circuits of a Hewlett-Packard HP-2240 measurement and control processor which, in turn, is interfaced with a Hewlett-Packard HP-1000 computer system. The transducer array is calibrated so that a voltage produced at either of the signal-producing transducers can be related to a known pressure differential measured by a water manometer. The calibrations relating to the signals derived from each of the two signal-producing transducers are performed separately so that smoke flow rates can be computed from a predetermined relationship between smoke flow and the two pressure differentials being monitored.
A computer program written in the FORTRAN language is suitable for programming the HP-1000 computer system to process the digitized voltage information received from the HP-2240 measurement and control processor. In this manner the computer can be programmed to monitor the voltage signals at specified intervals (for example, 40 milliseconds) until the signal derived from the "mouthend" transducer exceeds a preset threshold level (for example, 0.015 volts above "baseline"). As the threshold signal level is exceeded it is presumed that the smoker is taking a puff and the subsequent signals from the two signal-producing transducers are stored for processing. As the puff is completed and the signal from the "mouthend" transducer falls below the threshold level, storage of the monitored signals is halted until evidence of a further puff is detected via the monitored signal voltage. This procedure is repeated for each detected puff taken by the sensory evaluation panelist. The stored data for each smoking product smoked by a panelist are then processed by the programmed computer to determine the desired smoking parameters such as duration of puff, interval between puffs, puff volume and average system pressure differential at the mouthend of the sensor probe. The puff volume is determined by converting the signal voltage data to flow rates and numerically integrating the flow rates as a function of time to obtain puff volume. The average system pressure differential is computed by integrating the pressure differential values detected at the mouthend of the sensor probe. The smoking parameters determined are then utilized in a separate program routine that deals with sensory evaluation ratings elicited from the panelists. This separate program routine is modified in accordance with the wishes of the sensory evaluation analyst to ensure that the sensory evaluation ratings are obtained after certain criteria have been met. The separate program routine generates instructions and prompts to the panelist on the display screen of the monitor associated with the HP-1000 computer system. The display includes a line scale with equally spaced divisions and the computer system includes means for moving a cursor to a point on the line scale indicating the panelist's intensity rating of a particular sensory attribute and for signalling the computer to accept the rating entered. The panelist is asked to refrain from taking further puffs until the requested intensity rating or other information has been entered by the panelist and accepted by the computer system.
Using the system described above, a standard full-flavor cigarette was evaluated by nine expert smokers who were requested to follow instructions as they appeared on the display screen of the monitor. The first instruction appearing asked the smoker to light the cigarette and to wait for further instructions. The second instruction was programmed to occur 30 seconds after the first lighting puff was detected by the flow sensor system and consisted of a prompt to smoke the cigarette as desired. After the detection of each puff, the computer was programmed to display a first ballot asking the smoker to rate the strength of the puff just taken on a scale from 0 to 60 which was also displayed on the screen. Although the displayed scale reflected only minimum (0) and maximum (60) markings, the computer recognized 61 discrete positions on the scale. After the rating was entered and accepted by the computer, a second ballot was displayed asking the smoker to rate the tobacco taste of the puff just taken on a scale of 0 to 60. Following entry and acceptance of the smoker's intensity ratings for the two attributes, the smoker was instructed to puff as desired. This cycle of events continued until the smoker completed the smoking process. At this point the sensory evaluation analyst intervened to stop the computer program and to reset the system for the next smoker. In order to obtain a representative assessment of each panelist's ratings for the specified attributes, a total of five cigarettes from the test batch of cigarettes was smoked by eight of the panelists on five consecutive days. The data obtained from the nine smokers were then analyzed by averaging the measured puff volumes and pressure drops as well as the number of puffs for each smoked cigarette to obtain per-cigarette values for each smoker. The average values calculated for each of the five cigarettes smoked by each panelist were then averaged to reflect an average value based on five replications (three replications for panelist No. 5). The data for the attribute ratings by each panelist were averaged in the same manner. The results of the smoking evaluations by the nine panelists are shown in Table 1 and they indicate the fluctuations inherent between the individual panelists in measured puffing behavior and sensory attribute ratings.
TABLE 1______________________________________ PressurePuff Drop No. Tobacco No. ofPan- Volume (mm of Strength Taste Replica-elist(ml) H.sub.2 O) Puffs (0 to 60) (0 to 60) tions______________________________________1 33.8 297.9 15.2 41.7 39.2 52 63.3 589.2 5.6 37.6 35.4 53 56.9 587.6 12.2 39.9 39.5 54 47.0 441.6 9.8 19.1 18.2 55 83.4 844.8 5.3 31.3 35.4 36 37.3 344.6 8.4 40.3 34.1 57 53.7 538.4 7.2 39.1 44.7 58 23.5 215.4 13.4 26.8 21.6 59 51.9 563.4 8.8 41.7 38.9 5______________________________________
The collected data were also subjected to another analysis in which the data were normalized with respect to the total time each cigarette was smoked. The total smoking time used by each individual was divided into five equal time intervals. The measured puff volumes and attribute ratings within each time interval were averaged and the results thus obtained were averaged across individuals to obtain averages on a "by-interval" basis. The results shown in Table 2 clearly indicate a trend toward smaller puff volumes as smoking time increases. Also, the perceived strength and tobacco taste increase during the smoking process but decrease significantly during the last stages of the smoking process.
TABLE 2______________________________________Time Increment Puff Volume Strength Tobacco Taste______________________________________1 51.5 29.7 30.22 47.9 31.8 31.83 44.8 33.2 32.04 41.8 33.8 32.05 35.8 32.4 29.8______________________________________
The methods of analysis described above are intended to be illustrative. Additional analyses could be done depending on the type of experiment conducted and the information desired. Also, other objective responses could be monitored which would indicate flow profile shape, work expended during puffing and puff duration and these objective responses could be correlated with more extensive subjective sensory attribute ratings. These and other variations in the sensory evaluation technique disclosed will be apparent to those skilled in the art and any such variations are deemed to fall within the scope of the appended claims.
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A method and system for effecting sensory evaluation of a smoking product wherein selected smoking parameters are monitored precisely while a smoking product is being smoked ad libitum by a sensory evaluation panelist. The monitored smoking parameters are used to coordinate a sequence of instructions and prompts that is communicated to the sensory evaluation panelist and is designed to elicit sensory ratings from the panelist for the product being smoked. This allows the smoking product to be evaluated with the least possible disruption to the panelist's normal smoking patterns and leads to a better understanding of the smoking characteristics of the product being evaluated.
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DESCRIPTION
The invention relates to a roofing membrane which consists of a roofing membrane which cannot be pierced by roots as the base material and absorbers for water retention arranged on this base, held in a stable manner on the roofing membrane by means of a web coating.
BACKGROUND OF THE ART
It is known that absorber particles e.g. hydrophilic acrylamide polymers, are added to soil for the purpose of water retention in sandy soils, in order to reduce the quantity or water which sinks to a level beyond the reach of roots.
Similarly for retention, suitable gel granulates are added to various substrates used for grass covering of roofs to ensure sufficient water supply for the plants despite a relatively small volume of substrate (e.g. EP 369062).
However, freely mixing absorbers into vegetation substrates does not allow fixing of the absorber particles at a defined level in the substrate layer. Because the absorber particles wander, they become irregularly distributed in the substrate which has a negative effect on the retention capacity. Simultaneously, the volume alteration resulting from the absorption of water results in repeated shifting of the substrate particles within the vegetation structure and thus causes damage to the capillary root system. The shifting of the absorber particles can also impair the local stability of the vegetation substrate.
SUMMARY OF THE INVENTION
The current invention is thus designed in response to the requirement to create a root-impenetrable roofing membrane which has water retaining properties without possessing the disadvantageous effects involved when using non-fixed absorber particles. The water retaining roofing membrane is designed both for sloping and flat roofs and should allow an essentially constant retention and release of moisture which promotes plant growth. Additionally, the draining behavior of extensive roof greening projects with a small layer thickness should be positively influenced by this water retaining roof protection membrane, because the draining coefficient is kept low.
This task of the invention is resolved by the fact that the root-impenetrable roofing membrane serves as a direct base material for the moisture absorber. The absorber is fixed to the roofing membrane by means of a web which is water penetrable and attached to the roofing membrane. This fixing means that the absorber is not flushed out in heavy rainfall and also prevents it from wandering into higher levels of the substrate or shifting to the edges on sloping roofs. The advantage of this solution lies in the fact that the moisture absorber can be applied in a pre-determined distribution and dosage and the fixing ensures that the desired positioning of the absorber is maintained. The fixing of the web in accordance with the invention allows unimpeded water absorption and expansion of the absorber, Using a fleece-type web means that saturation of the gel particles with fine-grain substrate fractions is prevented, giving the roofing membrane a certain drainage effect in addition to its water retaining function, and simultaneously reducing unwanted excess water. Used in dry regions this roofing membrane ensures an efficient utilization of the low level of precipitation due to the surface-remote position of the absorber particles and the resulting low evaporation coefficient, so that a high quality roof vegetation is also possible in such areas.
Another advantage is the reduction of additional roof burden from the build-up of the vegetation when this water retaining roofing membrane is used, because roof structures with a few layers and very low layer heights can be used without detrimental effects on the vegetation and thus the function of the roof greening system. Equally advantageous is the option of varying the retention volume of the roofing membrane in accordance with the invention by employing suitable absorber distribution and concentration for different types of use (flat or sloping roofs).
A further version of the invention uses a water pervious web for fixing the absorber particles which is applied to the membrane in the manner of a quilt. When a roofing membrane manufactured in such a way is used, which can be used on more steeply inclines roofs, it is possible to adjust the size of the areas formed by the quilt-type coating to suit different requirements. In this way it is possible on sloping roofs to use membranes with a higher water retention capacity near the ridge than on the rest of the roof surface.
A further version of the invention takes account of the fact that it can be expedient for use of flat roofs to fix the absorber particles by means of a fully laminated perforated film. By using an adequately perforated film the unimpeded contact of water with the absorber particles is ensured. The volume increase of the absorber particles which results from the water absorption quickly causes the necessary lifting of the film from the base material, thus creating sufficient volume for the full utilization of the water retention capacity.
It is also possible to apply absorber particles with a particle size of ≧2 1000 μm in small quantities directly onto the membrane surface without any further fixing.
It is possible to use bituminous root-impenetrable roofing membrane as well as corresponding root-impenetrable membranes based on synthetic films as the base material for the absorber particles and the coating in accordance with the invention. The application of the absorber particles and the coating with the web are carried out while the base material is still in a plastic condition. The fixing of the web can be varied by using differently designed pressure rollers.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is more closely described with the help of the figures.
They show the following:
FIG. 1: a top view of a roofing membrane with quilt-type laminated fleece
FIG. 2: a cross section of a roofing membrane with laminated fleece and absorber particles
FIG. 3: a cross section of a root-impervious bituminous roof membrane with details of the layer structure.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the quilt-type lamination (2) of the fleece with which the absorber particles are fixed on the roofing membrane. The areas (6) in which the absorber particles are held in a stable manner and which offer sufficient space for the volume increase of the absorber particles, can be infinitely varied in size and shape (3) shows an edge strip free of absorber particles for the purpose of adhering the strips of roofing membrane together.
FIG. 2 shows a schematic cross section of a roofing membrane in accordance with the invention. The absorber (4) is applied in a defined dosage on the base material (5), which can be either a plastic film or a bituminous roofing membrane. The absorber (4) is expediently applied in a quantity which corresponds to a water storing capacity of 1-5 l/m 2 . The fleece (1) is firmly joined to the base material at predetermined intervals by means of lamination (2).
FIG. 3 shows a cross sectional detail of the roofing membrane in accordance with the invention shown in FIG. 2 on the basis of a bituminous root-impervious membrane. The build-up shows the fleece (1) with the laminated area (2) used for fixing the absorber particles (4). The laminated area expediently has a width of 10 to 30 mm. The bitumen membrane itself consists of two APP or SBS modified layers of bitumen (5a) and a combination insert (5b) which provides firmness and dimensional stability. The root-imperviousness of the membrane is achieved either with a Cu film in (5b) and/or with the addition of "Preventol" in (5a).
In a further version of the invention which is not represented in a diagram, the welding film (5c) can be applied in a highly perforated form on the top as a fixing aid for the absorber particles.
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A roofing membrane has a quantity of water-retaining particles fixed in the upper surface of the membrane. A fleece web affixed to the membrane surface in a quilt-like manner may provide zones of selectable size for holding the particles in place. By varying the amount of the absorber particles, the water-retaining capacity of the roofing membrane may be varied to the particular intended use, such as on a flat roof or a sloped roof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/824,926 filed Sep. 8, 2006, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to methods for achieving a pigment dye look. More specifically the present invention relates to methods for achieving a pigment dye look without the use of pigments or formaldehyde in fabric dye form.
[0004] 2. Description of the Related Art
[0005] Methods for dyeing knit fabrics—or more specifically, processes for producing “distressed”, “laundered”, or “vintage” looks in knit fabrics—typically do not utilize pigment dyes. Such processes using pigment dyes are not typically used in the industry because pigment dyes stain the inside of dye equipment, thus not allowing for commercially viable fabric dye with use of pigments. At present, pigment dyes for knit fabrics are done mainly in garment dye form, which is a less exact science, is more costly, and is restrictive to only garment dye facilities.
[0006] Thus there is a need in the art for an improved method for producing articles having a “pigment” dye look without the use of pigment dyes.
SUMMARY OF THE INVENTION
[0007] The present invention relates to methods for dyeing knit fabrics—or more specifically, processes for producing “distressed”, “laundered”, or “vintage” looks without the use of pigment dyes—and articles produced by same. The present invention provides the ability to achieve a “pigment dye look,” without the use of pigment, and dyed in large scale jet equipment. In the present invention, large fabric dye houses worldwide can produce fabric in their normal dye production as modified by the teachings disclosed herein, and after completion of a garment, with use of a wash down process, the desired look is achieved.
[0008] In some embodiments, a method of dying knit fabrics includes treating a knit fabric with a cationic agent to add a positive charge to the knit fabric; and contacting the treated knit fabric with a negatively charged direct dye, wherein the direct dye adherence to the knit fabric is improved, with more uniform coloring and improved transfer resistance, while minimizing dye over-penetration, with reduced direct dye usage. In some embodiments, the method may further include cutting and sewing the dyed knit fabric to form a garment; and washing down the cut and sewn dyed knit fabric to produce a garment. In some embodiments an article may be provided that is produced by embodiments of the methods disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] So that the manner in which the above recited features and advantages of the present invention may be attained and can be understood in detail, a more particular description of embodiments of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other embodiments.
[0010] FIG. 1 depicts a fabric preparation process in accordance with some embodiments of the invention.
[0011] FIG. 2 depicts a treatment process in accordance with some embodiments of the invention.
[0012] FIG. 3 depicts a cationization process in accordance with some embodiments of the invention.
[0013] FIG. 4 depicts a dye process in accordance with some embodiments of the invention.
[0014] FIG. 5 depicts a dye process for dark colors in accordance with some embodiments of the invention.
[0015] FIG. 6 depicts a washdown process in accordance with some embodiments of the invention.
[0016] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
[0017] Fabric dyed in large scale jet equipment are always subject various nuances with the equipment. Dyeing of fabrics depends on weight, rope length, water PH, circulating speed time, type of fabric, type of dyes used etc. which ordinarily experienced operators understand. The present invention modifies the process of conventional operations of dyeing when using direct dyes by adding steps prior to and after the dye portion of the entire process.
[0018] In all forms of fabric jet dye equipment, the operator feeds fabric into an opening at one end of the machines. With pulleys inside the machine, the fabric is continuously run in a loop fashion, while various operations are performed, usually using “in ports” (for adding various chemicals or dyes etc), as well as a pipe for adding new water, and a drop value for discharging exhausted dyes or chemicals from the machine.
[0019] One aspect of the invention is the pretreat process. All knit fabrics prior to dyeing go through a pretreat process, example: scour, de-size, and/or bleach processes to prepare fabric for dyeing by eliminating unwanted waxes, oils, paraffin, yarn dust, and the like. The present invention adds a specific chemical process along with a cationization process, which allows dyes to move onto the fabric quicker, thereby reducing dye and water consumption. At the same time, this process—using a chemical, for example in one embodiment, “The Colortex effect,” (e.g., Grandex 640), produced by Grant Industries—exhausts the dyes without total penetration, so in effect, the outside of the yarn is dyed, and not totally through. This allows for a wash down process to achieve the desired look, without the use of pigment dyes.
[0020] Pretreatment with “the Colortex Effect” is accomplished by contacting the goods with the chemical; this is done by injecting the chemical, in aqueous solution at a concentration selected by the operator, into the dyeing vessel through one or more injection ports. The process is run until proper exhaustion of the chemical is achieved.
[0021] Adjustments to temperature, pH, and run time are handled by skilled personnel running the machines. In one embodiment, concentration of “the Colortex Effect” chemical may vary depending on the nature of the greige goods, as well as the desired shade or color of the finished goods. In general, the concentration of the chemical ranges from about 2% to about 8% (by weight in aqueous solution). For light colors, less of the chemical is used. For darker colors, more of the chemical is used.
[0022] In another embodiment, the bath is heated during pre-treatment from a starting temperature to an end temperature. The starting temperature remains constant during injection of “the Colortex Effect” chemical. Then depending on the machine, the speed at which the machine is run and the nature of the fabric, a gradual increase of heat is applied. A range of between 90 and 100 degrees Fahrenheit has been found to be effective as a starting temperature for pre-treatment of greige goods in jet machinery. The bath may then be heated, with a heat-up rate of about 3 degrees per minute. In another embodiment, the bath is heated to an end temperature of around 140-180° F. and the process continues until the desired exhaustion is achieved. Usual run time is around 30-45 minutes.
[0023] Once exhaustion is accomplished, the bath is dropped, and an overflow process of cold water is added to offset the dropping bath. This will lower the temperature of the fabric, as well as impart a positive charge to the fabric.
[0024] As fabric is dyed, it is then framed and rolled into rolls to be sent onto the cutting room. Goods are cut and sewn in normal fashion, using polyester or nylon thread for high speed sewing. Optionally, the thread may be directly matched to the current fabric color.
[0025] Once fabric is cut and sewn into garments, the final phase is the wash down process-which will yield our desired effort. This will remove excess dye from the goods, as well as create a distressed look. A number of different wash-down processes may be used to arrive at different appearances we are trying to achieve. Known wash-down processes include the use of acid enzymes, detergents, stonewashing, phosphates, neutral enzyme etc. Neutral enzymes can be used for “softer” wash-down. Acid enzymes, detergents, and stones can be used for a more distressed look.
[0026] Another way of achieving a desired wash down is to over load the machine (must be rotary equipment), and underload the water ratio. Also, adding salt or sand will allow for a much stronger wash down. Just prior to rinsing, a formaldehyde free fix is added to the bath to stabilize the color. A thorough wash down is required to neutralize enzymes. A softener may be added if required for a certain type of “hand”.
[0027] The use of direct dyes saves money, as well as having a long shelf life. Also, direct dyes are formaldehyde free. They also produce a much softer hand than pigment, as direct dyes will dissolve and penetrate the roping which has occurred in the dye machines, something a pigment dye cannot do.
[0028] The use of the chemical in the pretreat phase, such as “The Colortex Effect” chemical, as well as abrasion or friction in the washdown phase in common lay terms, achieves a desired effect.
[0029] The inventive process is a way to create consistent looking quality knits with a weathered or “pigment dye” effect, without the use of pigments, and in jet dye form (not garment dyeing). This process is friendly to the environment as water-soluble direct dyes are used and the process is formaldehyde free. Also, with the use of direct dyes, the range of available colors is greatly expanded versus pigments or sulfurs. In addition, there is no capital expenditure on the part of a dyehouse using this process, except for certain chemicals and dyestuffs.
[0030] The process described above may be summarized as a four part process: 1) Pretreat of Fabric; 2) Dye of Fabric; 3) Cut and Sew; and 4) Washdown. For example, FIG. 1 depicts a fabric preparation process in accordance with some embodiments of the invention as discussed herein; FIG. 2 depicts a treatment process in accordance with some embodiments of the invention as discussed herein; FIG. 3 depicts a cationization process in accordance with some embodiments of the invention as discussed herein; FIG. 4 depicts a dye process in accordance with some embodiments of the invention as discussed herein; FIG. 5 depicts a dye process for dark colors in accordance with some embodiments of the invention as discussed herein; and FIG. 6 depicts a washdown process in accordance with some embodiments of the invention as discussed herein.
[0031] In the Pretreat of Fabric step, a fabric pretreat is performed using agents to desize, scour, and prebleach. In addition, a neutralization and a cationic pretreat is performed. The cationic pretreat will take neutral cotton and add a positive charge. This charge will allow the negatively charged dyes to move more quickly onto the fabric, with less salt and a lower water ratio. Moreover, the pretreat of fabric step facilitates lower consumption of dye. The pretreat agent further facilitates the washdown effect described below with respect to step four (washdown).
[0032] The Dyeing of Fabric step, uses only high quality direct dyes and no reactive dyes. High quality direct dyes have excellent washfastness properties. Suitable examples of high quality direct dyes are available from, in a non-limiting example, Everlight. Some specific examples of high quality direct dyes available from Everlight include, Yellow RL Direct—Yellow 86, Orange 2 GL—Orange 39, Red BWS—Red 243, Blue 4BL—h/c 200, and the like. After dyeing of fabric, a formaldehyde free fix is utilized to facilitate handling of fabric after proper framing and rolling.
[0033] In the Cut & Sew step, polyester thread is used. The polyester thread facilitates sewing at high speeds with minor disruptions. The thread color may be matched exactly to the color dyed, even though in washdown fabric will be lighter, which helps to promote the look of the finished product. In some examples, a lot of top stitching, buttons, pockets, double needle, and the like, may be utilized to further promote the look of the fabric after washdown.
[0034] In the Washdown step, agitation and abrasion are is utilized to “beat up” the dye job without damaging the garment. With proper speeds and abrasion, dyes which have not adhered to the cationized cotton will break away, or wash off. This facilitates achieving a desired “pigment dye look”. Conventionally, many washdown processes are too long in time, washing right past the desired look. The finished fabric or garment may desirably have color highs and lows around the seams, pockets, zippers, and the like, and not a uniform washdown of the entire garment.
[0035] With the use of high quality direct dyes, a warm soap and water washdown may be utilized. For example, a washdown process may include a 40 minute warm soap and water washdown, after which the bath may be dropped, a 5 minute wash may be performed, followed by a 20 minute enzyme bath, then a fix. The inventors have discovered that most fixing agents will not pass testing. One example of a suitable fixing agent is available in Europe from Bayer, and in the United States from Starchem, under the trade name Dyeset NOZ.
[0036] Thus, an improved process for Exemplary advantages of the inventive process are: 1) much larger quantity runs in piece goods versus garment dye forms; 2) better color consistency; 3) less crocking; 4) substantial savings of dyestuff versus pigment dye process; 5) use of jet dyeing equipment, as there are no pigments in this process; 6) eliminated production mistakes in the manufacturing process; 7) allows for use of polyester thread for high speed sewing; 8) achieve a nice soft hand; 9) total process is formaldehyde free.
[0037] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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Embodiments of the present invention provide methods for achieving a pigment dye look and articles produced by same. In some embodiments, a method of dying knit fabrics includes treating a knit fabric with a cationic agent to add a positive charge to the knit fabric; and contacting the treated knit fabric with a negatively charged direct dye, wherein the direct dye adherence to the knit fabric is improved, with more uniform coloring and improved transfer resistance, while minimizing dye over-penetration, with reduced direct dye usage. In some embodiments, the method may further include cutting and sewing the dyed knit fabric to form a garment; and washing down the cut and sewn dyed knit fabric to produce a garment.
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BACKGROUND OF THE INVENTION
The field of the invention is convertible sofas and the invention relates more particularly to convertible sofa mechanisms which unfold in three sections from the sofa seat portion.
Most commonly used convertible sofas utilize a foldable mattress which is maintained within the convertible sofa when the bed is folded into its couch configuration. Then when the mechanism is unfolded for use as a bed, the mattress is maintained on the upper surface. Unfortunately, such mattresses, since they need to be folded, must be thin and such convertible sofas are, thus, inherently uncomfortable and are only satisfactory for small children or for emergency use. Also, the forward edge of such convertible sofas, both in the folded sofa configuration or the extended bed configuration, have a hard forward edge which makes it uncomfortable to sit on the forward edge of the convertible sofa or the bed.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved three-section convertible sofa mechanism which converts into a bed having a mattress of full thickness and which eliminates the uncomfortable forward edge of the convertible sofa, both in the sofa configuration and in the bed configuration.
The present invention is for an improved three-section convertible sofa mechanism for installation in a convertible sofa which may be forwardly extended to a full length bed which has a head section, a middle section and a foot section. The improvement comprises a base member supported on the floor, said member having a right side, left side, front edge and a back edge and having an upwardly extending support along its front edge. First and second inverted "J-shaped" channels are held along the right and left sides of the base member, respectively, and oriented so that the terminus of the "J" faces the front edge of the base. First and second main bellows members are held by the base and are adjacent to first and second inverted "J-shaped" channels. Each of the main bellows has a straight sidewardly-facing channel on its upper surface. A head section is held by the base above and generally parallel thereto, said head section having a right side, left side, front edge and a back edge. Right and left cam follower means are affixed to the right and left edges of the head section, each of the cam follower means being captured both by the inverted "J-shaped" channel and by one of the straight, sidewardly-facing channels on the upper surface of each of the bellows. Thus, when the main bellows is inflated, the cam follower means and their associated head section are carried outwardly along said straight, sidewardly-facing channels and upwardly, outwardly and downwardly along said "J-shaped" channels an extent sufficient to cause the head section to rest near its front edge on the upwardly extending support on the base member. A middle section, having a right side, a left side, a front edge and a back edge is hingedly affixed at its back edge to the front edge of the head section, and in its folded condition is supported in a parallel manner above the head section, said middle section having leg means affixed along the right and left edges at the back edge thereof. A foot section has a right side, a left side, front edge and a back edge and the foot section is hingedly affixed at its back edge to the front edge of the middle section and has leg means affixed along the right and left edges thereof at the front edge of the middle section. The foot section is moveable between a folded configuration where one end is parallel to and above the middle section and to an extended configuration when it is in line with the middle section. A preferred configuration of the convertible sofa has its outermost legs comprising a subframe which contains a pair of pivotable polygonal members, each member being moveable between a folded position and an extended position. Each polygonal member has in its folded position a flat base edge resting on the base member, an angled, inwardly and downwardly-facing edge, an angled, inwardly and upwardly-facing edge, an upwardly-facing slot having an inward edge and an outward edge. A pivot hole is positioned in the polygonal member near the outward edge of the slot. The polygonal member also has an angled, outward and upwardly-facing edge and an angled, outwardly and downwardly-facing edge. A pivot pin is affixed to the subframe which is affixed to the right and left edges of the foot section along the front edge thereof. The pivot pin fits in the pivot hole of the polygonal member. A support arm is affixed to the front edge of the foot section and positioned and shaped so that its lower end fits into the slot of the polygonal member and has a length about several inches above the lower end of the slot when no additional weight is exerted on the front edge of the foot section. Biasing means are held between the subframe and the front edge of the foot section. Each of the polygonal members is positioned adjacent the right and left edges of the subframe so that when the subframe is lifted, the polygonal member pivots downwardly so that its angled, outwardly and downwardly-facing edge rests on the adjacent edge of the subframe and the angled, inwardly and downwardly facing side rests on the floor, and the lower end of the support arm is moveable between a first position about several inches above the outward edge of the slot when no additional weight is exerted on the front edge of the foot section and the second position when it is in contact with the outward edge when additional weight is exerted on the front edge of the foot section. In this manner, the front end of the foot section has a biased movement when weight is exerted on it and no uncomfortable forward edge is present.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the convertible sofa of the present invention in its sofa configuration.
FIG. 2 is an enlarged cross-sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is an enlarged perspective view of the right and forward edge of the mechanism of the present invention.
FIG. 4 is an enlarged plan view of the right edge of the mechanism of the present invention.
FIG. 5 is a front view, partly in cross-section taken along line 5--5 of FIG. 2.
FIG. 6 is an enlarged view of the right front corner of the convertible sofa mechanism as depicted in its sofa configuration with weight placed on the forward edge.
FIG. 7 is a front view of the right forward edge of the mechanism of the present invention in its unfolded configuration with no weight placed thereon.
FIG. 8 is a view of the right front corner of the mechanism of the present invention showing the polygonal member pivoted from its bed position to its sofa position.
FIG. 9 is an enlarged front view of the right front corner of the mechanism of the present invention showing the polygonal member in its convertible sofa configuration.
FIG. 10 is a perspective view of a double mechanism configuration of the front portion of the convertible sofa mechanism of the present invention.
FIG. 11 is an enlarged perspective view of the middle leg of the convertible sofa mechanism of the present invention.
FIG. 12 is a side view of the right side of the convertible sofa mechanism in its sofa configuration.
FIG. 13 is a right side view of the convertible sofa mechanism of the present invention as it is being unfolded to a bed configuration.
FIG. 14 is a side view of the convertible sofa mechanism showing the next configuration from FIG. 13 as the mechanism is being unfolded into a bed configuration and also shows the completed bed configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A convertible sofa 10 is shown in perspective view in FIG. 1 and has a front apron 11, a left arm 12, and a right arm 13. A pair of seat cushions 14 and 15 rest on the bed of couch 10, and a pair of back cushions 16 and 17 are supported along the back rest 18 of the couch.
The novel mechanism of the present invention which is convertible from the sofa configuration, as shown from the exterior in FIG. 1, is shown in a right side view in FIG. 2. The mechanism is strapped to the couch member which consists of the arms and back, and the mechanism rests on a base member 19 which is not only supported by strap 20 but also by a plurality of wheels 21 which rest on floor 22 and facilitate moving the convertible sofa mechanism into the sofa. Wheels 21 support a bellows motor carriage 23 which supports bellows motor 24. Wheels 21 also support a bellows carriage 25 upon which bellows 26 rest. A straight, sidewardly-facing channel 27 is affixed to the top surface of the bellows and causes a cam follower to ride upwardly along an inverted "J-shaped" channel 28 as described more particularly below. Bellows 26 preferably is wider at the rear thereof to increase the area of the bellows and thereby increase the lifting force. This shape is shown in FIG. 4.
The manner in which bellows 26 causes the mechanism to be moved upwardly and outwardly is indicated best in FIG. 3 where the inverted "J-shaped" channel 28 captures a cam follower 29 which also passes through the straight, sidewardly-facing channel 27. Cam follower 29 is held by a plate 30 which is riveted, or otherwise affixed, to frame 31 of the head section of the convertible sofa mechanism. The right side of frame 31 is shown in FIG. 3 and indicated by reference character 32. A head board 33 is supported by frame 31 at the back edge 34 thereof. Frame 31 is hingedly connected at its right and left sides near the front edge 35 to the back edge 36 of the middle section 37. Middle section 37 has a right edge 38 and a front edge 39. Middle section 37 is hingedly affixed to foot section 40 at its rear 41. The front of foot section 40 is indicated by reference character 42 and its right side is indicated by reference character 43.
In assembled form, the right side of the mechanism is shown in plan view in FIG. 4. There it can be seen that cam follower 29 fits in the channel of inverted "J-shaped" channel 28 and also passes through straight channel 27 on the top of bellows 26. It also may be seen in FIG. 3 that the inverted "J-shaped" channel 28 also supports a pivot pin 44 which passes through a hole 45 at the lower end of straight channel 27.
Thus, returning to FIG. 2, it can be readily seen that as bellows 26 are being filled with air, cam follower 29 moves upwardly in the inverted "J-shaped" channel 28. Four positions are indicated in FIG. 2, and the lowermost position is indicated by reference character "1." As the bellows is raised to position 2, the inner middle and foot sections are all raised upwardly, and as the cam follower reaches position 3, and has almost reached its upwardmost position, and as it moves from position 3 to position 4, it moves forwardly and slightly downwardly where it rests on a second bellows 46. During this same series of movements, the head section has moved so that it rests at its forward edge on an upright support plate 47. Upright support plate 47 is held by the base member 19 and is also supported between the left and right arms 12 and 13 by strap 20. Strap 20 is affixed to the front apron 11 at each end thereof and encircles the sides and back of the convertible sofa mechanism. The convertible sofa mechanism is attached to the sofa arm and back frame by simply being stapled to the left and right arm frames and to the back frame. The unfolding motion is also depicted in FIG. 13 where it can be seen that the head section 31 is supported both by cam follower 29 and the upright support plate 47. After the bellows have been inflated, the middle and foot sections may be manually folded out.
The left side of the mechanism has an analogous bellows, inverted "J-shaped" channel, and the like and functions in the same manner described above. Of course, a single motor 24 can supply all bellows.
As shown in FIGS. 12 and 13, middle section 37 is supported above head section 31 by a cushion 48. This provides a beneficial give when one is sitting on the seat cushions 14 or 15 since pressure on seat cushion 14 will also be transmitted through cushion 48 to head section 31 which is supported by cam follower 29. This downward movement, by compression of cushion 48, is further enhanced by the presence of a slot 49 in arm 50 which is welded, or otherwise affixed, to the back edge 36 of the middle section. Slot 49 also holds a pin 51 in arm 52 which, likewise, has a pin 53 which is held by arm 54 affixed near the front edge of head section 31. It can be seen in FIG. 14 in phantom view that as the middle and foot sections are folded out, that arm 50 is moved into an upright position and middle section 37 is aligned with head section 31.
A leg 55 is hingedly affixed at the intersection of the middle section and the foot section and this hinge configuration is shown in enlarged view in FIG. 11. There leg 55 can be seen to have a pair of ears 56 and 57 which hold a pin 58 which, in turn, holds an ear 59 affixed to the middle section and an ear 60 affixed to the foot section. It can also be seen that a tongue 61 on the foot section fits into a groove 62 at the forward edge of the middle section.
A plurality of slats 63 are held to the edges of the frame members by a plurality of springs 64 in a relatively conventional manner. The cushion 48 is slightly narrower than the seat cushions 14 and 15 or the back cushions 16 and 17. This inner cushion 48 remains at the head portion of the bed between the arms of the couch, and its narrow width permits the positioning of the inverted "J-shaped" channel 28 along its side without rubbing.
Another novel feature of the convertible sofa of the present invention is the method by which the forward edge of either the sofa or the couch is permitted to give in a manner similar to a soft edge couch but not usually possible with a convertible sofa. This downward movement is enabled, both in the contracted position as a convertible sofa and the extended position as a bed, by a novel polygonal member shown in FIGS. 5 through 10. The assembly is held in a subframe indicated generally by reference character 70 which fits adjacent upright support plate 47 when the assembly is in its convertible sofa configuration. Then, as the bellows are inflated, section 70 is lifted upwardly out from behind front apron 11 and forms the forward leg of the bed. First, as shown in FIGS. 5 and 6, the assembly is shown in its couch or folded configuration where it can be seen that polygonal member 71 is in its upper configuration and supported by a pin 72 and also supported by resting its base edge 73 on the floor 74 of subframe 70. Polygonal member 71 also has an angled, inwardly and downwardly-facing side 75 and an angled, inwardly and upwardly-facing side 76. An upwardly-facing slot 77 is shaped to support a support arm 78. Polygonal member 71 has three flat surfaces 79, 80 and 81 which cooperate with surface 82 as is clear from FIGS. 8 and 9. An angled, outwardly and downwardly-facing side 83 has a notch 84 which contacts a pin 85 on an arm 86 Which supports the member 70 in its lower configuration as shown in FIG. 7. Polygonal member 70 may have a weight 75' along side 75.
The function of polygonal member 70 is clear from a comparison of FIGS. 6 and 7 when the mechanism is in its convertible sofa position and the member is in its more upright position. It can be seen that support arm 78 is permitted several inches of movement into the upwardly-facing slot 77 which permits some downward movement of the forward edge of the convertible sofa. If sufficient pressure is provided, the bottom of support arm 78 will contact the base of slot 77. Once the subframe 70 is lifted, the floor 74 drops down an amount such that the lower dumbbell member 85a and the upper dumbbell member 86a contact the upper and lower ends of channel 87 which extends the height of subframe 70 permitting polygonal member to move downwardly to its position shown in FIG. 7. At this point, the angled, inwardly and downwardly-facing side 75 contacts the floor 74 of the subframe 70, but once again the edge of the bed still may move downwardly as indicated in FIG. 7 where now the bottom surface 88 of support arm 82 will contact inner side 89 of slot 77. Also, surface 82 of support arm 78 will contact surface 80 of the polygonal member 71 and, thus, the downward movement of the forward edge of the bed will be limited. As shown most clearly in FIG. 9, the outermost coil spring 90 is supported by a plate 91 affixed to subframe 70 and at its upper end to a pocket 92 in a forward plate 93. Forward plate 93 is shown in perspective view in FIG. 10. A spring 94 is held on a plate 95 at its lower end and in a pocket 96 located at the front portion 43a of right side 43 of the foot section. An outer spring 97 is held on a plate 98 and contacts the lower surface of dumbbell member 86 to permit a downward movement of the right edge of the assembly.
When it is desired to reconvert the unit from its bed configuration back to a convertible sofa configuration, a right edge front portion 43a is depressed as indicated in FIG. 8, and an actuating arm 99 moves downwardly and its lower cam surface 100 contacts surface 81 of polygonal member 71 moving it upwardly as indicated in FIG. 8. This same motion is transmitted to an analogous actuating arm 99' by a cable 101 which passes through guides 91a and over pulleys 102 through 104 and analogous pulleys not shown on the other end of the mechanism. In the event a pair of convertible sofa mechanisms are placed side by side as indicated in FIG. 10 of the drawings, it would be necessary to push down on either the right or left outer front portion 43a or 43a' together with the front portions 112 and 113. This returns all polygonal members to an upward position for its sofa configuration.
To return the bed to its convertible sofa configuration, the foot and middle sections are folded back over the cushions 48 and the bed is in a position similar to that shown in FIG. 13. Then kick plate 104 is pushed back which moves arm 105 through link 106, arm 110 moving an inner valve 107 and directing air from tube 111 into tube 108 thereby expanding second bellows 46. This pushes cam follower 29 first upwardly from position 4 to position 3 as shown in phantom lines in FIG. 2 at which point gravity causes bellows 26 to deflate and cam follower 29 moves downward1y along the straight portion of the inverted "J-shaped" channel 28 to its final position as shown in FIG. 2. An important feature of the present invention is the controlled movement of the mechanism from its bed configuration to its convertible sofa configuration. This is brought about by use of the bellows 26. At all times when the device is in its bed configuration, the bellows are in the position indicated by the number 4 in FIG. 2 of the drawings. The straight, sidewardly-facing channel 27 is in a slightly passed the upright orientation and is held in that position by cam follower 29. When the foot and middle sections have been folded back and second bellows 46 has been inflated to the position indicated by number 3 in FIG. 2, the mechanism does not suddenly collapse, but instead is gently lowered by controlling the rate of flow out of bellows 26. This may be accomplished by the use of a three-way valve which in position one directs air from blower motor 24 to bellows 26, in a position two where it directs air from blower motor 24 to second bellows 46 and a third position where air is allowed to escape bellows 26 in a controlled manner. The construction of such three-way valves is conventional and, thus, not shown in detail in the drawings.
Although not shown in the drawings, it is, of course, likely that a fabric apron will cover the subframe 70 for aesthetic reasons. It is also likely that attachment means such as the hook and eye configuration sold under the trademark, "Velcro," will be used to hold the cushions together in their bed configuration.
By the use of polygonal members and the extending subframe, the front support of the convertible sofa assembly automatically converts from its compressed configuration of the convertible sofa position to an extended configuration in its bed mode without the necessity of any action on behalf of the user. Then to reconvert this sub assembly to its convertible sofa position, the user needs only to push downwardly on the edge (and center if two mechanisms are used) and the polygonal members reconvert to their compressed mode for use as a convertible sofa.
As indicated in FIG. 10, a pair of mechanisms can be matched together for a wider couch and bed. It can also be seen that full six-inch thick cushions can and should be used as a mattress as indicated in FIG. 14. There it can be seen that the inner cushion 48 is placed at the head of the mattress, the back cushion 16 can be placed in the middle and the seat cushion 14 can be placed at the foot. A preferred length for the inner cushion is twenty-two and three-fourths inch, twenty-seven inches is preferred for the back cushions and twenty-four inches for the seat cushion providing a total length mattress of seventy-three and three-quarter inches for a bed of adequate length.
The present embodiments of this invention are thus to be considered in all respects a illustrative and not restrictive; the scope of the invention being indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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An improved three-section convertible sofa mechanism for installation in a convertible sofa. The mechanism has three sections which unfold from a sofa configuration into a bed configuration. The conversion is assisted by a motor-operated pair of bellows which assist in the lifting and positioning of the mechanism during the unfolding operation. The front edge of the convertible sofa and of the bed both deflect downwardly to eliminate the usual uncomfortable forward edge of such convertible sofas.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of Korean Patent Application No. 10-2009-0038432 filed in the Korean Intellectual Property Office on Apr. 30, 2009, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] Aspects of the present invention relate to a plasma display device. More particularly, aspects of the present invention relate to a plasma display device that improves uniformity of luminance of a panel.
[0004] 2. Description of the Related Art
[0005] As an example, a plasma display device includes an X-board assembly, a Y-board assembly, and an address buffer board assembly that control an X electrode, a Y electrode, and an A electrode, respectively, that drive a plasma display panel (PDP). The Y-board assembly that controls the Y electrode has a sustain circuit and a scan IC circuit on one substrate, and therefore when a sustain voltage waveform is applied, a current path is formed to be short. In this case, distortion of the sustain voltage waveform is reduced, thereby improving uniformity of panel luminance.
[0006] However, because the sustain circuit uses a large insulated gate bipolar transistor (IGBT) and a large field effect transistor (FET) operating with a large current and the scan IC circuit uses surface mount devices (SMD), when elements having different structures are disposed on one substrate, a process of manufacturing a printed circuit board assembly (PBA) becomes complicated.
[0007] The Y-board assembly is disposed in a vertical direction at a short side of the PDP to be connected thereto. Therefore, in a large PDP, there are large differences in the length of current paths for applying a sustain voltage waveform, i.e., current paths reaching Y electrodes from the Y-board assembly, according to position in a vertical direction of the PDP.
[0008] That is, in a vertical direction of the PDP, a current path is short around the center of the PDP and is lengthened toward both ends of the PDP. Therefore, toward both ends from the center in a vertical direction of the PDP, distortion of the Y-sustain voltage waveform increases and ringing and overshooting are aggravated.
[0009] A peak-to-peak voltage YVs (pk-pk) of the Y-sustain voltage waveform depends on a position in a vertical direction of the PDP (see FIG. 5A ). Thereby, luminance (L) distribution in a vertical direction of the PDP is non-uniformly displayed.
[0010] The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY
[0011] Aspects of the present invention have been made in an effort to provide a plasma display device having advantages of inexpensively improving uniformity of luminance in a vertical direction of a PDP.
[0012] Aspects of the present invention provide a plasma display device including: a plasma display panel (PDP) having an X electrode and a Y electrode that are disposed parallel to each other while intersecting an address electrode at a discharge cell; a Y-board assembly that controls the Y electrode of the PDP; a Y-buffer-board assembly including a scan integrated circuit (IC) connected to the Y-board assembly and that applies a scan voltage waveform and a sustain voltage waveform to the Y electrode; and a current supply element included in the Y-buffer-board assembly to supply a ground voltage to the Y-board assembly and to prevent overshooting of the sustain voltage waveform.
[0013] According to an aspect of the present invention, the Y-board assembly may include an isolation switch receiving the ground voltage from the current supply element.
[0014] According to an aspect of the present invention, the current supply element may include a diode having an anode terminal connected to a ground pattern of the Y-buffer-board assembly, and a field effect transistor (FET) having a drain terminal connected to a cathode terminal of the diode and a source terminal connected to an OUTL voltage.
[0015] According to an aspect of the present invention, the OUTL voltage outputs the sustain voltage waveform, and may be a voltage of a contact point to which a source terminal of the isolation switch is connected.
[0016] According to an aspect of the present invention, the current supply element may include a reverse blocking-insulated gate bipolar transistor (RB-IGBT) having a collector terminal connected to a ground pattern of the Y-buffer-board assembly and an emitter terminal connected to an OUTL voltage.
[0017] According to an aspect of the present invention, the current supply element may include a capacitor interposed between a ground pattern of the Y-buffer-board assembly and a power source line of the sustain voltage waveform.
[0018] According to an aspect of the present invention, the current supply element may include a diode including a cathode terminal connected to a side of the capacitor connected to the power source line and an anode terminal connected to an OUTL voltage.
[0019] According to an aspect of the present invention, the Y-buffer-board assembly may include a ground pattern, and the ground pattern may be grounded to a chassis base.
[0020] According to another aspect of the present invention, because a ground voltage is supplied to a Y-board assembly by mounting a current supply element in the Y-buffer-board assembly, a peak-to-peak voltage Vs(pk-pk) of a sustain voltage waveform of a Y electrode can be uniformly formed. Therefore, overshooting of the sustain voltage waveform of the Y electrode is prevented and thus luminance distribution in a vertical direction of the PDP is uniformly displayed.
[0021] Additional aspects and/or 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0023] FIG. 1 is a schematic diagram illustrating a plasma display device according to a first exemplary embodiment of the present invention.
[0024] FIG. 2 is a schematic diagram of a Y-board assembly and a Y-buffer-board assembly of FIG. 1 .
[0025] FIG. 3 is a schematic diagram of a Y-board assembly and a Y-buffer-board assembly in a plasma display device according to a second exemplary embodiment of the present invention.
[0026] FIG. 4 is a schematic diagram of a Y-board assembly and a Y-buffer-board assembly in a plasma display device according to a third exemplary embodiment of the present invention.
[0027] FIGS. 5A and 5B are graphs illustrating a relationship between a peak-to-peak voltage and luminance of a Y-sustain voltage waveform in exemplary embodiments of the present invention and the conventional art.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0028] Reference will now be made in detail to the present embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0029] FIG. 1 is a schematic diagram illustrating a plasma display device according to a first exemplary embodiment of the present invention. Referring to FIG. 1 , the plasma display device includes a PDP 10 that embodies an image, and printed circuit board assemblies (PBAs) that are formed to drive the PDP 10 and are electrically connected to the PDP 10 .
[0030] The PDP 10 includes address electrodes 14 that are disposed to generate a plasma discharge in a discharge cell (DC), and X electrodes 11 and Y electrodes 12 that are disposed parallel to each other while intersecting the address electrodes 14 . The DC has a well-known configuration, and thus a detailed description of the configuration thereof will be omitted.
[0031] The PBAs are formed as a multiple thereof to divide and perform functions that are related to driving of the PDP 10 . For example, the PBAs include an X-board assembly 21 that controls the X electrodes 11 , a Y-board assembly 22 and a Y-buffer-board assembly 23 that control the Y electrodes 12 , and an address buffer board assembly 24 that controls the address electrodes 14 .
[0032] In the X-board assembly 21 , a flexible printed circuit (FPC) 41 is connected to the X-electrodes 11 of the PDP 10 to apply a sustain voltage waveform. In the address buffer board assembly 24 , a tape carrier package (TCP) 42 is connected to the address electrodes 14 to apply an address voltage waveform.
[0033] In the Y-board assembly 22 , an FPC 43 is connected to the Y electrodes 12 of the PDP 10 to apply a scan voltage waveform and a sustain voltage waveform. In this case, the Y-board assembly 22 is electrically connected to the Y-buffer-board assembly 23 through a connection member 44 , and the FPC 43 connects the Y-buffer-board assembly 23 and the PDP 10 .
[0034] Further, the PBAs control the X-board, the Y-board, the Y-buffer-board, and the address buffer board assemblies 21 , 22 , 23 , and 24 and supply power thereto, and further include a control board assembly (not shown) and a power board assembly (not shown).
[0035] When the PDP 10 is driven, a reset discharge occurs according to a reset voltage waveform that is applied to the Y electrode 12 in a reset period. In a scan period following the reset period, an address discharge occurs by a scan voltage waveform that is applied to the Y electrode 12 and an address voltage waveform that is applied to the address electrode 14 . Thereafter, in a sustain period, a sustain discharge occurs by a sustain voltage waveform that is applied to the X electrode 11 and the Y electrode 12 .
[0036] The X electrode 11 and the Y electrode 12 are electrodes applying a sustain voltage waveform necessary for the sustain discharge. The Y electrode 12 performs a function of an electrode for applying a reset voltage waveform and a scan voltage waveform. The address electrode 14 applies an address voltage waveform. The X electrode 11 , the Y electrode 12 , and the address electrode 14 can perform different functions according to voltage waveforms that are applied thereto, and thus are not limited to the stated functions.
[0037] FIG. 2 is a schematic diagram of a Y-board assembly and a Y-buffer-board assembly of FIG. 1 . Referring to FIG. 2 , the Y-buffer-board assembly 23 includes a connector 45 that is connected to one end of the FPC 43 (see FIG. 1 ) that is connected to the PDP 10 , and a connection member 44 that is connected to the Y-board assembly 22 and another Y-buffer-board assembly 23 that is mounted at a position adjacent thereto.
[0038] Further, the Y-buffer-board assembly 23 includes a ground pattern 47 around a mounting hole (not shown) that is formed in the Y-buffer-board assembly 23 and a mounting hole (not shown) for receiving a setscrew S. When the Y-buffer-board assembly 23 is mounted to the chassis base, the ground pattern 47 is electrically connected to the setscrew S and a boss (not shown) of the chassis base to be grounded.
[0039] In a configuration that controls the Y electrode 12 , the Y-board assembly 22 forms a sustain circuit 51 that uses a large IGBT and a large FET operating with a large current. The Y-buffer-board assembly 23 includes a scan IC circuit 52 that uses a surface mounted device (SMD) such as a scan IC 53 . The sustain circuit 51 and the scan IC circuit 52 use well-known technology and therefore a detailed description thereof will be omitted.
[0040] Further, the Y-board assembly 22 further includes an isolation switch 54 that connects the sustain circuit 51 and the scan IC circuit 52 . The Y-buffer-board assembly 23 includes a current supply element for preventing overshooting of a sustain voltage waveform by supplying a ground voltage that is formed in the ground pattern 47 to the isolation switch 54 .
[0041] The isolation switch 54 is turned on when an OUTL voltage is in a range from 0 volts to a sustain voltage (Vs) level. Therefore, the current supply element is formed to use a gate signal of the current supply element as a gate signal of the isolation switch 54 .
[0042] In the first exemplary embodiment, the current supply element includes a diode 61 and a FET 62 . In the diode 61 , the anode terminal is connected to the ground pattern 47 of the Y-buffer-board assembly 23 to transfer a ground voltage to a cathode terminal. In the FET 62 , the drain terminal is connected to the cathode terminal of the diode 61 and the source terminal is connected to the OUTL voltage. In order to use a gate signal of the isolation switch 54 , the gate terminal of the FET 62 can be connected (not shown) to the gate terminal of the isolation switch 54 .
[0043] The OUTL voltage outputs a sustain voltage waveform, and when outputting the sustain voltage waveform, the OUTL voltage changes within a range from a 0 volt level to the sustain voltage (Vs) level, or in other words a range from 0V-Vs. When the OUTL voltage of the Y-buffer-board assembly 23 is below 0V, the current supply element (that is, the diode 61 and the FET 62 ) supplies the ground voltage (0V) to the Y-board assembly. Therefore, the Y-sustain voltage waveform does not fall below 0V. Thereby, distortion of the Y-sustain voltage waveform is reduced, and uniformity of luminance in a vertical direction of the PDP 10 can be improved.
[0044] Hereinafter, various exemplary embodiments of the present invention are described, and constituent elements identical to or corresponding to those of the first exemplary embodiment will be omitted and only dissimilar constituent elements will be described in detail.
[0045] FIG. 3 is a schematic diagram of a Y-board assembly and a Y-buffer-board assembly in a plasma display device according to a second exemplary embodiment of the present invention. Referring to FIG. 3 , in the first exemplary embodiment, the current supply element includes a diode 61 and a FET 62 , and in the second exemplary embodiment, the current supply element includes a reverse blocking IGBT (RB-IGBT) (not shown).
[0046] In the RB-IGBT, the collector terminal is connected to a ground pattern 47 of a Y-buffer-board assembly 223 , and the emitter terminal is connected to an OUTL voltage. In order to use a gate signal of the isolation switch 54 , the gate terminal of the RB-IGBT can be connected (not shown) to a gate terminal of the isolation switch 54 .
[0047] FIG. 4 is a schematic diagram of a Y-board assembly and a Y-buffer-board assembly in a plasma display device according to a third exemplary embodiment of the present invention. Referring to FIG. 4 , the current supply element of the first and second exemplary embodiments prevents an OUTL voltage from falling below the ground voltage, and the current supply element of the third exemplary embodiment prevents an OUTL voltage from rising above a sustain voltage (Vs).
[0048] The current supply device of the third exemplary embodiment includes a capacitor 81 and a diode 82 . The capacitor 81 is interposed between a ground pattern 47 of a Y-buffer-board assembly 323 and a power source line of a sustain voltage (Vs) pulse to suppress the sustain voltage (Vs) from changing in the power source line.
[0049] The cathode terminal of the diode 82 is connected to the capacitor 81 side that is connected to the power source line of the sustain voltage (Vs), and the anode terminal is connected to the OUTL voltage. When the OUTL voltage of the Y-buffer-board assembly 23 exceeds the sustain voltage (Vs), the current supply element (that is, the capacitor 81 and the diode 82 ) supplies the sustain voltage (Vs) to the Y-board assembly. Therefore, the Y-sustain voltage does not exceed the sustain voltage (Vs). In the third exemplary embodiment having the capacitor 81 , a change of the sustain voltage (Vs) is suppressed, compared with the first and second exemplary embodiments, thereby more effectively reducing distortion of the Y-sustain voltage waveform.
[0050] The current supply device of the first to third exemplary embodiments can have other configurations, and can embody the above-described operation effect by combining two or more configurations.
[0051] FIGS. 5A and 5B are graphs illustrating a relationship between a peak-to-peak voltage and luminance of a Y-sustain voltage waveform in the conventional art and in exemplary embodiments, respectively. FIG. 5A illustrates a measured result of a peak-to-peak voltage and luminance in a vertical direction of a PDP when having no current supply element that is described in the present exemplary embodiment, and FIG. 5B illustrates a measured result of a peak-to-peak voltage and luminance in a vertical direction of a PDP when having a current supply element that is described in the present exemplary embodiment.
[0052] Referring to FIG. 5A , peak-to-peak voltage YVs (pk-pk) of a Y-sustain voltage waveform largely depends on a position in the vertical direction of the PDP 10 , and thus luminance (L) distribution in the vertical direction of the PDP 10 is non-uniform.
[0053] Referring to FIG. 5B , peak-to-peak voltage YVs (pk-pk) of a Y-sustain voltage waveform depends less on a position in the vertical direction of the PDP 10 , and thus luminance (L) distribution in the vertical direction of the PDP 10 is more uniformly displayed.
[0054] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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A plasma display device that inexpensively improves uniformity of luminance in a vertical direction of a PDP. The plasma display device includes: a plasma display panel (PDP) having an X electrode and Y electrode that are disposed parallel to each other while intersecting an address electrode at a discharge cell; a Y-board assembly that controls the Y electrode of the PDP; a Y-buffer-board assembly including a scan integrated circuit (IC) connected to the Y-board assembly to apply a scan voltage waveform and a sustain voltage waveform to the Y electrode; and a current supply element included in the Y-buffer-board assembly to supply a ground voltage to the Y-board assembly and to prevent overshooting of the sustain voltage waveform.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of U.S. Provisional Patent Application Ser. No. 60/508,160 filed Oct. 2, 2003 entitled “COMPACT JACQUARD SELECTING CARD USING PIEZOELECTRIC ELEMENTS”, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to selecting cards for Jacquard-type equipment. More specifically, the present invention relates to a piezoelectric actuated selecting card for use in a Jacquard loom.
2. Description of the Prior Art
The use of Jacquard selection devices in weaving looms to produce intricate patterns by controlling the lifting of selected warp yarns is well known in the art. The separation formed between the lifted warp yarns and the non-lifted warp yarns is referred to as the shed. The Jacquard mechanism allows for independent movement of each warp yarn by controlling hooks (latches, catches) which engage matching hooks on rods (healds) connected to each warp yarn in a harness. A lifting device (or board) is used to raise or lower those warps in the harness whose corresponding hooks have been engaged. By coordinating the movement of the hooks, sequences of warp yarns can be selected and lifted while filling yarns are passed through the shed. In this manner, the Jacquard selection device is used to create the woven pattern.
Jacquard selection devices can be used in looms in either a closed shed or an open shed arrangement. In the closed shed arrangement, a single lifting device having an engaging hook for each warp in the harness is used. Whereas, the open shed configuration uses a double hook system of two lifting devices which provide pairs of engaging hooks which connect with pairs of (ascending and descending) rods that lift a single warp. The open shed configuration has two lifting devices and requires only a single move of each lifting device to create the shed, while the closed shed configuration has one lifting device but requires two moves.
Historically, the Jacquard mechanism involved a paper selection card having a pattern of punched holes. The selection card would allow those rods (or hooks) located at a hole to pass through and lift the corresponding warps, whereas the rods would be blocked at the locations without holes. By changing or shifting the selection card after each pass, the weave pattern could be formed.
This process was mechanically complex and often led to breakdowns and fabric quality problems. The mechanical complexity has been a major obstacle to increasing the efficiency of Jacquard machines. In response, several electrically selected loom latches have been proposed. For example, U.S. Pat. No. 6,073,662 to Herbepin, which is incorporated herein by reference, teaches the use of an electromagnetic device having a coil to control the position of each catch relative to a corresponding hook in a Jacquard selection device. When an electromagnet device is powered, the attached catch is positioned to engage the corresponding hook. The shed is opened by operation of a lifting board. Despite such proposed solutions, electrical and electromagnetic selection devices remain relatively large in comparison to the scale of the weave pattern.
A refinement of this electrical approach has been the application of piezoelectric elements to Jacquard selection devices. Piezoelectric actuator elements are devices that produce a lateral or longitudinal displacement with a high force capability when an operating voltage is applied. There are many applications where a piezoelectric actuator may be used, such as ultra-precise positioning and the generation/handling of high forces or pressures in static or dynamic situations.
Actuator configuration can vary greatly depending on application. For example, a flexure strip of piezoelectric material can be used to produce a transverse displacement. Piezoelectrics can also be stacked together to increase the displacement.
These devices are especially useful for controlling vibration, positioning applications and quick switching. For example, piezoelectric actuators can be designed to produce strokes of several micrometers at ultrasonic (>20 kHz) frequencies.
The critical specifications for piezoelectric actuators are the displacement, force and operating voltage of the actuator. Other factors to consider are stifffiess, resonant frequency and capacitance. Stiffness is a term used to describe the force needed to achieve a certain deformation of a structure. For piezoelectric actuators, it is the force needed to elongate the device by a certain amount.
Numerous approaches have been proposed to improve the operation of Jacquard-type weaving machines by incorporating piezoelectric elements. For example, U.S. Pat. No. 5,392,818 to Seiler discloses a needle selector for a Jacquard weaving machine similar to prior art mechanical devices only using piezoelectric transducers to adjust each blocking element. U.S. Pat. No. 6,470,919 to Wardle discloses an individual warp selector wherein a piezoelectric element drives a motor which mechanically moves a rigid heald. U.S. Pat. No. 5,464,046 to McIntyre discloses another individual warp selector wherein a piezoelectric element mechanically slides a warp selector in the longitudinal direction. U.S. Pat. No. 5,647,403 to Willbanks discloses using a piezoelectric element as a mechanical brake on the movement of a Jacquard warp selector. U.K. Patent No. GB 2 276 637 to Seiler and U.S. Pat. No. 5,666,999 to Dewispelaere disclose using piezoelectric elements as controls (locks) on the movement of catches for engaging lifting hooks in an open shed loom arrangement. However, each of these approaches simply uses the piezoelectric element to activate the mechanical elements which select the warp yarns. Because these approaches retain many of the complex mechanical features of the prior art, they exhibit many of the same limitations. For example, the size of these devices is not amenable to weaving high density patterns.
Therefore, a need exists for a Jacquard selection device which is mechanically reliable, operates at high-speed, has low power consumption, and is small enough to provide for high density warp selection.
The present invention provides a solution to the problem of providing a high density Jacquard selection device which is high-speed, reliable, and low power.
SUMMARY OF THE INVENTION
Accordingly, the present invention is an electronic selection card for a Jacquard machine which is high density, compact, and reliable.
The present invention is a selection device for a Jacquard machine. The device has a parallel array of evenly spaced piezoelectric actuated flexure elements which lie in a plane. Each flexure element in the array has a corresponding hook element connected to one end. A holding bar connects a second end of each flexure element in the array and lies in the plane. An axial rod parallel to the holding bar passes through an axis hole in each hook element, thereby providing a common axis for each hook element to pivot. Each hook element is independently positioned by actuating the piezoelectric in the corresponding flexure element, thereby causing the flexure element to bend out of the plane and forcing the connected hook element to pivot about the common axis.
Other aspects of the present invention include that the selection device may be an electronic selection card for a Jacquard loom used to weave fabric patterns. The hook elements may be used to select warp yarns from a harness for lifting to form a shed during weaving.
In a preferred embodiment, the array comprises twenty-four (24) piezoelectric actuated flexure elements and corresponding hook elements spaced within a length of less than 90 mm.
In another embodiment, each hook element comprises two opposing hooks.
The present invention will now be described in more complete detail with frequent reference being made to the drawing figures, which are identified below.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, reference is made to the following description and accompanying drawings, in which:
FIG. 1 is a front and side view of an exemplary compact selection card in accordance with the teachings of the present invention;
FIG. 2 is a side view of an exemplary double hook compact selection card in accordance with the teachings of the present invention; and
FIG. 3 shows comparison views of the closed shed operating cycle for a prior art electric selection device and a piezoelectric selection device in accordance with the teachings of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is a compact selecting card for use in a Jacquard device; e.g. a loom. The selecting card comprises an array of selecting hooks which are individually positioned by piezoelectric actuators. Such a card provides many advantages over prior art electronic selection cards. For example, the present card exhibits improved operating speed and positional control, lower power consumption, and increased lifetime.
FIG. 1 is a front and side view of an exemplary compact selection card in accordance with the teachings of the present invention. The selection card has a parallel array of evenly spaced piezoelectric actuated flexure elements 20 which lie in a plane. Each flexure element in the array has a corresponding hook element 40 connected to one end. A holding bar 10 connects the other end of each flexure element 20 in the array and lies in the plane. An axial rod 30 parallel to the holding bar passes through an axis hole in each hook element 40 , thereby providing a common axis for each hook element to pivot. The holding bar 10 and axial rod 30 combine to create a no-play assembly for the flexure elements 20 . This allows the piezoelectric elements to supply all their force and control to the attached hooks 40 . Each hook element 40 is independently positioned by actuating the piezoelectric in the corresponding flexure element 20 , thereby causing the flexure element to bend out of the plane and forcing the connected hook element to pivot about the common axis.
The present selection device is suitable for use in a Jacquard loom used to weave fabric patterns. The hook elements may be used to select warp yarns from a harness for lifting to form a shed during weaving. This arrangement of flexure elements allows for a selection hook density such that each harness in a loom can be driven independent from one another.
In a preferred embodiment, the array comprises twenty-four (24) piezoelectric actuated flexure elements and corresponding hook elements spaced within a length of less than 90 mm. These hooks correspond to the yarns in a 24 warp yarn harness. This hook density is sufficient for each harness on a loom to be driven independently. For control of fewer than 24 yarns, the harness is simply not threaded for those yarns. Conversely, to control more than 24 yarns, multiple selection cards and harnesses can be used.
FIG. 2 is a side view of another embodiment of the invention in which each hook element comprises two opposing hooks. As in the single hook embodiment, this double hook selection card has a parallel array of evenly spaced piezoelectric actuated flexure elements 20 which lie in a plane. A holding bar 10 connects one end of each flexure element 20 in the array and lies in the plane. Attached to the other end of each flexure element are a pair of hook elements 40 . Axial rods 30 parallel to the holding bar pass through an axis hole in each hook of the double hook elements 40 , thereby providing common axes for the hook elements to pivot. The holding bar 10 and axial rods 30 combine to create a no-play assembly for the flexure elements 20 . This allows the piezoelectric elements to supply all their force and control to the attached hooks 40 . Each pair of hooks are independently positioned by actuating the piezoelectric in the corresponding flexure element 20 , thereby causing the flexure element to bend out of the plane and forcing the connected hook elements to pivot about the common axis. Because of the double hook configuration, a preloaded mechanism 50 such as a spring is needed to bias the hooks back into their neutral in plane position.
Both the single hook and double hook embodiments of the present selection card can be used in conjunction with various lifting devices in both closed shed and open shed configurations.
FIG. 3 shows comparison views of the operating cycle of a closed shed configuration for: 3 A) a prior art electric selection device and 3 B) a piezoelectric selection device in accordance with the teachings of the present invention.
The prior art electric devices in the closed shed configuration commonly use two plates moving in a 4 step cycle. Typically, the upper plate 80 acts as the lifting device and contains the selection device, while the lower plate positions the rods of the harness. In step S 1 , the upper plate 80 (or top lifting board) is in a raised position and the lower plate 70 is in a lowered position, thereby forming a wide separation between the plates. The upper plate hook element is not engaged with the hooked rod (or heald) 60 . Note the shown upper plate hook corresponds to one of the hooks in a selection device while the hooked rod corresponds to one of the warps in the harness. The hooked rod passes through the lower plate and connects, typically through an eyelet, to a warp yarn 90 . The hooked rod 60 is biased by a spring or weight 100 such that the rod and the connected warp yarn are pulled down as shown when the lower plate is in the lowered position and the hook is not engaged. This results in the connected yarn being in a lowered position. As shown in step S 2 , the plates are then moved towards each other. In this configuration, the upper plate is in a lowered position and the lower plate is in a raised position, thereby forming a narrow separation between the plates. By moving the lower plate from the lowered position to the raised position the hooked rod is also raised such that the connected yarn is in a flat or neutral position. In step S 3 , the upper plate hook is positioned by the electric mechanism to engage the hooked rod. Typically, the electrical mechanism is an electromagnetic coil which is activated to switch the hook between positions. The upper plate and lower plate are then moved apart in step S 4 (to their respective positions in step S 1 ). Because the upper plate hook is engaged with the hooked rod, when the upper plate moves to the raised position the hooked rod and connected yarn are pulled up as well. As shown, the connected yarn is pulled into a raised position above the neutral position. In this manner, each warp yarn in the harness can be controlled by engaging or not engaging its connected rod with the corresponding hook element in the selection device.
For the piezoelectric device shown in 3 B, the electrical mechanism is replaced by the holding bar 10 , flexure elements 20 , and hooking elements 40 of the present selection card. This piezoelectric device similarly uses two plates moving in the same 4 step cycle as the prior art electric devices. For this type of design, the present selection cards are attached in position to the upper plate (top lifting board). The harness is positioned by the lower plate such that the rods in the harness can be engaged by the selection card hooks.
Another aspect of the invention is a feedback mechanism which can be integrated into the electrical control circuitry for the piezoelectric elements to determine the current position of the hook. In this manner, the proper functioning of each of the hook elements in the selection card can be actively monitored.
The present invention is applicable for use in many types of Jacquard equipment or any unit where binary positioning by mechanical components is required. As discussed herein, the present device may be used, in a Jacquard machine, to activate the position of each harness. In other applications, the device could be used to activate intermediary components linking each hook to parts that require setting in a binary position.
Modifications to the above would be obvious to those of ordinary skill in the art, but would not bring the invention so modified beyond the scope of the present invention. The claims to follow should be construed to cover such situations.
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A compact electronic selection card applicable for use in Jacquard equipment, having a high-density array of selecting hooks which are individually positioned by piezoelectric actuator elements. Each piezoelectric element directly controls a selecting hook for engaging a corresponding hooked rod connected to a warp yarn. The engaged rods are then lifted to form the shed. Because each element directly positions the hook rather than indirectly controlling a positioning mechanism, the selection card is mechanically simple and compact.
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[0001] This is a Continuation of International Application PCT/EP2012/003954, with an international filing date of Sep. 21, 2012, which was published under PCT Article 21(2) in German, and the complete disclosure of which is incorporated into the present application by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a carrier unit for a weight switching device of an electronic weighing cell, comprising a first shift weight carrier which is vertically movable relative to a base, for vertically mounting, with play, a first shift weight arrangement which has two parallel carrier arms spaced apart from one another and connected by a bridging piece.
[0003] The invention also relates to an electronic weighing cell, comprising
a device base, an electronic weighing sensor arranged on the device base, a load receiver which is mechanically coupled to the weighing sensor and which supports a weighing pan holder and a shift weight receiver, and a weight switching device, comprising a carrier unit with shift weights and a lifting unit for loading and unloading the shift weight receiver with the shift weights as required.
BACKGROUND OF THE INVENTION
[0008] Carrier units of this type are known from JP 62027626 A and weighing cells of this type are known from DE 33 30 988 C2.
[0009] In the present context, a weight switching unit is understood to mean, in general, a device for loading and unloading a load receiver of a weighing cell as required. In particular, substitution switching and adjustment switching are known. In the latter, a distinction is often made between calibration switching and linearization switching processes. Of particular interest are automated weight switching processes, such as are used particularly in electronic weighing cells in which the load receiver, for example, a boom arm, represents the connection between a weighing pan which supports the weight to be measured and an electronic weighing sensor.
[0010] Substitution switching processes usually serve to extend the measuring range. Electric weighing sensors, in particular those which operate using the principle of electromagnetic force compensation are mostly only available in a small but very accurately digitizable measuring current range. Since the measuring current or compensation current is in direct relation to the weight force loading the weighing sensor, this leads to a correspondingly small weight measuring range. In order to be able also to measure weights below the weight measuring range thus defined, it is known to “shift” the range into the permissible weight measuring range by additional loading of the weighing sensor with known substitution weights.
[0011] When adjustment switching is performed, by contrast, known adjusting weights are measured alone in order to determine and/or set instrument parameters. Calibration is normally said to occur when device parameters are determined under full load, whilst linearization is often considered to be when, to determine a, particularly, linear characteristic, device parameters are determined at multiple load levels and then interpolated or extrapolated for further load levels.
[0012] From the aforementioned DE 33 30 988 C2, there is known an electronic weighing cell of which the load receiver connects a weighing pan with a weighing sensor operating using the electromagnetic force compensation principle. Arranged below the weighing pan at the load receiver is a shift weight receiver for receiving shift weights as required. The shift weights are part of a weight switching device which is not in direct contact with the load receiver and consists of a carrier unit and an associated lifting unit. The shift weights mounted, with vertical play, in the carrier unit can be placed onto or lifted off the shift weight receiver individually or together by a vertical movement brought about by the lifting unit in order thereby to generate different substitution or adjustment states. Associated disadvantages are, in the case of substitution, the asymmetrical loading of the load receiver which can lead to tilting and thus to measuring errors (off-center load errors) and, in the case of adjustment, the small number of different, settable adjusting states.
[0013] From JP 62027626 A mentioned in the introduction, there is known a carrier unit of a weight switching device wherein a fork-shaped shift weight carrier is pivotably mounted on a motor-driven pivot shaft at the side facing away from the free ends of the carrier arms. A ring-shaped calibration weight lies on the free ends of the carrier arms so that a center of the ring corresponds with the center of the weighing pan post of a weighing cell. By pivoting the carrier unit, the ring-shaped calibration weight can be placed onto and lifted off the load receiver carrying the weighing pan post, concentrically with said post. In principle, the ring-shaped calibration weight would also be suitable as a substitution weight. However, a disadvantage is the low number of substitution or adjustment states that can be realized.
[0014] From DE 87 15 016 U1, there is known a weighing cell in which the adjusting weights lie, in the normal position, on a shift weight storage place arranged under the weighing pan and, when needed, are lifted out by two wedges which are displaceable by horizontally pivotable levers in the intermediate space between the device bottom and the shift weights and are pressed against an upper stop. Disadvantages herein again are the small number of adjustment and substitution states that can be created and the asymmetries thereof.
[0015] From DE 28 41 996 C2, there is known a weighing cell with a plurality of substitution weights symmetrically arranged in pairs. The substitution weights hang on cams of a plurality of cam shafts arranged over one another and can be lowered and raised in pairs together or individually onto/from shift weight receivers arranged over one another. Disadvantageous herein is the significant structural space required by the weight switching device.
[0016] Finally, from DE 10 2005 033 952 B4, there is known a monolithic weight switching device, the functional details of which are not, however, disclosed in said document.
OBJECTS AND SUMMARY OF THE INVENTION
[0017] It is an object of the present invention further to develop a carrier unit of this type and an electronic weighing cell of this type such that a plurality of substitution states and adjustment states can be realized with a minimum space requirement.
[0018] This object is achieved in that a second shift weight carrier for vertically mounting, with play, a second shift weight arrangement which likewise has two parallel carrier arms spaced apart from one another and connected by a bridging piece, is likewise arranged vertically movable relative to the base, wherein the carrier arms of the first shift weight carrier are arranged between and parallel to the carrier arms of the second shift weight carrier and wherein each shift weight carrier is articulated to a common crosspiece by two parallel links which are arranged outside the two carrier arms, parallel thereto and enclosing the carrier arms between one another, and are connected to the shift weight carrier at their free ends.
[0019] The object is further achieved in that the carrier unit is configured as a carrier unit of the aforementioned type which is rigidly connected via its crosspiece to the device base, under each of the carrier arms thereof there is mounted in suspended manner and parallel to said arm a roller-shaped shift weight, and the carrier unit is arranged above the shift weight receiver, and that the lifting unit is configured for selective vertical movement of the shift weight carrier.
[0020] Preferred embodiments of the invention are also disclosed and claimed in the dependent claims.
[0021] The invention provides firstly for the carrier unit to be equipped with a second essentially identically configured shift weight carrier. This is based on the intention of increasing the number of available shift weights in order to be able to realize more adjustment states and/or substitution states. However, the invention goes beyond this starting point which is essentially known from the prior art in two particulars in order to minimize the structural space for the doubled shift weight carrier. According to the first further aspect of the invention, interleaving of the shift weight carriers in one another is provided. The second shift weight carrier encompasses, with its carrier arm pair, the first shift weight carrier. In order to achieve balanced loading of the load receiver, a particular spacing is required between the carrier arms of each shift weight carrier. The carrier arm spacing of the second shift weight carrier must only be increased slightly above the necessarily required dimension in order to create room for the first shift weight carrier in the intermediate space between the carrier arms. A second further-reaching aspect of the present invention lies in optimizing the vertical movement of each shift weight carrier.
[0022] As distinct from the generic prior art upon which the invention is based, no pivot movement is realized by the invention, but rather a purely vertical movement. The purely vertical movement permits a smaller travel overall than a pivot movement, the minimum travel of which is determined by the spacing required at the end of the carrier close to the pivot axis between the shift weight and the shift weight support, wherein the spacing at the end remote from the pivot axis is always overdimensioned. The purely vertical movement, however, reduces the vertical structural space. The purely vertical movement is achieved with the arrangement of a pair of parallel links for each shift weight carrier. The parallel links which, as a person skilled in the art would know well, comprise two parallel link levers connected to spring joints, are arranged parallel to the carrier arms and outside the two shift weight carriers which are interleaved with one another. In other words, the interleaved combination of the two shift weight carriers is bordered laterally by two parallel links in each case, of which each is connected to a carrier arm in the region of the end thereof remote from the crosspiece. The ends of the parallel links close to the crosspiece are articulated to the crosspiece and the ends of the carrier arms close to the crosspiece are not in direct contact with the crosspiece.
[0023] In the installed state within an electronic weighing cell, the shift weight carriers carry shift weights mounted hanging below and parallel to the carrier arms thereof, as is well known from the prior art. The carrier unit thus configured is fastened with the crosspiece thereof to the housing base and thus is not in direct contact with the load-dependently movable parts of the overall system, such as, in particular, the weighing pan and the load receiver. However, the carrier unit with the shift weights is positioned so that, in the lifted-off state, the shift weights hang directly above the shift weight receiver which is preferably arranged below the weighing pan. Lowering one and/or the other shift weight carrier lays the suspended shift weights into the shift weight receiver so that the load receiver is loaded with the additional weights as needed. The lifting and lowering of the shift weight carrier is carried out by a lifting unit which is suitably configured to lift and lower the first, the second or both shift weight carriers.
[0024] Using the invention, with almost the same structural space, the number of adjusting or substituting states is markedly increased without new unwanted off-center load errors necessarily arising. It is possible, in particular, to provide a weighing cell which offers to the user the possibility of adjusting, i.e. calibrating and linearizing, while simultaneously providing the possibility of substitution weighing.
[0025] In a preferred embodiment of the invention, it is provided that the carrier arms of each shift weight carrier are arranged at the same height as one another and the carrier arms of the other shift weight carriers. The carrier arms therefore lie in a common plane when in the common raised state and in the common lowered state. Only when in different lifting states do the carrier arms of the two shift weight carriers lie in offset, parallel planes. This arrangement ensures a minimum space requirement in the vertical direction.
[0026] In a development of the invention, by contrast, it is provided for the parallel links that the parallel links of each individual shift weight carrier are offset in height relative to one another. In other words, each shift weight carrier is attached to a lower-lying parallel link and to a higher-lying parallel link. The parallel links of each shift weight carrier are, particularly, spaced apart approximately along the diagonals of the shift weight carrier. This measure only appears to increase the vertical dimension. As a result of the height offset of the parallel links, the supporting link parallelogram becomes higher and therefore stiffer. If it were desired to achieve the same stiffness with parallel links arranged at the same height, the link levers thereof would each have to be spaced further apart vertically so that the stated further-reaching inventive measure leads finally to a material saving without any vertical space requirement disadvantage.
[0027] In a development of this aspect, it is provided that the parallel links arranged on one side of the shift weight carriers are offset from one another in height and, in particular, are arranged vertically over one another. This leads to a reduction in the horizontal space requirement in comparison with variants in which the parallel links, like the carrier arms, are arranged laterally adjoining one another.
[0028] In order to achieve a further saving of vertical space, in another development of the aforementioned aspect, it is provided that the parallel links of the first and second shift weight carriers are arranged in pairs at the same height. Expressed differently, the parallel links of the two shift weight carriers are diagonally interleaved. Thus, on one side of the carrier unit, the parallel link of the first shift weight carrier lies above the parallel link of the second shift weight carrier, whereas on the other side of the carrier unit, the parallel link of the second shift weight carrier lies above that of the first shift weight carrier, so that the respective upper parallel links are arranged at the same height and the respective lower parallel links are also arranged at the same height. With this mirror-symmetrical height offset of the parallel links of the two shift weight carriers, the vertical structural space is optimally used, leading to a minimum vertical space requirement and simultaneously high stiffness.
[0029] Preferably, the crosspieces, the first and second shift weight carriers and the respective associated parallel links are configured together as one piece. This prevents a loss of adjustment over the course of time. It is particularly preferred that the crosspieces, the first and second shift weight carriers and the respective associated parallel links are configured together monolithically, i.e. machined, particularly milled, from one block of material. The monolithic construction method of lever systems known, in principle, from weighing technology has the advantage, in the context of the present invention, of optimum reproducibility and parameter stability in the device.
[0030] Favorably, each shift weight carrier has a supporting projection on the crosspiece side. These supporting projections which, for space optimization, preferably project adjacent to one another into a vertically open cut-out in the crosspiece, serve as an attachment point for a lifting unit of a weighing cell containing the carrier unit according to the invention.
[0031] A motor-driven camshaft can be used, in particular, as the lifting unit, on the cams of which the supporting projections of the shift weight carrier rest. Depending on the position of the eccentric cams, which are also designated crank disks herein, different lifting states of the shift weight carriers can be realized. In order to enable very direct guidance, the supporting projections can be elastically pre-tensioned against the cams using a pre-tensioning force, for example, a spring force. Alternative embodiments of the lifting unit, for example, fashioned with pneumatic or hydraulic cylinders, with piezoelectric motors, inter alia, can also be used.
[0032] As mentioned above, it is preferably provided that a roller-shaped shift weight is mounted suspended under each carrier arm and parallel thereto. It is herein particularly preferably provided that each shift weight comprises a roller body with axial bearing posts which are formed on both sides and which lie in axially oriented, laterally chamfered guide grooves which are formed into cover plates with which bearing chambers are downwardly closed, said bearing chambers being formed in the associated carrier arm open at their ends and at their bottom sides and their end sides facing toward one another and spaced apart from one another by more than the roller body length and by less than the overall length of each shift weight. For the suspended mounting of the shift weights which must permit the vertical play that is required in order to decouple mechanically the shift weights in the state placed on the shift weight storage place from the carrier unit, an undercut structure is required which is difficult to achieve, particularly with a monolithic production method. It is therefore provided that the shift weights protrude with their bearing posts into bearing chambers of the carrier arms which are large enough to enable sufficient play (both vertically and horizontally). These chambers which are necessarily open at their end sides facing one another, through which the bearing posts of the shift weights protrude, are also downwardly open, so that the shift weights can be inserted from below. Axial insertion is not possible since the separation of the bearing chambers is too small for this. The shift weights, the roller bodies of which are too large to be able to penetrate into the bearing chamber cannot be displaced far enough in one direction axially for the bearing post to come free from the bearing chamber at the other side. However, for suspended mounting of the shift weights, the open undersides of the bearing chambers must be closed. The cover plates which have an axial, self-centering guide groove which accommodates the respective bearing post in a reproducible manner and are, for example, screwed on, serve this purpose. Therefore, despite the maintenance of the necessary play for the storage place of the shift weights, a precisely defined, reproducible position of the shift weights in the suspended state is ensured.
[0033] The exact number of adjusting and/or substitution states that can be realized depends, firstly, on the number of lifting states of the individual shift weight carriers and, secondly, on the design of the relative mechanical arrangements of the shift weight mounting and the shift weight receiver. In order to achieve the greatest possible modularity, it is preferably provided that shift weights of each individual shift weight carrier are mounted at the same height as one another, and more preferably, the shift weights of the first shift weight carrier are mounted offset in height relative to the shift weights of the second shift weight carrier. In this way, the carrier unit offers a universal starting configuration which can be used by different weighing cells through the special design of the shift weight receivers therein in order to realize the respectively required weight switching states.
[0034] In particular, it is provided in a preferred embodiment of an electronic weighing cell that the shift weight receiver and the mounting of the shift weights are height-matched to one another such that the shift weights of one shift weight carrier, when lowered evenly, load the shift weight receiver with a time offset and the shift weights of the other shift weight carrier, when lowered evenly, load the shift weight receiver simultaneously. The simultaneous placement of two shift weights, particularly symmetrically to the load conduction point of the load receiver beneath the weighing pan is particularly suitable for weight switching in the context of substitution weighing, where off-center load errors are to be avoided if possible. On weight switching in the context of an adjustment, particularly calibration or linearization, the independence of the loading with different weights is of greater significance than the off-center load error, which with always the same adjusting weight, can be calculated out with suitable adjusting routines. Thus, the shift weights placed with a time offset during even lowering of the associated shift weight carrier are preferably used as adjusting weights.
[0035] Accordingly, in a development of the electronic weighing cell according to the invention, it is further provided that a control system is actively connected to the lifting unit and is configured to use the shift weights simultaneously loading the shift weight receiver during even lowering of the associated shift weight carrier as substitution weights in the context of a substitution weighing routine and to use the shift weights loading the shift weight receiver with a time offset during even lowering of the associated shift weight carrier as calibration or linearization weights in the context of a calibration and/or linearization routine.
[0036] Further features and advantages of the invention are disclosed in the following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 shows a perspective representation of a carrier unit according to the invention with shift weights;
[0038] FIG. 2 shows a perspective representation of the carrier unit of FIG. 1 in the assembled position with the lifting unit and the load receiver of a weighing cell;
[0039] FIG. 3 shows a perspective view from below of the subject matter of FIG. 1 ;
[0040] FIG. 4 shows a perspective view from below of the subject matter of FIG. 2 ; and
[0041] FIGS. 5 a - 5 d show schematic sketches of the principle of different weight switching states of a weighing cell according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0042] FIGS. 1 to 4 show the same preferred embodiment of the carrier unit 10 according to the invention in different views alone ( FIGS. 1 and 3 ) and in the assembled position ( FIGS. 2 and 4 ). FIG. 5 shows different weight switching states that can be realized with the carrier unit 10 of FIGS. 1 to 4 . The same reference signs in the figures relate to the same or analogous components. Some reference signs are given in the form N-x or as N-xR or N-xL, where N is a reference sign used at another point or in isolation, x can be “1” or “2” and expresses the association with the first or second shift weight carrier, whilst “L” and “R” denote “left” or “right”, making reference to FIG. 1 . Where a reference sign N is used in isolation, association and orientation make no difference. FIGS. 1 to 4 will now be considered together, followed by FIG. 5 .
[0043] The fixed reference element of the carrier unit 10 is the crosspiece 12 . With this, the carrier unit 10 is fastened in a weighing cell to the device base thereof. The mounting takes place, as shown in FIGS. 2 and 4 , directly via the cantilever 14 of a load receiver 16 configured as a boom arm. The load receiver 16 is connected by a linkage and gearing system (not shown) to a weighing sensor (also not shown). The load receiver 16 is also connected to a weighing pan (also not shown) which rests on a load post (not shown) which is fastened in a receptacle 18 in the cantilever 14 and extends vertically through the carrier unit 10 . As shown, in particular, in FIG. 4 , the cantilever 14 is firmly connected to a shift weight receiver 20 so that shift weights 22 - 1 R, 22 - 1 L, 22 - 2 R and 22 - 2 L mounted, with play, on the shift weight carrier can load the weighing sensor via the load receiver 16 in addition to the weight on the weighing pan when the shift weights are placed on the shift weight receiver 20 . This concept is known from the prior art. It is usually the task of such carrier units, in cooperation with a lifting unit, to enable selective loading and/or unloading of the shift weight receiver 20 with the shift weights 22 .
[0044] Four parallel links 23 - 1 R, 23 - 1 L, 23 - 2 R and 23 - 2 L extend horizontally perpendicularly to the crosspiece. Each of the parallel links consists of two link levers 24 which are articulated via spring joints 26 , on one side, to the crosspiece 12 and, on the other side, to a head piece 28 connecting the link levers 24 . The parallel link principle known from the prior art permits a purely vertical movement of an element connected to the head piece 28 with slight pivoting of the parallel link 23 .
[0045] Each head piece 28 is connected to the end of one of four carrier arms 30 - 1 R, 30 - 1 L, 30 - 2 R and 30 - 2 L. The carrier arms 30 extend parallel to the parallel links 23 in the direction toward the crosspiece 12 . On the crosspiece-side ends thereof, said carrier arms 30 are connected to one another in pairs, each with a bridging piece 32 - 1 , 32 - 2 , specifically the carrier arm 30 - 1 R via the bridging piece 32 - 1 to the carrier arm 30 - 1 L, and the carrier arm 30 - 2 R via the bridging piece 32 - 2 to the carrier arm 30 - 2 L. Thus, for each pair of carrier arms 30 - 1 R/ 30 - 1 L, 30 - 2 R/ 30 - 2 L, together with a respective bridging piece 32 - 1 , 32 - 2 , a shift weight carrier 34 - 1 , 34 - 2 is formed which is articulated by a set of parallel links 23 - 1 , 23 - 2 to the crosspiece 12 .
[0046] The two shift weight carriers 34 are arranged at the same height and interleaved with one another. In particular, the first shift weight carrier 34 - 1 is arranged in the interior of the second shift weight carrier 34 - 2 . This is different for the associated parallel links 23 . The parallel links 23 - 1 R and 23 - 1 L supporting the first shift weight carrier 34 - 1 are arranged offset in height from one another. The same applies to the parallel links 23 - 2 R and 22 - 2 L supporting the second shift weight carrier 34 - 2 . It is, in particular, clearly apparent from the drawings that the parallel links 23 arranged, in each case, on one side of the shift weight carriers 34 are arranged directly over one another. In other words, the parallel links 23 of the two shift weight carriers 34 are diagonally interleaved with one another.
[0047] A shift weight 22 is mounted suspended under each carrier arm 30 . The shift weights 22 have an essentially roller-shaped body with two recesses 36 located close to the ends thereof. The recesses 36 match corresponding indentations in the shift weight receiver 20 so that the shift weights 22 can be placed into the shift weight receiver 20 substantially without axial play. In the embodiment illustrated, the shift weights 22 are suspended at the same height under the carrier arms 30 . In order to achieve a time-offset loading of the shift weight receiver 20 on lowering of, in particular, the second, outer shift weight carrier 34 - 2 , the indentations of the shift weight receiver 20 associated with the corresponding shift weights 22 - 2 R and 22 - 2 L are configured having different depths. In FIG. 5 , which will be considered in greater detail below, the different realizable weight switching states are shown in a schematic representation. The suspension of the shift weights 22 is performed with bearing posts 48 which project on both sides axially from the end faces of the roller bodies of the shift weights 22 . With these bearing posts 48 , the shift weights are laid from below into open pockets of the carrier arms 30 and the pockets are closed with screwed-on cover plates 50 . The cover plates 50 each have a guide groove 52 in which the bearing posts 48 rest in a self-centering manner. The bearing chambers have sufficient height to permit vertical play of the shift weights 22 so that said weights are decoupled in force-free manner from the respective shift weight carrier 34 after placement on the shift weight receiver 20 .
[0048] In order to actuate the shift weight carrier 34 , a lifting unit is provided in the assembled overall system, as shown in particular in FIGS. 2 and 4 . A supporting projection 38 - 1 , 38 - 2 which extends into a vertically open cut-out 40 in the crosspiece 12 is connected to each bridging piece 32 . These supporting projections 38 rest on two link disks 42 which are mounted non-rotatably on a cam shaft 44 which is connected to the output shaft of an electric motor. A rotation of the cam shaft 44 raises and lowers the supporting projections 38 according to the shape of the crank disks 42 . By this, the whole of the shift weight carriers 34 are raised and lowered and, with them, the shift weights 22 . The preferred switching scheme is illustrated in schematic form in FIG. 5 which is described in greater detail below. A slotted disk 46 which is also non-rotatably connected to the cam shaft 44 serves as an optical position sensor with which the current cam shaft position is transmitted to a central control unit.
[0049] FIG. 5 shows, in four sub-diagrams, the four weight switching states which can be realized with the preferred embodiment of the present invention. The two shift weights 22 - 1 R and 22 - 1 L which are carried by the first, inner shift weight carrier 34 - 1 are suspended at the same height and the associated indentations in the shift weight receiver 20 are configured having equal depth. Thus, on lowering or raising the first shift weight carrier 34 - 1 , the shift weights are always simultaneously set down or raised. The first shift weight carrier 34 - 1 preferably serves for substitution; the shift weights 22 - 1 R and 22 - 1 L are thus preferably substitution weights. In contrast thereto, the shift weights 22 - 2 R and 22 - 2 L of the second shift weight carrier 34 - 2 preferably serve as adjusting weights, in particular as calibration and/or linearization weights. With these weights, the weight suspension and the specific design of the shift weight receiver 20 are matched to one another such that on lowering or lifting of the second shift weight carrier 34 - 2 , the weights are set down or raised with a time offset. Accordingly, the link disk for the second shift weight carrier 34 - 2 provides three different positions which are illustrated in FIGS. 5 a / 5 b, 5 c / 5 d. It should be noted that in the representation in FIG. 5 , the shift weight receiver 20 has a uniform height so that the described time offset is achieved by suspending the shift weights 22 - 2 R and 22 - 2 L offset in height. In the embodiments of FIGS. 1 to 4 , however, as shown in particular by FIG. 4 , the shift weights 22 - 2 R and 22 - 2 L are arranged at the same height, whereas the corresponding indentations in the shift weight receiver 20 have different depths. Both variants are functionally equivalent and mixed variants are also conceivable.
[0050] It should be understood that the embodiments covered by the description above and shown in the figures are merely illustrative exemplary embodiments of the present invention. A broad spectrum of possible variations is self-evident to a person skilled in the art, based on the present disclosure. In particular, a person skilled in the art could adapt the particular geometry and dimensions of the individual elements to the requirements of the respective individual case. It is naturally also conceivable for the principle according to the invention to be extended with one or more shift weight carriers, shift weights or weight switching states.
REFERENCE SIGNS
[0000]
10 Carrier unit
12 Crosspiece
14 Cantilever
16 Load receiver
18 Receptacle
20 Shift weight receiver
22 - 1 R Shift weight
22 - 1 L Shift weight
22 - 2 R Shift weight
22 - 2 L Shift weight
23 - 1 R Parallel link
23 - 1 L Parallel link
23 - 2 R Parallel link
23 - 2 L Parallel link
24 Link lever
26 Spring joint
28 Head piece
30 - 1 R Carrier arm
30 - 1 L Carrier arm
30 - 2 R Carrier arm
30 - 2 L Carrier arm
32 - 1 Bridging piece
32 - 2 Bridging piece
34 - 1 First shift weight carrier
34 - 2 Second shift weight carrier
36 Recess
38 - 1 Supporting projection
38 - 2 Supporting projection
40 Vertical cut-out in 12
42 Crank disk
44 Cam shaft
46 Position sensor
48 Bearing post
50 Cover plate
52 Guide groove
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A carrier unit for a weight switching device includes a first shift weight carrier ( 34 - 1 ) which moves vertically in relation to a base, for vertically mounting a first shift weight arrangement ( 22 - 1 R, 22 - 1 L) which has two spaced-apart, parallel carrier arms ( 30 - 1 R, 30 - 1 L) connected by a bridging piece ( 32 - 1 ). A second shift weight carrier ( 34 - 2 R, 34 - 2 L) for vertically mounting, with play, a second shift weight arrangement ( 22 - 2 R, 22 - 2 L) which likewise has two spaced-apart, parallel carrier arms ( 30 - 2 R, 30 - 2 L) connected by another bridging piece ( 32 - 2 ), is likewise arranged in a vertically movable manner in relation to the base. The carrier arm pair ( 30 - 1 R, 30 - 10 of the first shift weight carrier ( 34 - 1 ) is arranged between and parallel to the carrier arm pair ( 30 - 2 R, 30 - 2 L) of the second shift weight carrier ( 34 - 2 ), and each shift weight carrier ( 34 - 1; 34 - 2 ) is articulated to a common crosspiece ( 12 ) by two parallel links ( 23 - 1 R, 23 - 1 L; 23 - 2 R, 23 - 2 L).
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PRIORITY CLAIM
[0001] This application is a continuation of U.S. patent application Ser. No. 14/455,103, filed Aug. 8, 2014, which is a continuation-in-part from U.S. patent application Ser. No. 14/184,217, filed Feb. 19, 2014, now U.S. Pat. No. 8,899,973, issued on Dec. 12, 2014, which is a continuation from U.S. patent application Ser. No. 13/544,519, filed on Jul. 20, 2012, now U.S. Pat. No. 8,758,008, issued on Jun. 24, 2014, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/598,662, filed Feb. 14, 2012; the disclosures of which are incorporated herein by reference in their entireties.
TECHNICAL FIELD
[0002] The subject matter described herein relates to candles with items embedded within and methods for manufacturing and selling same.
BACKGROUND
[0003] People like to give and receive presents. In some cultures it is customary to wrap a gift present in an attractive package which is pleasing to the eye of the recipient and which also prevents the recipient from immediately knowing the nature or value of the present, which peaks the interest of the recipient, increases the recipient's anticipation of the unwrapping of the gift, and increases the recipient's delight and enjoyment of the gift revealed.
[0004] Candles are popular gifts due to their pleasant form, color, and/or scent. A burning candle provides a warm, relaxing atmosphere, and candles are associated with love, romance, or special occasions. Candle bodies are typically made of an opaque or translucent material, such as wax, which is consumed while the candle burns.
[0005] Candle bodies thus make an ideal container within which to hide an item, such as jewelry, gifts traditionally given on romantic or special occasions, or other items, where the presence, nature, or value of the item is slowly revealed as the candle body is consumed, to the delight of the recipient of the candle. In addition, the excitement of anticipation one feels while waiting to find out the nature or value of a gift received may be heightened when the recipient of a candle containing an embedded item knows beforehand that there is a possibility that the value of the embedded item can be larger, and sometimes much larger, than the purchase price of the candle within which the item is embedded.
[0006] Thus, there is a need for candles with items embedded within them where the presence, nature, or value of the embedded item is obscured by the candle body and therefore unknown to the purchaser or user of the candle until the candle body has been consumed sufficiently to reveal the presence, nature, or value of the item.
SUMMARY
[0007] According to one aspect, the subject matter described herein includes a method for manufacturing a candle having an item embedded within. In some embodiments, the method can comprise providing a first set of items, each item having a first value, providing a second set of items, each item having a second value different from the first value, combining the first and second sets of items to create a third set of items, and distributing the items of the third set among a set of candles, wherein each candle of the set of candles comprises an enclosure that forms a periphery of the candle, wax that forms a body of the candle, and a wick. One item from the third set can be enclosed within a first container that is embedded within the wax of the candle body, wherein the first container can be attached to the inside of the enclosure that forms a periphery of the candle such that the presence of the first container is visible through the enclosure but the nature of the embedded item from the third set, the value of the embedded item from the third set, or the value of the embedded item from the third set relative to a purchase price of the candle is not discernable while the item from the third set is embedded in the candle.
[0008] According to another aspect, the subject matter described herein includes a candle with an embedded item. The candle includes a candle body including wax and a wick, where the candle body includes an embedded item such that the presence, nature, and/or value of the item is obscured by the candle body.
[0009] According to another aspect, the subject matter described herein includes a candle with an embedded item. The embedded item can in some embodiments comprise an object that is redeemable for a prize. The embedded item can in some embodiments comprise an object of value such as a ring for example and an object that is redeemable for a prize of greater value. The object that is redeemable for a prize can comprise a token that may be exchanged for the prize. The object that is redeemable for a prize can display a prize identifier for identifying the prize, the type of prize, or the value of the prize. The prize identifier can comprise one or more characters. In some aspects, the object that is redeemable for a prize can be redeemable by submitting the prize identifier to a first party. The first party, in response to receiving the prize identifier, can provide the identified prize. In some aspects, the object that is redeemable for a prize can be redeemable by entering the prize identifier (for example a random code or numerical indicator) into a web page that transmits the prize identifier to the first party. The object that is redeemable for a prize can be redeemable by transmitting the prize identifier to the first party via a letter, an email, a text message, or a telephone call.
[0010] As used herein, the term “wax” refers to substances that can be used to form a candle body and which are consumed, usually as fuel, while the candle burns. Examples include, but are not limited to, animal fats or waxes, such as tallow, insect waxes, such as bee's wax, plant waxes and fats, such as soy-based products, and petroleum-based substances, such as paraffin.
[0011] As used herein, the term “wick” refers to any object which holds the flame of a candle. Examples include, but are not limited to, string, cord, wood, or other objects that draw the liquid fuel to the flame, usually via capillary action.
[0012] According to yet another aspect, the subject matter described herein includes a method for manufacturing a candle that contains an item whose presence, nature, and/or value is obscured from the buyer. The method includes attaching an item to the inside of a container, and filling the container with wax such that the wax obscures the nature or value of the item.
[0013] According to yet another aspect, the subject matter described herein includes another method for manufacturing a candle that contains an item whose presence, nature, or value is obscured from the buyer. The method includes adding a first amount of wax to a container or mold, allowing the first amount wax to harden sufficiently enough to support an item that is placed on the surface of the wax, placing the item on the surface of the wax; and adding into the container a second amount of wax at least sufficient to obscure the presence, nature, or value of the item.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Preferred embodiments of the subject matter described herein will now be explained with reference to the accompanying drawings, wherein like reference numerals represent like parts, of which:
[0015] FIG. 1 shows a method for making a candle that contains an item according to one embodiment of the subject matter described herein;
[0016] FIGS. 2A through 2D show the steps of a method for manufacturing a candle having an item embedded within according to an embodiment of the subject matter described herein; and
[0017] FIGS. 3A through 3C show the steps of an alternative method for manufacturing a candle having an item embedded within according to an embodiment of the subject matter described herein, in which the candle can be partially constructed and the item introduced or placed into the candle before construction of the candle is completed.
DETAILED DESCRIPTION
[0018] The subject matter described herein includes a candle having an embedded item within and methods for manufacturing and selling same. Example embedded items include, but are not limited to, jewelry, such as rings, earrings, and chains, precious or semiprecious stones, pearls, etc. Alternatively, or in addition, in some embodiments example embedded items include, but are not limited to, tokens or redeemable objects that can be redeemed in exchange for jewelry, such as rings, earrings, and chains, precious or semiprecious stones, pearls, etc. As an example, a method for manufacturing a candle having a ring embedded or token for a ring within is disclosed.
[0019] FIG. 1 shows a method for making a candle that contains an item according to one embodiment of the subject matter described herein. At step 100 , a first set of items, each having a first value, is created. For example, a set of rings, each ring worth $10, can be collected and optionally prepared for embedding within the finished product candles. At step 102 , a second set of items, each having a second value, is created. For example, a set of rings, each ring worth $100, can be collected and optionally prepared for use. Other sets of rings can be collected, each additional set having rings each worth another value, such as $1,000 per ring, $5,000 per ring, and so on. The values used above are for illustration only and are not limiting. All items in a set need not be the same. For example, a set of items can include different types of items, such as rings, earrings, pins, etc., but having the same or very similar relative value. Moreover, items in one set need not be the same as items in another set. For example, the first set of items could be rings and earrings while the second set of items could be bracelets and necklaces.
[0020] At step 104 , the sets of rings are combined. At step 106 , the combined set of items is distributed among a set of candles such that each candle includes one item from the combined set embedded within the candle. Optionally, in some embodiments, in step 108 the candles can be sold for a first price, where the value of the embedded item is not known to the purchaser at the time of purchase. In one embodiment, the value of the item cannot be determined by the purchaser of the candle until the candle has been burned or the wax melted to expose the item (or allow the item to be removed and unwrapped if the item has been encased in a pouch, bag, or protective wrapping.) In one embodiment, the purchaser knows that a candle might contain an embedded item but cannot determine at the time of purchase whether the candle does or does not contain the embedded item.
[0021] Referring again to FIG. 1 , in some embodiments at step 100 , a first set of items, each having a first value, is created. For example, a set of rings, each ring worth $ 10 , can be collected and optionally prepared for embedding within the finished product candles. Then, in some embodiments at step 102 , a second set of items, each having a second value, is created. For example, tokens, vouchers or redeemable objects (referred to collectively as redeemable objects) for a set of rings, each ring worth $100, can be collected and optionally prepared for use. Other sets tokens, vouchers or redeemable objects for rings can be collected, each additional set of tokens, vouchers or redeemable objects being redeemable for rings each worth another value, such as $1,000 per ring, $5,000 per ring, and so on. The values used above are for illustration only and are not limiting. All items, tokens, vouchers or redeemable objects in a set need not be the same. For example, a set of items can include different types of items, such as rings, earrings, pins, etc., but having the same or very similar relative value. Moreover, items or redeemable objects in one set need not be the same as items in another set. For example, the first set of items could be rings and earrings while the second set of items could be bracelets and necklaces, or redeemable objects for the same.
[0022] In some embodiments, at step 104 , the sets of rings and redeemable objects are combined. At step 106 , the combined set of items is distributed among a set of candles such that each candle includes one item from the combined set embedded within the candle. Thus, in some aspects a candle can have embedded therein an item from the first set of items, e.g. a ring, having a first value, or an item from the second set of items, e.g. a redeemable object for a ring of a second value. Alternatively, in some embodiments at step 106 the combined set of items is distributed among a set of candles such that each candle includes one item from the first set of items, e.g. a ring of a first value, and one item from the second set of items, e.g. a redeemable object for a ring of a second value.
[0023] Thus, in some embodiments, a candle can have a ring with a first value, or a ring with a second value, or a ring with a first value plus a redeemable object for a ring of a second value, or a ring with a second value plus a redeemable object for a ring of a first value. In some embodiments, a candle can have a ring of a first value, or a redeemable object that is redeemable for a ring of a second value. In some embodiments, the ring of the first value is a value less than the purchase price of the candle, and the redeemable object for a ring of a second value has a value greater than, in some instances significantly greater than, the purchase price of the candle. In some embodiments, a candle can have a redeemable object redeemable for a ring of a first value, or a redeemable object that is redeemable for a ring of a second value. In some embodiments, the ring of the first value is a value less than the purchase price of the candle, and the redeemable object for a ring of a second value has a value greater than, in some instances significantly greater than, the purchase price of the candle.
[0024] Optionally, in some embodiments, in step 108 the candles can be sold for a first price, where the value of the embedded item(s) is not known to the purchaser at the time of purchase. In one embodiment, the value of the item(s) cannot be determined by the purchaser of the candle until the candle has been burned or the wax melted to expose the item (or allow the item to be removed and unwrapped if the item has been encased in a pouch, bag, or protective wrapping.) In one embodiment, the purchaser knows that a candle might contain an embedded item, and/or a redeemable object that is redeemable for an item of value, but cannot determine at the time of purchase whether the candle does or does not contain the embedded item(s).
[0025] FIGS. 2A through 2D show the steps of manufacturing a candle having an item embedded within according to one embodiment of the subject matter described herein. In FIG. 2A , an enclosure or container 200 is provided. In one embodiment, enclosure or container 200 can be intended to contain the finished product, and can be made of glass, plastic, or other material, and can be transparent, translucent, opaque, or some combination. Alternatively, enclosure or container 200 may not be intended to contain the finished product, e.g., the container can be a mold that is used (and possibly reused) during manufacture and is not a part of the finished product.
[0026] An item 202 , such as a ring, jewelry, prize, redeemable object or other item, is placed into a pouch 204 or other item container. In FIG. 2B , adhesive 206 can in some embodiments be applied to the pouch 204 containing item 202 , and pouch 204 can be attached to the inside wall of candle enclosure or container 200 , such that the pouch is affixed to the inside of the candle container, as shown in FIG. 20 . Wax 208 can then be poured into candle enclosure or container 200 , covering the pouch 204 and obscuring the item 202 from view, resulting in the product shown in FIG. 2D . In one embodiment, a wick can be placed or affixed within container 200 prior to adding wax 208 . Alternatively, a wick can be inserted into wax 208 after it has been poured into enclosure or container 200 .
[0027] For example, in one embodiment, rings of different values are placed into small plastic bags, and in some embodiments each small plastic bag can be wrapped in gold foil or the like. Alternatively, in one embodiment, rings and/or redeemable objects of different values are placed into small plastic bags, and in some embodiments each small plastic bag can be wrapped in gold foil or the like. For each ring and/or redeemable object wrapped in plastic and gold foil, a small gold foil indicator is glued to the gold foil that contains the ring and bag. The small gold foil indicator is glued to the inside of the glass container, which allows the customer to see the location of the ring and/or redeemable object within the container. The small gold foil indicator is visible through the glass container. Wax is poured into the glass container and a wick is installed into the wet wax. In one embodiment, the wax is soy wax. The wax cools or is cooled, and labels are applied to the glass container and/or the wax. In one embodiment, the item can be affixed in more than one place to the container prior to filling the container with wax. In one embodiment, the process can include applying labels or decorations to the inside or outside of enclosure or container 200 prior to adding wax 208 . For example, the process can include applying a safety label to the bottom of a glass container that will contain the candle wax.
[0028] FIGS. 3A through 3D show the steps of an alternative method for manufacturing a candle having an item embedded within, in which the candle can be partially constructed and the item introduced or placed into the candle before construction of the candle is completed. In FIG. 3A , for example, a candle mold or container 300 can be partially filled with wax 302 A, which is allowed to harden until it is firm enough to support the item 304 (e.g. ring and/or redeemable object) in the desired location within the candle body. In FIG. 3B , item 304 is placed onto or into the firm wax 302 A at or near the desired location within the candle body, and in FIG. 3C , additional wax 302 B is placed into mold 300 . The amount of additional wax 302 B is sufficient to at least cover and obscure item 304 and can partially or completely fill container 300 . In one embodiment, a wick is then inserted into wax 302 A and 302 B. In an alternative embodiment, the wick is placed within container 300 prior to adding wax 302 A and/or wax 302 B.
[0029] The subject matter described herein also includes a candle with an item embedded within, such as are shown in FIGS. 2D and 30 . In one embodiment, the item can be a ring, other types of jewelry, other types of prizes, a redeemable object that is redeemable for jewelry or other object, or other item. In one embodiment, the candle is designed such that the existence, nature, or value of the embedded item and/or redeemable object cannot be determined without burning the candle or otherwise melting the wax so that the item is exposed to view.
[0030] In one embodiment, a purchaser or recipient is not aware at the time of purchase or receipt that the candle contains an embedded item at all. In one embodiment, the purchaser or recipient is aware at the time of purchase or receipt that the candle does contain an embedded item, but the candle is designed so that at the time of purchase or receipt, a purchaser or recipient of the candle does not know or cannot determine the general nature of the item, the exact nature of the item, the absolute value of the item, the price range of the item, the value of the redeemable object or the value of the object for which it can be redeemed, and/or the value of the item relative to the purchase price of the candle.
[0031] The candle can comprise wax within a shell or container, or wax not contained in a shell or container. The wax and/or container can be transparent, translucent, or opaque. For example, all or part of the container can be transparent allowing the wax to be seen, but the opacity of the wax prevents the buyer from determining the nature or value of the item embedded within. Alternatively, the wax can be translucent but the container is also translucent with the result that the nature or value of the item embedded within the wax is indiscernible. Alternatively, the nature or value of the item can be obscured by an opaque material (other than the wax of the candle) that surrounds or covers the item and where the item and the opaque covering are both embedded within the candle wax. In one embodiment, the wax and container can be transparent or translucent enough to see the item but the opaque material in which the item is wrapped obscures the nature or value of the item. In one embodiment, the item can be covered or wrapped with a material that prevents damage to the item from the heat of the candle flame as the candle wax is burned away to expose the item.
[0032] The subject matter described herein also includes a method for making a candle that contains an item such that the nature and/or value of the item is obscured from the buyer and/or recipient. In one embodiment, the value of the embedded item, or object redeemable for an item, can be less than the sale price of the candle, equal to the sale price of the candle, greater than the sale price of the candle, or much greater than the sale price of the candle. For example, a candle can be sold for $25 that contains within it a ring which can have a value of $10, $100, $1,000, or $5,000, or a redeemable object that can be redeemed for a ring which can have a value of $10, $100, $1,000, or $5,000.
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A candle with an embedded item and methods for manufacturing same are disclosed. A method for manufacturing a candle having an embedded item can include providing a first set of items of a first value and a second set of items of a second value different from the first value, combining the two sets to create a third set, and distributing the items of the third set among a set of candles, one item per candle, where the presence, nature, or value of the item within the candle is obscured. The method can further include selling the candles for a first price, wherein, the presence of the embedded item, the nature of the embedded item, the value of the embedded item, or the value of the embedded item relative to the first price is not known to the purchaser. The embedded item can comprise an object redeemable for a prize.
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BACKGROUND
[0001] 1. Field
[0002] Embodiments of the present invention relate to remote actuated pivoting clamp mechanisms suitable for application in hot rolling mills and more particularly to a clamp mechanism suitable for retaining split box structures, including split guides, that may be used in cooling system water box nozzle assemblies and equalization troughs.
[0003] 2. Description of the Prior Art
[0004] Steel bars and rods are produced by hot rolling steel billets in a continuous hot rolling process. During different steps of the rolling process the rolled products may require motion restraint, so that they follow a designated transport path, temperature equalization or quenching by application of cooling water. After the metal forming steps, the rolled products are conveyed along one or more lines running through sequential split box structures, also known as split guides, that are analogous to tunnels that direct them along desired paths. Water box cooling lines spray the hot rolled product surface with pressurized water. Nozzle assemblies include a plurality of annular-shaped nozzles that are retained within the split shell nozzle assembly boxes. The annular nozzles spray water on the hot metal that is transported through the nozzle annular interiors. Nozzle assemblies and their split shell boxes are sequentially arrayed along the cooling line and are of known construction. The nozzle assemblies are in communication with a pressurized water manifold, and must be held in fixed position to avoid water leaks and potential loss of cooling efficiency if insufficient flow and/or pressure are not maintained at each nozzle due to leaking water diversion. Temperature equalization troughs also transport hot metal rolled products via internal pathways within static guide split shell box structures, but do not apply a cooling fluid. Rather, equalization troughs reduce or minimize further temperature loss from the product surface, thereby allowing heat to “soak” out from the interior; i.e., “equalizing” the temperature between the interior and the exterior of the hot rolled product.
[0005] Conventionally, rolling mill line split guide structure water box nozzle assemblies and equalization troughs have been held in fixed position by screw-driven manual “C clamps”, such as shown in U.S. Pat. No. 5,257,511, the entire contents of which is incorporated herein by reference. In order to avoid nozzle leakage and potential loss of cooling efficiency, each individual C clamp is hand tightened by mill personnel to a torque specification. The hand tightening procedure is time consuming, as a cooling line may have hundreds of nozzle assemblies within a facility, and is subject to human error if torque is not in compliance with the specification.
[0006] An alternative to nozzle assembly retention by C clamps is disclosed in U.S. Patent Publication No. US 2010/0006188 A1, the entire contents of which are incorporated herein by reference. The Publication discloses use of a remote actuated pivoting clamp support that may be coupled to a plurality of nozzle assemblies for simultaneous clamping of a series of sequential nozzle assemblies along a cooling line. One long lateral side of the clamp support is pivotally engaged with the water box frame that retains the sequence of nozzle assemblies in an array. The other lateral side of the clamp support is linked to a pivoting shaft that is driven by an actuator. When the driven shaft pivots, the other lateral side of the clamp support may be swung from an open to a closed position. Rotating torque force must be maintained on the driven shaft in order to retain the nozzle assembly in the closed or “clamped” position, requiring constant energy consumption and wear and tear on the actuator and entire linkage assembly. The pivoting shaft and linkage does not maintain constant force on each serial nozzle assembly due to deflection variations along the shaft length. Thus a higher than otherwise needed constant force is applied to the shaft assembly by the actuator in order to assure that each individual nozzle assembly meets minimum clamping force specifications. In turn, a larger actuator and pivoting shaft is required to generate and transfer the higher force needed to assure clamping of each nozzle assembly within minimum specification. Larger actuators and shaft structures necessitate greater energy consumption during operation and use of additional material for construction strength. The angular linkage also stresses the water box frame as the actuator exerts clamping force on the nozzle assembly. Therefore, water box frame rigidity needs to be increased in order to counteract the linkage stress, also increasing material consumption during manufacture.
SUMMARY
[0007] Briefly described, embodiments of the present invention relate to the creation of a clamping mechanism that can be remotely actuated, for example without the necessity of hand tightening, and is suitable for application to rolling mills, including their temperature equalization troughs and water box nozzle assemblies.
[0008] Another embodiment of the invention relates to a water box nozzle assembly clamping mechanism that remotely actuates a plurality of nozzle assemblies arrayed along a cooling line in parallel, under manual user or automated system control.
[0009] An additional embodiment of the present invention relates to a temperature equalization trough split guide assembly clamping mechanism that remotely actuates a plurality of split guides arrayed in a cooling line in parallel, under manual user or automated system control.
[0010] Yet another embodiment of the present invention relates to a nozzle assembly clamping mechanism that remotely locks a nozzle assembly in a clamped position and thereafter does not require or reduces requirement for external actuator force to maintain the nozzle assembly in the clamped position. Additionally, it is desirable that the clamping mechanism remotely unlocks itself when it is desired to release the nozzle assembly unit from the water box assembly frame.
[0011] Another embodiment of the present invention relates to a nozzle assembly clamping mechanism that does not stress the water box frame while applying and/or maintaining nozzle assembly clamping force.
[0012] These and other embodiments are achieved in accordance with the present by a remote actuated clamping mechanism for objects to be clamped in hot rolling mills, including for rolled product motion restraint split guide, equalization trough and cooling system water box nozzle assembly retention. The clamping mechanism includes a central pivoting elongated clamp member having an engagement surface proximal one end that engages the split box nozzle assembly, equalization trough, split guide or other clamped object and a link pivot proximal the other end. The clamp member is pivotally coupled to a structural member that is independent of the water box or equalization trough frame. A pivoting link has a first end pivotally coupled to the clamp member link pivot and a second end that is pivotally coupled to an actuator shaft. The actuator shaft is capable of translation to a locked position that maintains engagement between the clamp member and the clamped object, such as for example a split box nozzle assembly, wherein the link blocks clamp member motion. Actuation force does not have to be maintained on the actuation shaft when the clamp member is in the locked position. The actuator shaft is also capable of translation to an unlocked position that enables clamp member pivoting motion out of engagement with the nozzle assembly or other clamped object. The actuator shaft may be translated by an actuator that is controlled by a factory automation system.
[0013] Aspects of the present invention feature a remote actuated pivoting clamp mechanism that includes a structural member having sequentially arrayed thereon a plurality of opposed pairs of pivot points respectively sharing a collinear first pivot axis. A plurality of pairs of elongated clamp members corresponds to each pair of structural member pivot points. Each clamp member has an engagement surface proximal one end, a link pivot proximal the other end, and a central pivot intermediate the ends that is pivotally coupled to a respective one of the structural member pivot points about the first axis. The mechanism also has a plurality of pivoting links respectively corresponding to each pair of clamp members, with each link having a first end pivotally coupled to both of the clamp member pair respective link pivots about a second collinear axis parallel to the first axis, and a second end. An actuator shaft is pivotally coupled to each of the respective link second ends about a third axis parallel to the first axis at each respective pair of opposed pivot points. The shaft is capable of toggled translation of all pivoting links to a locked position wherein each respective pair of the first and third axes are proximal each other and the link blocks clamp member motion. The shaft is also translatable to an unlocked position that enables pivoting motion of each clamp member about its respective first axis.
[0014] Aspects of the present invention also feature a remote actuated pivoting clamp mechanism for clamping hot rolling mill guide split boxes. The mechanism features a plurality of sequentially arrayed split boxes, each having opposed halves defining a path there through and a first engagement surface on at least one of the halves. A structural member has aligned with each respective split box a plurality of opposed pairs of pivot points respectively sharing a collinear first pivot axis. Each pivot pair corresponding to a split box is sequentially arrayed on the structural member. A plurality of pairs of elongated clamp members corresponds to each pair of structural member pivot points. Each clamp member has an engagement surface proximal one end for mating engagement with a corresponding first engagement surface, a link pivot proximal the other end, and a central pivot intermediate the ends that is pivotally coupled to a respective one of the structural member pivot points about the first axis. A plurality of pivoting links respectively corresponds to each pair of clamp members. Each link has a first end pivotally coupled to both of the clamp member pair respective link pivots about a second collinear axis parallel to the first axis, and a second end. An actuator shaft is pivotally coupled to each of the respective link second ends about a third axis parallel to the first axis at each respective pair of opposed pivot points. The shaft is capable of toggled translation of all respective pivoting links to a locked position wherein each respective pair of first and third axes are proximal each other. Each link blocks its respective clamp member motion and maintains mating engagement between each respective pair of first and clamp member engagement surfaces. The shaft is also capable of translation of all respective pivoting links to an unlocked position that enables clamp member pivoting motion about its respective first axis and disengagement of each mating pair of first and clamp member engagement surfaces.
[0015] Aspects of the present invention additionally feature a method for remotely actuating a pivoting clamp mechanism for clamping hot rolling mill cooling line split boxes. The clamp mechanism used to perform the method has a plurality of sequentially arrayed split boxes, each having opposed halves defining a path there through and a first engagement surface on at least one of the halves. A structural member has aligned with each respective split box a plurality of sequentially arrayed opposed pairs of pivot points respectively sharing a collinear first pivot axis. A plurality of pairs of elongated clamp members corresponds to each pair of structural member pivot points. Each clamp member has an engagement surface proximal one end for mating engagement with a corresponding first engagement surface, a link pivot proximal the other end, and a central pivot intermediate the ends that is pivotally coupled to a respective one of the structural member pivot points about the first axis. A plurality of pivoting links respectively corresponds to each pair of clamp members. Each link has a first end pivotally coupled to both of the clamp member pair respective link pivots about a second collinear axis parallel to the first axis, and a second end. An actuator shaft is pivotally coupled to each of the respective link second ends about a third axis parallel to the first axis at each respective pair of opposed pivot points. The shaft is capable of toggled translation of all respective pivoting links to a locked position wherein each respective pair of first and third axes are proximal each other. In the locked position each link blocks its corresponding respective clamp member motion and maintains mating engagement between each respective pair of first and clamp member engagement surfaces. The shaft is also capable of translation of all respective pivoting links to an unlocked position that enables clamp member pivoting motion about its respective first axis and disengagement of each mating pair of first and clamp member engagement surfaces. An actuator for translating the actuation shaft is coupled thereto. A control system, in communication with the actuator, includes a controller having a processor and memory accessible by the processor. The memory includes therein software that when executed by the processor selectively causes the actuator to translate the actuation shaft. The control system also has an interface coupled to the controller, for issuing commands to translate the actuation shaft. The clamping method is performed by issuing an actuator shaft translation command to the control system with the interface. After receipt of the translation command the processor executes actuator translation software, causing the actuator to translate the actuation shaft to the locked or unlocked positions.
[0016] The objects and features of the present invention may be applied jointly or severally in any combination or sub-combination by those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The teachings of aspects of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
[0018] FIG. 1 is an elevational perspective view of a hot rolling mill with a nozzle assembly clamping mechanism, in accordance with an exemplary embodiment of the present invention;
[0019] FIG. 2 is bottom plan perspective view of FIG. 1 , in accordance with an exemplary embodiment of the present invention;
[0020] FIG. 3 is a cross-sectional view taken along line 3 - 3 of FIG. 1 , in accordance with an exemplary embodiment of the present invention;
[0021] FIG. 4 is a perspective view of a load transfer assembly including a spring assembly, in accordance with an exemplary embodiment of the present invention;
[0022] FIG. 5 is a cross-sectional view taken along line 5 - 5 of FIG. 4 , in accordance with an exemplary embodiment of the present invention;
[0023] FIG. 6 is an elevational view showing the clamping mechanism in a locked position, in accordance with an exemplary embodiment of the present invention;
[0024] FIG. 7 is an elevational view showing the clamping mechanism in an unlocked position, in accordance with an exemplary embodiment of the present invention;
[0025] FIG. 8 is an elevational view showing the clamping mechanism in an unlocked position that facilitates removal of a nozzle assembly, in accordance with an exemplary embodiment of the present invention;
[0026] FIG. 9 is an elevational view showing the clamping mechanism in an unlocked position, with the clamp member shown in partial broken-away section, in accordance with an exemplary embodiment of the present invention;
[0027] FIG. 10 is a schematic diagram of the remote actuation clamping mechanism actuated by an actuator that is controlled within an automated system, in accordance with an exemplary embodiment of the present invention;
[0028] FIG. 11 is an alternative embodiment clamping mechanism with an adjustable length pivoting link, in accordance with an exemplary embodiment of the present invention;
[0029] FIG. 12 is another alternative embodiment clamping mechanism with a constant force, adjustable length pivoting link, in accordance with an exemplary embodiment of the present invention; and
[0030] FIG. 13 is another alternative embodiment clamping mechanism for a temperature equalization trough assembly guide.
[0031] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
[0032] After considering the following description, those skilled in the art will clearly realize that the teachings of my invention can be readily utilized in remote actuated pivoting clamp mechanisms suitable for application in hot rolling mills and more particularly to a clamp mechanism suitable for retaining cooling system nozzle assemblies, as well as other objects to be clamped in a rolling mill, including by way of further example split guides and those used for temperature equalization troughs. Exemplary embodiments of the present invention that are described herein facilitate parallel remote actuation of a plurality of clamp mechanisms that are dedicated to different objects, such as split box static guides, equalization troughs or nozzle assemblies serially arrayed along a hot rolling mill cooling system. Remote actuation can be accomplished under manual or automatic control.
[0033] Hot Rolling Mill Cooling System Overview
[0034] Referring to FIGS. 1-3 , hot rolled material is sequentially fed through the rolling mill cooling system 20 along path P. The cooling system 20 has a cooling header 30 that provides cooling water to the nozzle assemblies 40 . As shown in the figures, a plurality of nozzle assemblies are sequentially aligned in parallel along the cooling path P. Each nozzle assembly 40 has an upper half 42 and lower half 44 , each half retaining sleeve-like annular nozzles 46 . The rolled material passes through the annular nozzle 46 sleeves interior portions 48 that are respectively aligned along the cooling path P. The nozzle assemblies 40 are of known construction.
[0035] The cooling system 20 has a structural member 50 , including a pair of opposed clamping member trunnions 52 that can have a common axial alignment axis. In some embodiments, the structural member 50 can be structurally isolated and independent from the cooling header 30 and nozzle assemblies 40 .
[0036] Clamping Mechanism Structure
[0037] Referring to FIGS. 1-3 , the clamping mechanism 58 includes clamp member 60 that has a central pivot 62 that is pivotally coupled to the clamping member trunnion 52 . Alternatively, one may choose to configure the clamping mechanism so that the trunnion is formed in the clamp member 60 and the central pivot is formed in the structural member 50 . Clamp member 60 also defines an engagement surface 64 on one end and a link pivot aperture 66 for pivotal receipt of link pivot pin 68 on the other end. As shown in FIGS. 1-3 , the clamping mechanism 58 has a pair of laterally aligned clamp members having a common central pivot axis through respective central pivots 62 . The pair of clamp members 60 provides for a uniform application of clamping force on both sides of the nozzle assembly 40 .
[0038] Pivoting link 70 is pivotally coupled to the clamp member 60 by the link pivot pin 68 that passes through the link first end aperture 72 . The second end of the pivoting link opposite the first end 72 can define a second end aperture 74 . As shown most clearly in FIGS. 2 and 3 , the pivoting link 70 has a pair of yoke arms 76 , each defining a second aperture 74 , for more generally uniform structural support to both of the clamp members 60 .
[0039] The clamping mechanism 58 also has an actuator shaft 80 defining a plurality of actuator shaft apertures 82 , each pivotally coupled to the second end of a corresponding pivoting link 70 by an actuator shaft pin 84 captured within an actuator shaft aperture 82 and pivoting link second end aperture 74 . The actuator shaft 80 is captured within actuator shaft supports 54 that are coupled to the structural member 50 . As will be explained in greater detail herein when describing operation of the clamping mechanism 58 , the actuator can translate in both directions of the double arrow F A .
[0040] As shown in FIGS. 1 and 3 , load transfer assembly 90 includes a housing 91 having therein a load transfer frame 92 with a pair of opposed load transfer frame first engagement surfaces (trunnions 94 ) that engage with a clamp member engagement surface 64 on each of the clamp members 60 . As shown, the transfer frame trunnions 94 can share a common axis. The corresponding abutting and mating engagement surfaces 64 on the clamp member 60 and 94 on the load transfer assembly 90 may be of many desired profiles, and may be reversed. For example and not limitation, the engagement surface 64 may have a trunnion profile and the load transfer frame first engagement surfaces 94 may have a corresponding concave profile.
[0041] The exemplary load transfer assembly 90 in FIGS. 3-5 comprises a pair of disc or cupped springs 96 and shim stacks 98 . The biasing element springs 96 help to distribute equalized compressive force to the nozzle assembly 40 top surface upstream and downstream the trunnions 94 , for pressurized water sealing along the lateral joining surface between the upper nozzle assembly 42 and lower nozzle assembly 44 halves, as well as the lower half 44 to the cooling header 30 . The springs 96 also help equalize load transferred to each of tandem paired clamp members 60 that flank each nozzle assembly 40 to the left and right of the cooling path P. Shim stacks 98 can be varied to raise or lower the load transfer engagement surface trunnion 94 relative to the clamp member engagement surface 64 , thereby increasing or decreasing the load applied to the respective nozzle assembly.
[0042] Clamping Mechanism Operation
[0043] FIGS. 6-9 show general operation of the clamping mechanism 58 . In FIG. 6 , when the actuator shaft 80 is translated in the direction of the F A force arrow, pivoting link 70 is toggled to a locked (here vertical) position, with the actuator pin rotation axis parallel to and proximal the central pivot axis through the structural member trunnion 52 . In the locked position the pivoting link 70 applies a force on the clamping mechanism link pivot aperture 66 via the link pivot pin 68 in the direction of the force arrow F L . The elongated link pivot aperture 66 allows vertical movement of the clamp member 60 as the link 70 is toggled to the locked position, so that the clamp member engagement surface 64 is maintained in biased, abutting relationship with the load transfer assembly first engagement surface trunnion 94 . The clamp member central pivot 62 can be constructed without an elongated profile, and the profile can be non-linear to impart a camming motion.
[0044] When the pivoting link 70 is toggled to the locked position it may be constructed to be self locking, so that little or no force is maintained on the actuator shaft. While the pivoting link 70 is shown in FIG. 6 to be generally vertical and parallel to the clamp member 60 long axis, it can also be constructed to toggle over center (i.e., further counter clockwise) when in the locked position, such as by changing the center pivot 62 elongation profile.
[0045] The locked clamping mechanism 58 clamping force F L is resisted in the opposite direction by the structural member 50 actuator shaft supports 54 . The structural member 50 is structurally isolated from and does not pass the clamping force F A to the cooling header 30 or nozzle assembly 40 structures. The clamping force F L is transferred vertically through the load transfer assembly 90 , beneficially compressing the nozzle assembly 40 against the cooling header 30 without bending or twisting distortion.
[0046] Clamp mechanism can be released to an unlocked position as shown in FIGS. 6-9 by applying actuation force F A to the actuator shaft in the direction shown, so that the pivoting link 70 is no longer toggled with the actuator pin 84 proximal the clamp member central pivot 62 . If desired, a clamp lock, such as the toggle clamp 69 shown in FIG. 3 , may be provided to prevent inadvertent or unintentional displacement of the clamping mechanism 58 from its vertical unlocked position when the clamp mechanism 58 is unlocked and the opposed engagement surfaces 64 / 94 are not in contact with each other. In FIG. 8 , the clamp member 60 is tilted counterclockwise to enable service technician access to the nozzle assembly 40 , by sliding the trunnion 52 within the central pivot elongated slot 62 .
[0047] Automated Clamping Operation
[0048] The clamping mechanism 58 advantageously may be employed to clamp a sequence of nozzle assemblies 40 that are arrayed along a cooling system 20 cooling path P by pivotally coupling in parallel a series of respective pivoting links 70 to a common actuation shaft 80 , as is shown in FIGS. 1 and 2 . A single actuator, such as a pneumatic or hydraulic fluid driven cylinder or a gear driven motor, may translate the shaft. In this manner a plurality of clamping mechanisms 58 may be actuated simultaneously by a single actuator operation.
[0049] The clamping mechanism is suited for automated clamping and unclamping operations for rolling mill cooling systems 20 , such as by the exemplary factory automation system 100 schematically shown in FIG. 10 . The automated clamping system 100 includes a communications data bus of known architectural and communications design, such as one employing PROFIBUS® data communications protocols provided by Siemens Industry Solutions of Alpharetta, Ga., U.S.A. A controller 110 , such as a programmable logic controller (PLC) is in communication with one or more actuators 88 . The PLC 110 is of known design, such as a Siemens model S7 PLC also sold by Siemens Industry Solutions of Alpharetta, Ga., U.S.A. PLC 110 includes a processor 112 that accesses one or more computer memory devices 114 , in which are stored software instruction sets 116 that when executed by the processor causes it to operate the automation system 100 .
[0050] The processor 112 executing the software instruction sets 116 cause one or more actuators 88 to exert an actuation force F A a respectively coupled actuation shaft 80 , that in turn locks or unlocks the clamping mechanisms 58 . Two separate banks of clamping mechanisms 58 and actuators 88 are shown in FIG. 10 respectively on the left and right sides of the sheet. The PLC 110 causes one or more of the actuators 88 to exert actuation force on its actuator shaft 80 as part of an operational programming sequence within its accessible software 116 , or in response to commands received from engineering station 120 or any other human machine interface (HMI) 130 . For example, a service technician may initiate a command to the automation system through the HMI 130 to open one or more of the clamping mechanism banks 60 . The automation system 100 may include one or more types of sensors 140 to communicate rolling mill cooling system 20 operational parameters to the PLC 110 , such as by way of non-limiting example proximity sensors indicating whether one or more clamps are in locked or unlocked position, cooling water pressure or temperature, etc. PLC 110 may also be in communication with one or more other industrial automation controllers as part of an industrial automation network, such as controller 150 .
[0051] Clamping Mechanism Alternative Embodiments
[0052] FIGS. 11 and 12 show alternative pivoting link embodiments, for varying spacing between the clamping member 60 engagement surface 64 and the load transfer assembly first engagement surface trunnion 94 . In FIG. 11 the pivoting link 70 ′ defines a first end with aperture 72 ′and a second end with aperture 74 ′. Changing distance between the respective apertures 72 ′, 74 ′ by advancing or withdrawing the threaded shaft 77 ′ within the female threaded portion 77 ′ alters spacing between the engagement surfaces 64 , 94 . In FIG. 12 , the pivoting link 70 ″ defines a first end with aperture 72 ″ and a second end with aperture 74 ″. Helical coil spring 76 ″ is captured by threaded shaft 77 ″ and mating nut 79 ″. The coil spring 76 ″ provides for constant clamping force between the engagement surfaces 64 , 94 . Changing distance between the respective apertures 72 ″, 74 ″ by advancing or withdrawing the threaded shaft 77 ″ alters spacing between the engagement surfaces 64 , 94 .
[0053] As previously noted, the clamping mechanism may be applied in other assemblies within a rolling mill that require remote clamping in locked positions of one or more objects under common linear actuator control. In FIG. 13 the clamping mechanism 58 is used to apply clamping force to a thermal equalization line 20 ′ series of thermal equalization troughs 40 ′ having split box upper and lower halves 42 ′, 44 ′.
[0054] Although various embodiments which incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.
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Rolling mill split box guide nozzle and equalization trough assemblies are retained by a remote actuated clamping mechanism that includes a central pivoting elongated clamp member having an engagement surface proximal one end that engages the clamped object, and a link pivot proximal the other end. A pivoting link has a first end pivotally coupled to the clamp member link pivot and a second end that is pivotally coupled to an actuator shaft. The actuator shaft is capable of translation to a locked position that maintains engagement between the clamp member and the clamped split box nozzle assembly or equalization trough object, wherein the link blocks clamp member motion. The actuator shaft is also capable of translation to an unlocked position that enables clamp member pivoting motion out of engagement with the clamped object. The actuator shaft may be translated by an actuator controlled by a factory automation system.
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BACKGROUND OF THE INVENTION
This invention relates to a Christmas tree stand.
For supporting Christmas trees, stands are known which have a rigid frame into which the tree trunk is inserted and which include screws for clamping the trunk to the stand to form therewith a rigid unit. Such Christmas tree stands are available in a great number of varieties. For eliminating the screws, U.S. Pat. No. 1,732,284 discloses a Christmas tree stand having a rigid, bent sheet metal frame which includes an upper rigid ring for surrounding the tree trunk and several, freely suspended flat springs mounted on the ring in such an orientation that they are deformed outwardly by the inserted trunk. The springs, however, are too short for holding and centering trunks of irregular shape and different diameters. A Christmas tree stand of this structure thus has proved to be impractical.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved Christmas tree stand which, despite its relatively small structural dimensions, is capable of receiving trunks of different diameters and is adapted to center the trees even if the trunk has an irregular outer surface.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the tree stand comprises a rigid base; a plurality of resilient bars each having a bend and a first portion extending substantially vertically downwardly from the bend and terminating in a free end. The first bar portions are arranged in a circular array and together define a generally cylindrical shaft for receiving the trunk of a tree and holding the same by a resilient clamping force. Each resilient bar further has a second portion extending from the respective bend obliquely downwardly and away from the shaft and is affixed to the base.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional elevational view of a preferred embodiment of the invention.
FIG. 1a is a sectional view of a component of a variant of the same embodiment.
FIG. 2 is a top plan view of the same embodiment.
FIG. 3 is a top plan view of another preferred embodiment of the invention.
FIG. 3a is a top plan view of a further preferred embodiment.
FIG. 4 is a sectional elevational view of the embodiment shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to FIGS. 1 and 2, the Christmas tree stand shown therein comprises a plurality of bent bars 1 which are made of a resilient material such as round or flat steel and which are arranged in a circular array. The bars 1 have a vertically orientated free end portion which together form a generally vertically oriented, cylindrical shaft 2 for concentrically surrounding the inserted Christmas tree trunk (not shown). At their other end, the bars 1 are affixed to a rigid base 3. Thus, as viewed from their lower free end, the bars 1 extend upwardly in a vertical orientation, then, after a bend at the top, extend obliquely downwardly to the base 3.
The circumferentially arranged vertical end portions of the bars 1 can be spread radially outwardly, so that the shaft 2 can be adapted to the thickness of the particular tree trunk to be supported. The larger the diameter of the trunk, the greater the pressure exerted by the bars on the trunk. This pressure is derived from the resilient force urging the bars 1 back into their normal position. In order to prevent the trunk from moving laterally in the lower zone of the shaft 2, the base 3 carries a vertically upwardly oriented spike 4 which is aligned with the axis of the shaft 2 and which penetrates into the end face of the inserted trunk and thus ensures that the tree and the stand form a rigid unit. The clamping force of the bars 1 is enhanced by reinforcements 5 which are provided at the upper and/or lower bends of the bars 1. There are further provided adjusting devices 6 at the outside of the base 3 for a subsequent setting of the vertical position of the supported tree. The vertical end portions of the bars 1 which define the shaft 2 are provided with handles 7 to facilitate a manual radial spreading of the shaft 2 during the insertion or removal of the tree.
The spring force exerted by the Christmas tree stand described above is not generated solely by the spring effect of the vertically oriented free end portions of the bars 2. Rather, the bar portions leading to the base 3 contribute significantly to the spring force and thus make possible an adaptation of the shaft width to varying trunk diameters, while the structural height of the stand can be maintained relatively small. Also, the obliquely extending parts of the bars 1 form such an angle with the inserted trunk that in case of a tendency to topple, the force exerted by the trunk on the obliquely extending parts of the bars 1 lies in the direction of these bar parts and thus spreads the shaft portions to a lesser extent than what would correspond to the absolute value of the force exerted by the trunk. Upon insertion or removal of the trunk, the obliquely extending bar portions are bent outwardly. In case the trunk is not yet inserted into the shaft, such an outward bending causes the vertically oriented end portions of the bars 1 to move into that zone of the shaft 2 which is subsequently occupied by the trunk. These parts of the shaft 2 have to be separately bent outwardly when the trunk is inserted into the stand. As a result, the spring forces have an effect both in the upper and in the lower zones of the shaft. This effect is further enhanced by the reinforcements 5 at the bends of the bars.
It is particularly well seen in FIG. 2 how the plurality of bars 1 are assembled to define the shaft 2 which may be formed of two or more parts. In FIG. 2 there is illustrated a four-part design; the vertically oriented end portions of the bars 1 are interconnected in pairs by means of the handles 7. This arrangement ensures that the trunk is prevented from slipping through the clearance between two bars.
For stability, the base 3 has a dish-shaped design. By forming the base as a watertight pot 3a, a watering of the tree in the stand is feasible. The vertically oriented parts of the bars 1 forming the shaft 2 terminate with a clearance above the bottom of the pot 3a. According to a modification of the stand, the water pot 3a alone constitutes the base 3. In such a case, the components of the stand are secured to the outer wall of the water pot 3a which then at the same time constitutes the outer edge of the clamping system. The adjusting devices 6 then may be mounted on the lower edge of the pot.
The bars 1 may be made of round steel as shown in FIG. 1 or sheet metal as illustrated in FIG. 1a where the bar shown is designated at 1a. In the latter case the reinforcements 5 may be constitued by embossments provided in the bars at the bends.
In the case of round steel the reinforcements 5 may be constituted by webs as shown in FIGS. 1 and 2, or by flattening the upper and/or lower bends of bars 1 in a vertical direction. In order to maintain the height of the stand at a minimum without thereby adversely affecting its supporting stability, it may be of advantage to bend the bars 1 at the bottom side of the pot 3a so as to form radially outwardly directed horizontal bar ends 12. On the latter, as illustrated in FIG. 3a sleeves 11 may be inserted, the length of which corresponds to the desired supporting stability. One of such sleeves is shown in section in FIG. 3a. In case a rectangular shipping box is used for the stands, the radially outwardly extending bar ends may be of such a length that they project to the otherwise unutilized corners of the shipping box. The adjusting devices may be arranged either on the water pot as described above or they may be arranged at the ends of the insertable sleeves.
FIG. 4 is an elevational view of the Christmas tree stand described in connection with FIG. 3. In FIG. 4 there is shown in phantom lines the position of a bar 1 that had been pulled outwardly for enlarging the shaft 2. The vertically downwardly oriented bar portions of two adjoining bars 1 are connected to one another at their lower ends 13. In this manner, two adjoining bars 1 may be constituted of a one-piece bent member. Handles 7 may be provided additionally on the bars 1, but in this embodiment they need not serve as connecting components. The bar ends 13 are located with a clearance above the bottom of the pot 3a.
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 tree stand comprises a rigid base; a plurality of resilient bars each having a bend and a first portion extending substantially vertically downwardly from the bend and terminating in a free end. The first bar portions are arranged in a circular array and together define a generally cylindrical shaft for receiving the trunk of a tree and holding the same by a resilient clamping force. Each resilient bar further has a second portion extending from the respective bend obliquely downwardly and away from the shaft and is affixed to the base.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the lighting fixture art and more particularly to a cover plate arrangement adapted to both convert a recessed down light into a structure for mounting a dependent lighting fixture or provide a mounting for a new installation of a dependent or external lighting fixture.
2. Description of the Prior Art
Recessed down lights have been utilized in home, commercial and industrial applications for many years for directing a light beam through a hole in the ceiling to the area therebelow. The prior art recessed down lights included structure mounted above the plane of the lower surface of the ceiling and included various can type devices for retention of the light bulb, mounting structure for the can type device and a trim plate or rim surrounding the hole in the ceiling and through which the light bulb could be accessed for replacement. The holes in the ceiling to accommodate the down lights were substantially standardized as to the diameter thereof in order to match the size for conventional three inch, four inch, five inch and six inch size down lights. However, there have been many variations in the structure utilized for retention of the rims or other components in the down light assembly. In general, there have been two primary types of retention arrangements in the down lights. One of the prior art retention arrangements has been for the rim structure to have a plurality, usually three, upstanding, equally spaced, spring loaded hook type mounting fingers which project upwardly into the region above the ceiling for hooking engagement with an appropriate rim or other structure in the down light assembly. A second primary type mounting arrangement was to provide an inverted “C” shaped slot on the interior portion of the rim structure into which conventional “chicken leg” torsion spring wire retention devices were installed for engagement with a appropriate structure in the mounting arrangement above the ceiling level.
Another type of retention arrangement has been to retain a reflector and such structure has three equally spaced, punched out tongue or similar devices which engage a cooperative structure on the reflector for retention thereof.
In many applications it has been desired to change the down lights to a pendalier or other type of lighting fixture which is mounted below the plane of the lower surface of the ceiling. However, to accomplish such a replacement, a cover plate is required to cover the hole in the ceiling previously utilized in connection with the down light. One type of cover plate that has heretofore been utilized in some applications has been wherein there was provided a bridging structure such as a bar or other device having two spaced apart threaded apertures bridging the hole in the ceiling utilized by the down light. For such applications the cover plate had a pair of apertures therethrough in a spaced apart relationship and screws were inserted in the aperture to threadingly engage the matching threaded apertures in the bridging structure. Such a cover plate had the unsightly screw heads visible at the exterior surface of the cover plate and such cover plate did not have the structural elements necessary for attaching a new dependent or external lighting fixture. While such a cover plate did, in fact, cover the hole in the ceiling, the presence of screw heads detracted from the appearance of the cover plate. Further, if no nut type devices were appropriately positioned in the down light assembly for cooperative engagement with the screws inserted through the cover plate, such bridging structure over the hole in the ceiling had to be specially installed. In order to minimize cost, the cover plate for covering a hole in the ceiling of a down light when converting the down light to a pendalier or other type of externally mounted light fixture, it is desired that the cover plate be readily mountable in any type of the mounting arrangements heretofore utilized in mounting, for example, the rim of the down light. Additionally, the same type of cover plate should also be capable of utilization in new installations of pendalier or other externally mounted lighting fixtures particularly where the new lighting fixture was to be installed in a pattern where some, or most, of the pattern was previously comprised of down lights that were converted to an externally mounted lighting fixture.
Thus, there has long been a need for a cover plate to be utilized in both the conversion of down lights to externally mounted light fixtures and adaptable for installation and mounting in any of the three common mounting arrangements utilized in down lights as well as useful in mounting new externally mounted lighting fixtures.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a cover plate that may be conveniently utilized to cover the hole in the ceiling of a recessed down light after removal of the rim structure thereof.
It is another object of the present invention to provided a cover plate that may be utilized in retrofitting down light fixtures to a surface mounted external lighting fixture.
It is another object of the present invention to provide as cover plate that is readily attachable to a variety of mounting assemblies in existing recessed lighting fixtures.
It is yet another object of the present invention to provide as cover plate that is readily attachable to a variety of mounting assemblies in existing recessed lighting fixtures as well as useable in new installations of surface mounted external lighting fixtures.
It is a further object of the present invention to provide as cover plate that is readily attachable to a variety of mounting assemblies in existing recessed lighting fixtures as well as useable in new installations of surface mounted external lighting fixtures that is economical to manufacture and decorative when utilized.
The above, and other objects of the present invention are achieved, according to a preferred embodiment thereof, by providing a base plate of an appropriate diameter and having a central axis to cover the hole in the ceiling of an existing recessed down light which is to be converted to a pendalier light or other external light fixture. The base plate has an exterior or outer surface and an interior or inner surface and a preselected thickness therebetween. The size of the base plate is selected to cover at least the hole in the ceiling and may be greater than such hole as desired in some applications. The base plate has a peripheral edge extending therearound and there may be provided an outer rim around the peripheral edge and may extend inwardly from the inner surface any desired amount. If the rim is so utilized, the height of the rim may be selected to give the appearance of any desired thickness of the base plate when the cover plate is installed thereby to reduce the cost of providing an entire cover plate of the apparent thickness provided by the appearance formed by the rim. The inner edge of the outer rim abuts the lower surface of the ceiling surrounding the hole therein provided for the recessed down light.
An inner mounting plate which may be an “L” shaped plate in cross section has the a bottom or leg portion of the “L” coupled to the inner surface of the base plate and the upright portion of the “L” extending inwardly from the inner surface of the base plate. The leg portion of the inner mounting plate, in this preferred embodiment of the present invention, may have an outer peripheral edge spaced from the inner surface of the outer rim to define a shoulder portion therebetween. The diameter of the upright portion of the “L” of the inner mounting plate is selected to match the diameter of the inner interconnection structure of the recessed down light in order to allow convenient installation of the cover plate thereon. The interconnection portion of the recessed down light provided the necessary mounting assembly which allowed interconnection of the trim rim utilized to surround the hole in the ceiling through which the light from the recessed down light is directed to the area therebelow.
A plurality of mounting members are provided on the upright portion of the “L” of the inner mounting plate. A first portion of the plurality of mounting members may be hook type mounting members coupled to the inner mounting plate extending inwardly from the inner surface of the base plate. In the preferred embodiment of the present invention, it is desired to utilize five of the hook type mounting members. However, the number of hook type mounting members may be greater or less than five depending on the requirements of particular installations. A second portion of the mounting members may be slot mounting members in the form of an inverted “C” shaped slot. The inverted “C” shaped slot is adapted to receive the conventional “chicken leg” torsion spring wire retention devices.
A nipple accepting aperture is provided extending through the base plate and aligned with a central axis. An annular nipple of conventional design with a central passageway and external threads and preferably with wrench flats thereon is inserted into the nipple accepting aperture and has an inner portion extending inwardly from the inner surface of the base plate and an outer portion extending outwardly from the outer surface of the base plate. The outer portion of the nipple allows threading engagement with the desired external light fixture replacing the recessed down light. In this preferred embodiment of the present invention the base plate is free of any other apertures therethrough.
In use, to replace an existing recessed down light, the trim rim of the down light is removed and the bulb mounting structure thereof is also removed. The electrical conducting wires providing the electrical connection for a light bulb from the down light assembly are directed downwardly and extend through the central aperture of the nipple to regions external the base plate. The desired external light fixture may be threadingly connected to the external portion of the nipple and the electrical conducting wires appropriately connected thereto. The cover plate is then inserted over the hole in the ceiling and one or both of the two types of mounting members, the hook type mounting members and/or the “chicken leg” torsion spring devices engage the corresponding mounting structure in the recessed down light assembly.
The cover plate of the preferred embodiment of the present invention may also be utilized in new construction wherein an external lighting fixture is desired. Such applications often occur where a plurality of recessed down lights in a particular pattern or array are replaced with the cover plate of the present invention having the desired external light fixture mounted thereon and additional lighting fixtures are desired. The cover plate of the present invention in such embodiments provides a matching appearance to the new pattern or array of lighting fixtures. Alternatively, in new installations of external lighting fixtures, the cover plate of the present invention with the desired external lighting fixture thereon may be installed after installation of the required internal mounting assembly above the ceiling. As is well known in the prior art, the mounting assemblies of recessed down lights or other ceiling mounted light fixtures must, from safety considerations, be of a configuration that meets the many regulations defined by the various building codes, or other rules and regulations, in the geographical area of the installation. The cover plate of the present invention is compatible for installation in all such mounting assemblies.
BRIEF DESCRIPTION OF THE DRAWING
The above and other embodiments of the present invention may be more fully understood from the following detailed description taken together with the accompanying drawing wherein similar reference characters refer to similar elements throughout and in which:
FIG. 1 is a perspective view of a cover plate according to the principles of the present invention;
FIG. 2 is a side view of the embodiment shown in FIG. 1 ;
FIG. 3 is view along the line 3 — 3 of FIG. 1 ;
FIG. 4 is a partial sectional view along the line 4 — 4 of FIG. 3 ;
FIG. 5 is a perspective view of a conventional down light mounting structure on which the cover plate of the present invention may be mounted; is a partial sectional view taken along the line 5 — 5 of FIG. 3 ;
FIG. 6 is a partial sectional view of a nipple inserted into the base plate of the present invention;
FIG. 7 is a sectional view along the line 7 — 7 of FIG. 6 ;
FIG. 8 is a perspective view of a close coupled pendalier external lighting fixture mounted on the cover plate of the present invention;
FIG. 9 is a perspective view of another pendalier external lighting fixture mounted on the cover plate of the present invention; and,
FIG. 10 is a perspective view of another external lighting fixture mounted on the cover plate of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing there is illustrated in FIGS. 1 , 2 , 3 and 4 a preferred embodiment, generally designated 10 of the cover plate 12 according to the principles of the present invention. The cover plate 12 has a base plate 14 having an outer surface 16 and an inner surface 18 . The base plate 14 has a peripheral edge 20 extending between the outer surface 16 and the inner surface 18 . The peripheral edge 20 in this embodiment 10 of the present invention has a predetermined geometrical shape which is circular. In other embodiments of the present invention the preselected geometrical shape of the peripheral edge 20 of the base plate 14 may be any desired configuration for aesthetic or other functional reasons as may be desired or required for a particular installation. The base plate 14 has a central axis 22 . The base plate 14 has walls 24 defining a nipple accepting aperture 26 therethrough aligned with the central axis 22 . In the preferred embodiment 10 , the base plate 14 is free of any other apertures therethrough.
An outer rim 28 is provided along the peripheral edge 20 and extends a first preselected distance inwardly from the inner surface 18 of the cover plate 14 as shown most clearly on FIG. 4 . The height of the outer rim 28 indicated on FIG. 4 at H from the inner surface 18 of the base plate 14 to the inner edge 32 ′ of the outer rim 32 may be selected as desired to provide the appearance of any desired thickness T of the base plate 14 as may be desired for particular applications. The inner edge 32 ′ of the outer rim 32 abuts against the inner surface of the ceiling (not shown) after mounting of the cover plate 12 . Alternatively, the base plate 14 may be fabricated in the desired thickness T as indicated on FIG. 4 . The preselected geometrical configuration of the outer peripheral edge 20 of the base plate 14 may be any desired configuration as required or desired for particular applications and/or installations.
An inner mounting plate 30 is coupled to the inner surface 18 of the base plate 14 . In the preferred embodiment 10 of the present invention, the inner mounting plate 30 has an “L” shaped configuration and extends around and spaced toward the central axis 22 from the inner surface 32 of the outer rim 28 . Inner mounting plate 30 has a base flange or leg portion 34 of the “L” shaped inner mounting plate 30 coupled to the inner surface 18 of the base plate 12 and the base flange or leg portion 34 has a peripheral edge 38 spaced from the inner surface 32 of the outer rim 28 to define a shoulder portion 40 therebetween. Inner mounting plate 30 also has an upright portion 36 extending inwardly from the inner surface 18 of the base plate 14 a second preselected distance indicated on FIG. 4 at D which is greater than the first preselected distance H. The diameter of the upright portion 36 of the inner mounting plate 30 is selected to match the mounting assembly structure as discussed below of the recessed down light (not shown) that is to be replaced. Such mounting assembly structures have been substantially standardized with respect to the dimensions and the various mounting configurations thereof as utilized in the electrical light fixture industry.
In other embodiments of the present invention the base flange or leg portion of the “L” shaped inner mounting plate 30 may be directed inwardly toward the central axis 22 as indicted by the dotted line showing 34 ′ on FIG. 4 . In other embodiments of the present invention the upright portion of the inner mounting plate 30 may be welded, braised or otherwise secured to the inner surface 18 of the base plate 14 , for example by a plurality of angle brackets, so as to eliminate the base flange or leg portion 34 . The particular method chosen to fasten the upright portion 36 of the inner mounting plate 30 to the base plate 14 may be selected depending on the requirements of the particular application and the economy of manufacturing.
As shown most clearly in FIGS. 1 , 2 and 3 , a plurality of mounting members 50 are on the upright portion 36 of the inner mounting plate 30 . The plurality of mounting members 30 provides the structure for the interconnection to the mounting structure assembly on the recessed light fixture housing in the applications of the present invention wherein a recessed lighting fixture is to be replaced by an external lighting fixture.
A first portion 52 of the plurality of mounting members 50 are hook mounting members which has, in this embodiment 10 of the present invention, five hook mounting members 52 A, 52 , 52 C, 52 D and 52 E are coupled to the upright portion 36 of the inner mounting member 30 by, for example, rivet 53 . The rivet 53 may provide either a fixed coupling of the hook mounting members 52 or a pivotal mounting of the hook mounting members 52 to allow at least some pivotal movement thereof in the directions indicated by the arrow 55 to accommodate various ceiling thicknesses, mounting assembly configurations to which the cover plate 14 is to be attached, or the like. The use of five hook mounting members 52 is often desired because of the weight of the external fixture to be mounted on the cover plate 30 as described below whereas one of the conventional mounting arrangements in recessed lighting fixtures in the electrical lighting fixture art for connection, for example, by a trim rim, is to utilize three hook members for connection to a recessed lighting fixture. However, the use of more than five hook members or less than five hook members may be selected as required or desired for particular applications. The hook mounting members 52 A, 52 B 52 C, 52 D and 52 E are spaced around the upright portion 36 of the inner mounting plate 30 . The first plurality of hook mounting members 52 extend inwardly a third preselected distance indicated at H′ on FIG. 1 from the inner surface 18 of base plate 14 .
A second portion 56 of the plurality of mounting members 50 has, a pair of slot type mounting members 56 A and 56 B. Each of the slot type mounting members 56 A and 56 B has an inverted “C” shaped slot therein as indicated a 58 . The “C” shaped slot has a vertical passage way 60 communicating with a horizontally disposed slot 60 . The slot type mounting members 56 A and 56 B are mounted on, or made as a part of the inner mounting plate 30 on the upright portion 36 thereof and extend a fourth preselected distance above the inner surface 18 of the base plate 14 as indicated at H″. The slot type mounting members 56 A and 56 B are adapted to receive a conventional “chicken leg” torsion spring retention devoices of the type well known in the prior art.
The utilization of the cover plate 14 is achieved by inserting a conventional externally threaded nipple, preferably with wrench flats thereon, as is well known in the lighting fixture art, into the nipple accepting aperture 26 . FIGS. 6 and 7 illustrate a nipple 70 inserted into the nipple accepting aperture 26 and the nipple 70 is tubular with a threaded external surface 72 and with walls 72 defining an internal wire accepting aperture 76 to allow passage of the electrical conducting wires 78 therethrough to regions external the outer surface 16 of the base plate 14 for connection to an externally mounted light fixture as described below in connection with FIGS. 8 , 9 and 10 .
In preferred embodiments of the present invention, the nipple 70 has wrench flats 73 thereon for convenience in installation thereof. However, in some applications it may be desired to provide a nipple with no wrench flats. The nipple is held in place on the base plate 14 by an inner nut 80 that threadingly engages the outer surface 72 of the nipple 70 and bears against the inner surface 18 of the base plate 14 . An outer nut 82 may be utilized and threadingly engages the outer surface 72 of the nipple 70 and bears against the outer surface 16 of the base plate 14 . As described below in connection with FIGS. 8 and 10 an externally mounted lighting fixture may have structure that is utilized to replace the function of the outer nut 82 to retain the nipple 70 in place.
Referring to FIG. 5 , there is shown a conventional down light mounting structure generally designated 130 which is positioned above the ceiling 132 . The down light mounting structure 132 has a lower rim 134 that projects into the ceiling 132 . Internally of the mounting structure 130 are the appropriate interconnection devices for supporting the base plate of the present invention. The inner mounting plate 30 of a cover plate 12 is inserted into the opening 136 of the mounting structure 130 . The mounting members 50 of the cover plate 12 engage internal structure in the mounting structure 130 to provide the desired mounting of the cover plate 12 in the mounting structure 130 so that the inner surface 18 thereof is against the outer surface 138 of the ceiling 132 .
Referring now to FIG. 8 there is shown an embodiment 100 of the present invention in which a close coupled pendalier external mounted lighting fixture 102 is mounted on the base plate 14 of a cover plate 12 . The inner mounting plate 30 and the plurality of various mounting members 50 have been omitted from FIG. 8 for clarity in description. The electrical conducting wire 78 extends through a nipple in the base plate 14 , as shown in FIG. 6 and into the lighting fixture 102 for appropriate connection for providing electrical current to a light bulb contained in the lighting fixture 102 . In the embodiment 100 the upper portion 102 ′ of the lighting fixture 102 may threadingly engage the nipple to hold the lighting fixture 102 against the outer surface 16 of the base plate 14 of the cover plate 12 .
Referring now to FIG. 9 there is shown an embodiment 110 of the present invention in which a remote coupled pendalier external mounted lighting fixture 112 is mounted on the base plate 14 of a cover plate 12 . The inner mounting plate 30 and the plurality of various mounting members 50 have been omitted from FIG. 9 for clarity in description. The electrical conducting wire 78 extends through a nipple as described above in connection with FIGS. 6 and 7 and extends a predetermined outward distance from the base plate as shown at 114 and into the lighting fixture 112 for appropriate connection for providing electrical current to a light bulb contained in the lighting fixture 112 . In the embodiment 110 there may be provided a decorative outer nut 116 that threadingly engages the nipple to retain the nipple in place in the base plate 14 .
Referring now to FIG. 10 there is shown an embodiment 120 of the present invention in which an externally mounted lighting fixture 122 is mounted on the base plate 14 of a cover plate 12 . The inner mounting plate 30 and the plurality of various mounting members 50 have been omitted from FIG. 10 for clarity in description. The electrical conducting wire 78 extends through a nipple in the base plate 14 as described above in connection with FIG. 6 and into the lighting fixture 122 for appropriate connection for providing electrical current to a light bulb contained in the lighting fixture 122 . In the embodiment 120 the upper portion 122 ′ of the lighting fixture 122 may threadingly engage the nipple to hold the lighting fixture 122 against the outer surface 16 of the base plate 14 of the cover plate 12 .
The lighting fixtures illustrated in FIGS. 8 , 9 and 10 are only illustrative of the great variety of lighting fixtures that may be utilized in the present invention to replace an existing recessed down light or, as may be desired, in a new installation.
Although specific embodiments of the present invention have been described above with reference to the various Figures of the drawing, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims.
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A cover plate for use in replacing recessed lighting fixtures with pendalier or external mounted lighting fixtures and provided with matching interconnection mounting members for cooperative engagement with a variety of mounting structure assemblies heretofore utilized in recessed down lights.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a method and device for the application of a liquid medium onto a material web, and, more particularly, to a method and device for the application of liquid through viscid mediums onto a pre-dried material web.
[0003] 2. Description of the Related Art
[0004] In the direct application process a liquid or viscid medium is applied directly by an applicator device to the surface of a moving material web, which is supported during the application process by a rotating support surface, such as a backing roll or a continuous belt. The liquid or viscid medium is initially applied to a carrier surface, such as the surface of a roll serving as an applicator roll, or the surface of one side of a flexible belt, and is transferred therefrom to the material web.
[0005] Indirect application is normally accomplished by a so-called film press implemented by two rolls, which together form a nip, and which transfer the medium successively or simultaneously to both sides of the material web or to only one side of the web.
[0006] Reference is made to U.S. Pat. No. 5,683,509 which discloses a flexible continuous belt, together with a transfer roll, which form the press nip through which the web travels. A press shoe is located on the inside of the continuous belt, thereby extending the nip and pressing the coating medium, that is applied by this unit, into the web. This improves the coating result, specifically by avoiding film splitting.
[0007] Reference is also made to DE 198 23 739 A1, according to which, a material web is coated in the wet section or immediately following the wet section, of a paper machine.
[0008] Film or size presses have been in operation for years. They have some significant disadvantages when utilized with today's high-speed machines, and depending upon the type of fiber web and coating medium, they do not always provide sufficient coating quality.
[0009] The raw material quality of paper or cardboard is continuously degrading. This is particularly true of the production of corrugated board base paper, which is largely manufactured from recovered paper. There is also an ever increasing demand for a lower mass per unit area (also referred to as basis weight). The result of using poor raw material quality and lower basis weight is that the tensile strength of the web, following the film press coating application, is very low, resulting in frequent web breaks after the coating of the web. This results in enormous production down times and associated high costs.
[0010] Film Presses, variously known as Speedsizer, Speedcoater, Optisizer or metering size press, frequently cause nip flattening and crushing in the nip. These effects are particularly negative in corrugated board production.
[0011] In the field, web breaks, particularly in the production of corrugated board base paper, are reduced by using modified starches, that have a low viscosity and a high solids content, as a coating medium. The low viscosity provides effective penetration and the high solids content produce low remoistening, thereby rendering possible only a low drop in tensile strength following the film press. However, modified starches are more expensive as compared to crystal starches.
[0012] Even these measures do not always lead to satisfactory results.
SUMMARY OF THE INVENTION
[0013] The present invention provides a method and a device for the production of corrugated board base paper, whereby a deep penetration of coating medium containing starch into the material web, independent of the basis weight, and by utilizing the starch characteristics, is accomplished and web breaks are largely avoided.
[0014] The inventors recognized that the hitherto used starches, whose viscosity and solids contents were modified, produced only an insignificant increase in strength of the coated and impregnated material web, as compared to crystal starches.
[0015] The positive effects of the starch in the coating medium increase since the pre-dried corrugated board base paper web travels through a press nip only after coating, and because the web is dried a considerable distance after the nip, essentially the distance to the first dryer cylinder, being supported without free draw.
[0016] An advantage of the present invention is that a penetration through to the “sheet center” can be achieved, even at low basis weights, resulting in an increase of the web's tensile strength.
[0017] Another advantage is that it is now possible to use crystal starches in spite of intensive remoistening. Crushing during corrugated board base paper production is reliably avoided.
[0018] A further advantage of the present invention is that fewer web breaks occur following the coating process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0020] [0020]FIG. 1 is a schematic side view of one embodiment of a device for the one or two sided application of a liquid through viscid mediums onto a pre-dried material web of the present invention; and
[0021] [0021]FIG. 2 is a schematic side view of a second embodiment of the present invention.
[0022] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring now to the drawings, and more particularly to FIG. 1, there is illustrated a pre-dried corrugated board base paper web B that has a dry content of approximately 85 to 95%, following a last dryer cylinder 2 of pre-dryer group 3 , in a machine for the production of corrugated board base paper, running onto a first applicator roll 4 . Applicator roll 4 has an applicator device 5 assigned to it, with which web B is coated on it's top side B o . All known coating devices, such as a Short Dwell Time Applicator (SDTA), Long Dwell-Time Applicator (LDTA), open jet nozzle applicators or a curtain coating nozzles are suitable. A pre-penetration of the coating medium is achieved with this one- or two-sided application.
[0024] In order to support web B, a transfer belt, that is a flexible continuous synthetic or rubber belt, is routed around additional roll 16 , a support or backing roll 7 and around several guide or turning rollers 8 . A tension roll 21 , which is located on the paper machine floor PM B , reacts on belt 6 from the outside, thereby tensioning it.
[0025] Whereas a two-sided application is illustrated, applicator 5 a is assigned to support roller 7 . The coating medium is transferred from continuous belt 6 to underside B U of web B, as soon as belt 6 makes contact with web B. The application by applicators 5 and 5 a may occur simultaneously, or successively in an offset time sequence. If only a one-sided application is to occur, on either the topside or the underside of the web, one of the idle applicator devices are pivoted down. As can be seen in FIG. 1, rolls 4 and 7 together do not form a press nip. This is intentional, so that no crushing of the web is caused and no web breaks occur.
[0026] The embodiment illustrated in FIG. 1, includes a long pre-penetration segment P s , that ought to be considerably longer than 100 mm, thereby providing good penetration due to the capillary effect during the extended reaction time. This long distance is particularly advantageous in achieving the desired through-penetration.
[0027] Now additionally referring to FIG. 2, which essentially uses the identical references for the identical components as FIG. 1, there is shown another embodiment of the invention. In this embodiment there is no roll 4 ; only applicator device 5 is present for direct application of coating onto the topside of web B o . Alternatively, an additional continuous belt, in place of the roll 4 , may be utilized with which web B is supported, and indirect coating of the material web is achieved.
[0028] After passing penetration segment P s web B runs together with belt 6 , which can be used as an applicator and support belt, through press zone 9 . Press zone 9 may be realized in various ways. In order to allow a long dwell time and avoid crushing, as well as to be able to adjust variable line pressures across the entire width of web B, a shoe press is utilized. In press zone 9 the pre-penetrated starch can after-penetrate, thereby anchoring itself solidly in web B.
[0029] Alternatively, press zone 9 may include an additional flexible continuous belt 10 running over guide rollers 11 , 12 and 13 . Belt 10 runs with it's inside surface over a slide face of press shoe 14 , whereby the slide face, together with roll 15 , which could for example be a suction roll, forms a press nip N. Press shoe 14 is shown in only as a simplified depiction and may extend over a large area of belt 10 . Press zone 9 can also include rolls 15 and 16 which form a press nip N. In FIG. 1 and 2 , roll 15 is illustrated in a dash-dot configuration and embodies a so-called flexonip roll. This construction is already known from DE 198 20 516 A1, which is incorporated herein and made a part hereof, however there are no statements therein regarding supporting of the web after squeezing in the coating.
[0030] Roll 15 is one of those rolls, around which continuous belt 6 travels, forming the aforementioned backing surface to roll 16 and/or the belt acting as a press, support or applicator belt 10 . Continuous belt 10 , as well as continuous belt 6 , each form a support surface therebetween for web B that is penetrated through after Nip N. Support surface S F extends essentially to first dryer cylinder 18 , in the following dryer section 19 , of the paper machine.
[0031] As indicated by the dashed lines, in FIG. 2, continuous belt 10 can be extended, to a desired extent, by adjustment of guide roller 13 . Likewise belt 6 can also extend its support surface, to a desired extent, by adjusting upper guide roller 8 . As is also shown in FIG. 2, an extended support surface provides for a blow box or suction box 20 , or for another type of transfer aid, to facilitate transfer of web B, or of a transfer strip, to dryer cylinder 18 .
[0032] In FIG. 1 the possibility of supporting web B in the direction of the location of application is shown as a dotted line. For this purpose belt 10 , or a separate belt 10 a , is routed around roll 4 , or around an adequately positioned guide roller. Belt 10 a may also be additionally supported by roll 11 . Alternatively, continuous belt 10 a can replace roll 4 , thereby providing the aforementioned support of web B, as well as indirect coating, at the same location as is being done with roll 4 .
[0033] Belts 6 and 10 are equipped with a drive and rolls 4 , 7 and 15 are driven. Relative to belt 6 this drive is located at nip N, in order to ensure sufficient pull of web B. In addition, tensioning devices, such as tensioning roller 21 and tension control devices, for the belts are provided, as well as belt adjustments which are indicated by double arrows at guide rolls 8 and 13 .
[0034] In order to facilitate a flawless transfer of web B to dryer section 19 , a suction roll 22 , with or without foil 23 , is provided after press zone 9 or continuous belt 10 . This arrangement allows for a transfer of the web without ropes.
[0035] For the sake of completeness it must be mentioned that in order to facilitate a flawless transfer of web B, one or more showers (not depicted in the drawings) are provided prior to the point where belt 6 runs onto applicator roll 4 . These provide a targeted liquid application onto belt 6 or web B, in order to ensure adhesion of the transfer strip or web B. In order to avoid lifting of web B at press roll 16 , additional support belts, so-called fibron belts or other known transfer aids, can be provided. The paper machine section illustrated in FIGS. 1 and 2 is essentially consistent with a “closed transfer” into dryer section 19 .
[0036] It is also feasible to include an additional applicator device 5 c to continuous belt 10 , thereby providing for a double application onto topside B o of web B. This may occur with or without intermediate drying. Additional support belts 10 a . . . 10 n or 6 a . . . 6 n , on one or both sides of web B, may be provided, which have associated applicator devices 5 a . . . 5 n , being of the same type or acting independently from each other. An advantage of this type of arrangement is that only a fraction of the starch is applied by each applicator device. This reduces the re-moistening of web B immediately after the application. Web B does not loose consistency, thereby increasing runability.
[0037] Overall, it has been determined in tests that the consistency gain of the paper and cardboard web is not approximately 20N/% starch as was the case previously, but 40N/% starch. This means that, while maintaining the same quality the starch amount can be reduced by 30%. Alternatively the quality is increased when the same amount of starch is used. This is especially important considering the drop in quality of raw materials used in the production of corrugated board base paper.
[0038] Furthermore crystal starches can now also be used.
[0039] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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A method for the application of liquid through viscid medium onto the surface of a pre-dried material web including the steps of applying a viscid medium to at least one side of the material web, routing the material web through a press nip and supporting the material web substantially without free draw.
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BACKGROUND OF THE INVENTION
A railroad switch includes a switch point or rail having a point of switch at one end which terminates in a narrow tip adapted to be moved into contact with a stationary rail when rail traffic is to be diverted from the switch rail to the stationary rail or vice versa. The point of switch which may be three to four feet in length has a relatively thin cross sectional area, i.e., on the order of 1/16 to 1/4 of an inch. If as a railroad car or locomotive wheel traverses a switch point it is allowed to engage the point of switch, it will cause this area to wear rapidly thereby necessitating its frequent repair or replacement. The tips of switch points especially are subject to wear when wheels engage the point of switch, because they have the narrowest cross-sectional area and some switch points are equipped with replaceable manganese tips which may be changed when they become worn excessively. In addition, if a wheel is traveling in a facing direction, i.e., towards the point as it moves through a switch and it is allowed to contact the tip, it is possible for the flange of the wheel to climb the switch point rail and become derailed. Also, if a wheel has a worn or thin flange and the tip of the point is worn, a wheel moving in a facing direction may pick the point, i.e., pass between the rail and the point and thereby cause a derailment.
Consequently, it has become common practice to provide a switch point guard rail or bar adjacent the switch point at the point of switch. The guard rail is positioned to engage the rim of a car or locomotive wheel on the side opposite the flange and to push the wheel laterally away from the point of switch so that it is not abraded by the flange as the wheel passes over that area of the switch point. Of course, this causes the guard rail to wear in place of the switch point. Consequently, to maintain the effectiveness of the guard rail, periodically it must be replaced or repositioned to compensate for the wear. Previous switch point guards have been unitary structures which were positioned with respect to switch points by being spiked into ties for the railroad track. A disadvantage inherent in guard rails which are spiked into ties resides in the fact that the spikes must be removed to reposition the guard rails and as these rails are replaced, over a period of time the repeated spiking of the ties renders them useless and they too must be replaced. In response to the disadvantages found in unitary guard rail structures, some guard rail structures have been developed which permit the wear portion of the structure to be replaced or repositioned with respect to the switch point when it becomes worn without moving the portion of the structure spiked to the ties. One problem associated with those guard rail structure having a wear element which may be adjusted or repositioned has been their excessive complexity and their use of relatively large numbers of parts. Often guard rails must be repositioned under adverse weather and working conditions by relatively inexperienced crews. Consequently, those structures employing complex adjustment mechanisms with multiple parts may be improperly installed. Furthermore, complex guard rail structures are expensive and may lack the rigidity required to hold them in a predetermined position under conditions of heavy usage.
It is desirable to provide a guard rail having an adjustable wear element which may be repositioned when the wear element becomes worn to provide additional protection for the point of switch, which utilizes a minimum number of parts and which may be constructed with a minimum of expense. Furthermore, it is desirable to provide a guard rail having an adjustable wear element mounted on a support structure adapted to be spiked to the railroad track ties wherein the wear element may be adjusted or replaced without having to remove the support structure.
SUMMARY OF THE INVENTION
The instant invention provides an adjustable switch point guard for use at the switch point of a railroad track having a wear bar positioned to engage the rims of railroad car wheels to prevent the flanges of the wheels from engaging the switch point. This guard comprises an adjustment plate wherein the wear bar is rigidly affixed to the adjustment plate and located a predetermined lateral distance from the switch point. The wear bar has a vertical wear face which engages the rims of railroad car wheels. The guard includes a base plate which mounts the adjustment plate and an adjustment means for fixedly attaching the adjustment plate to the base plate at a plurality of positions such that the wear bar may be spaced a plurality of predetermined distances from the switch point. The adjustment means includes a plurality of bores formed in one of the adjustment plate or base plate at different lateral distances from the switch point and a threaded connector attached to the other of the base plate or the adjustment plate wherein the threaded connector is installed in one of the bores to locate the adjustment plate and the wear plate at one of the predetermined distances.
Also provided is a method of adjusting a switch point guard for use at the switch point of a railroad track having a wear bar positioned to engage the rims of railroad car wheels to prevent the flanges of the wheels from engaging the switch point. The switch point guard having an adjustment plate and the wear bar being rigidly affixed to the adjustment plate and located a predetermined lateral distance from the switch point. The wear bar has a verticle wear face which engages the rims of railroad car wheels. The switch point guard further having a base plate which mounts the adjustment plate and an adjustment means for fixidly attaching the adjustment plate to the base plate at a plurality of positions such that the wear bar may be spaced a plurality of predetermined distances from the switch point. The adjustment means includes a plurality of bores formed in one of the adjustment plate or the base plate at different lateral distances from the switch point and a threaded connector attached to the of the base plate or the adjustment plate. The threaded connector is installed in one of the bores to locate the adjustment plate and the wear plate at one of said predetermined distances and a nut is turned on to the threaded connector. The method of adjusting the switch point comprises the steps of removing the nut from the threaded connector, lifting the adjustment plate vertically upward from the base plate to withdraw the threaded connector from one of said bores, displacing the adjustment plate laterally and into alignment with another of said bores, lowering the adjustment plate onto the base plate to cause the threaded connector to be received in the other bore and turning the nut onto the threaded connector to fixedly attach the adjustment plate to the base plate.
DISCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view along line 1--1 of FIG. 2; and
FIG. 2 is a top view of the switch point guard mounted adjacent a switch point.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 2, it may be seen that a switch point or rail 10 lies adjacent a fixed traffic rail 12. In this figure, the tip 14 of the tapered point of switch portion 16 of switch point 10 has been brought into contact with the inner edge 18 of fixed rail 10 to obtain a switching condition. With this condition, the flange 20 of a railroad car wheel 22 will engage the inner edge 24 of switch point 10 when the wheel is traveling in a facing direction as may be seen in FIG. 1. If the wheel 22 is traveling in a trailing direction, it will simply transfer from the point of switch portion 16 of switch rail 10 to fixed rail 12 and flange 20 will engage inner edge 18 of that rail to turn the wheel in the direction of rail 12. The point of switch portion 16 of switch point 10 may be moved away from fixed rail 12 to allow traffic to proceed along rail 12 without entering switch point 10.
A guard rail assembly 30 is mounted along a railroad track adjacent the outer edge 32 of fixed rail 12. Referring again to FIG. 2, it may be seen that rail assembly 30 includes a wear bar 34 having a straight midsection 36 which lies parallel to fixed rail 12 and a pair of tapered ends 38 and 40 which are attached to opposite ends of midsection 36. Wear bar 34 has a verticle face 42 which engages the outer edge 44 of a car wheel 22 to push the wheel away from tip 14 and inner edge 24 of the point of switch 16 as depicted in FIG. 1. As a result, abrasion and wear of the inner edge 24 of point of switch 16 by wheel flanges 20 is prevented when the wheels traverse switch point 10. Typically, wear bar 34 is manufactured from a wear resistant alloy or subjected to a manufacturing process which increases is resistance to wear and abrasion. However, repeated contact with the outer edges 44 of car wheels 22 causes wear face 42 eventually to wear. When the wear reaches the point to where the flange 20 of the wheel 22 is not maintained a sufficient distance from tip 14 and inner edge 24 of point of switch 16, wear bar 34 must be replaced or repositioned. The guard rail assembly 30 of the present invention provides an adjustment whereby wear bar 34 may be moved inwardly towards fixed rail 12 to compensate for wear twice subsequent to its initial installation. Thereafter, wear bar 34 must be replaced.
Guard rail assembly 30 will now be discribed in detail. Wear bar 34 has a stepped bottom surface 50 that is mounted on a complimentary stepped top surface 52 of an adjustment plate 54. A plurality of welded joints secure wear bar 34 to adjustment plate 54. A verticle edge 56 formed on the top of adjustment plate 54 acts against a similar edge 58 formed on the bottom of wear bar 34 to resist lateral movement of the bar when the outer edge 44 of a car wheel 52 engages verticle face 42.
A pair of threaded fasteners 58 and 60 pass through bores 62 formed in adjustment plate 54. Fasteners 58 and 60 may be bolts which are retained in place by welding. Alternatively, bores 62 may be threaded and fasteners 58 and 60 may be threaded studs that are turned into bores 62.
The bottom surface 66 of adjustment plate 54 rests upon the top surface 68 of a horizontally extending base plate 70. Base plate 70 is supported by a pair of vertically extending gussets 72 and 74. The top surfaces of gussets 72 and 74 are rigidly affixed to the bottom surface 76 of base plate 70 by welds. Gussets 72 and 74 are mounted on end tie plates 80 and 82, respectively. Tie plates 80 and 82 are spiked into railroad ties 84 and 85 to secure guard rail assembly 30 in position adjacent to fixed rail 12 and switch point 10. Three pairs of bores A and A', B and B', and C and C' are formed in base plate 70. The center lines of each pair of bores, A and A', B and B' and C and C', are spaced apart by the same distance that separates the center lines of fasteners 58 and 60. In order to mount wear bar 34 and adjustment plate 54 on base plate 70, adjustment plate 54 is moved until threaded fasteners 58 and 60 are aligned with one of the pairs of bores. When wear bar 34 is new, fasteners 58 and 60 are aligned with bores A and A' as shown in FIGS. 1 and 2 and the fasteners are inserted into these bores. Thereafter, nuts 86 are turned onto fasteners 58 and 60 until they engage and compress lock washers 88 to thereby secure adjustment plate 54 to base plate 70.
It may be observed that bores B and B' are positioned inwardly of bores A and A' towards fixed rail 12 and that bores C and C' are positioned inwardly of bores B and B' towards fixed rail 12. Consequently, when wear bar 34 becomes worn in the initial position, it may be moved to a second position in which fasteners 58 and 60 pass through bores B and B'. When wear bar 34 becomes worn in the second position, it may thereafter be moved to a third position in which the fasteners 58 and 60 pass through bores C and C' respectively. Bore B and B' are offset laterally to one side of bores A and A', respective, and bores C and C' are offset laterally to the opposite side of bores A and A', respectively, so that wear bar 34 remains close to its initial position as defined by bores A and A' when it is in the second and third position.
In order to reposition adjustment plate 54 and wear bar 34 from one set of bores to another, it is necessary only to remove the nut 86 and washers 88 from fasteners 58 and 60 and, lift adjustment plate 54 vertically upward from base plate 70 to withdraw the fasteners 58 and 60 from the bores they occupy. Thereafter, adjustment plate 54 is moved horizontally until fasteners 58 and 60 are aligned with the bores in base plate 70 which define the next desired position for wear bar 34. Subsequently, plate 54 is lowered onto base plate 70 and thereafter nuts 86 are turned onto fasteners 58 and 60 until their lock washers 88 are compressed.
Although in the preferred embodiment the threaded fasteners are shown mounted on the adjustment plate 54 and the sets of positioning bores A and A', B and B' and C and C' are shown formed in base plate 70, the adjustment mechanism, would work equally well if the threaded fasteners 58 and 60 projected upwardly from the top surface 68 of base plate 70 and the adjustment bores A and A', B and B' and C and C' were formed in adjustment plate 54. In this instance, adjustment plate 54 would be repositioned on base plate 70 by removing the nut 86 and washer 88 from each threaded fastener 58 and 60, lifting adjustment plate 54 vertically upward from base plate 70 to cause fasteners 58 and 60 to be withdrawn from one of the sets of bores. Thereafter adjustment plate 54 would be moved to align the set of bores defining the desired position with fasteners 58 and 60 and would be lowered onto base plate 70 such that fasteners 58 and 60 would pass through the selected set of bores. Adjustment plate 54 would be secured onto base plate 70 by turning a nut 86 onto each fastener 58 and 60 until it compressed the lock washer 88.
It may be observed that adjustment plate 54 and wear bar 34 may be removed from base plate 70 and replaced or repositioned thereon without disturbing the base plate 70. Consequently, the support structure consisting of base plate 70, gussets 72 and 74 and end tie plates 80 and 82 remain in position when adjustment plate 54 and wear bar 34 are repositioned or replaced. Thus, end tie plates 80 and 82 are spiked into railroad ties 84 and 85 when the guard rail assembly 30 is installed initially and are not disturbed when wear bar 34 and adjustment plate 54 are replaced or repositioned.
Since certain changes may be made in the above-described system and apparatus without departing from the scope of the invention herein involved, it is intended that all matter contained in the description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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An adjustable switch point guard includes a wear bar rigidly affixed to an adjustment plate. The adjustment plate is mounted on a fixed base plate which is attached to railroad ties. A threaded fastener on one of the adjustment plate or the base plate engages a first pair of bores in the other of the adjustment plate or the base plate to position the wear bar and adjustment plate 54 relative to a switch point and a fixed rail. Additional setes of bores are provided to enable the adjustment plate and wear bar to be moved relative to the base plate.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a roadside narrowband wireless communication apparatus to be used for a road-to-vehicle narrowband wireless communication system.
[0003] 2. Description of the Related Art
[0004] A road-to-vehicle narrowband wireless communication system for communicating various information between a narrowband wireless communication apparatus mounted on a vehicle traveling on a road and a roadside antenna apparatus installed on the road has been known. The road-to-vehicle narrowband wireless communication system is becoming capable of handling plural service systems in addition to communication relating to receipt of tolls by ETC, such as so-called VICS for offering traffic information, the Internet, and communication for various services in parking areas are handled.
[0005] Since the service systems are originally independently constructed systems, they are different in radio frequency, and it is difficult to make an on-board unit to be compatible with all the services by the use of one wireless antenna. However, it is difficult to provide plural antennas on a vehicle from the view points of limited space area, cost, and appearance Also, it is undesirable from the cost point of view to install the roadside narrowband wireless communication system for each of the services.
[0006] In FIG. 2 of JP-A-2001-103016, there is disclosed a system wherein an integrated base station 200 (called also as roadside apparatus) provided with a synthesis division unit 203 for multiplexing different wireless communication frequencies of services to form a common frequency to be transmitted as one frequency and dividing signals for the services after the transmission is installed as a superordinate station to a roadside antenna apparatus (referred to as a local base station 400 in JP-A-2001-103016). The system is capable of communicating to and from the roadside antenna apparatus the radio signals at the common frequency corresponding to the plural services through an optical fiber. In this case, a narrowband wireless communication apparatus mounted on a vehicle is provided with an antenna for the common frequency, a synthesis division unit for separating the signal into plural wireless frequencies corresponding to the original plural services, and plural wireless applications for the separated plural frequencies.
[0007] Since such communication service is subject to service type change, service type increase, or increase in number of vehicles allowed to use the service simultaneously, the roadside narrowband wireless communication system has to undergo alteration (hereinafter referred to as maintenance) of system so as to be in conformity with the change and increases from time to time. The system disclosed in JP-A-2001-103016 also requires such maintenance, and, in the case of maintenance, a worker must go to each of the roadside antenna apparatus installed roadside to perform tasks of setting changes and the like. Such maintenance has a cost problem due to the large number of roadside antenna apparatuses installed at an interval of several kilometers along a road and the distance between the adjacent apparatuses, i.e., since the maintenance requires a large number of workers and long time, that is, increased cost.
[0008] Also, since the system disclosed in JP-A-2001-103016 communicates signals of a carrier frequency (very high frequency) of a wireless communication between the system and a vehicle from the integrated base station 200 to each of local base stations 400 via the optical fiber, the system has a drawback that the transmission device is remarkably expensive.
SUMMARY OF THE INVENTION
[0009] A roadside narrowband wireless communication apparatus used in conventional road-to-vehicle narrowband wireless communication system is provided with a roadside antenna apparatus and a roadside apparatus, and, due to the constitution, workers have to go to the roadside antenna apparatuses in order to perform maintenance work and setting changes. Therefore, the roadside narrowband wireless communication apparatus has a problem of increased cost due to the large number of workers and long time required for the maintenance work and setting changes.
[0010] Also, since the roadside narrowband wireless communication apparatus communicates signals of a carrier frequency (very high frequency) of a wireless communication between the system and a vehicle from the integrated base station 200 to each of local base stations 400 via the optical fiber, the system has a drawback that the transmission device is remarkably expensive.
[0011] An object of this invention is to solve the above problems and to provide a roadside narrowband wireless communication apparatus which enables maintenance work such as setting changes of a roadside antenna apparatus to be performed by remote control by the use of a roadside apparatus.
[0012] Another object of this invention is to provide a less expensive roadside narrowband wireless communication apparatus by performing signal transmission between the roadside antenna apparatus and a superordinate apparatus (roadside apparatus) by using a transmitting and receiving baseband signal having a frequency much lower than a wireless communication frequency.
[0013] A roadside narrowband wireless communication apparatus according to this invention comprises: a roadside antenna apparatus having a wireless communication unit provided in the vicinity of a road and communicating a radio signal to and from a wireless communication device mounted on a vehicle traveling on the road and a first multiplexing unit connected to the wireless communication unit and communicating a transmission baseband signal transmitted from the radio signal and an adjustment signal for adjusting the wireless communication unit as a multiplexed signal; a roadside apparatus having a second multiplexing unit provided in accordance with the roadside antenna apparatus and communicating the multiplexed signal to and from the first multiplexing unit, a wireless communication control unit connected to the second multiplexing unit and communicating a signal to be converted into the multiplexed signal to and from plural signal sources to generate the baseband signal, and a network connection unit connected to the wireless communication control unit and an external wired communication network and communicating data to be the transmission baseband signal to and from a system connected to the wired communication network; and an adjustment tool connected to the wireless communication control unit of the roadside apparatus and communicating the adjustment signal for remotely adjusting the roadside antenna apparatus.
[0014] A transmission speed of the multiplexed signal transmitted between the first multiplexing unit and the second multiplexing unit is higher than that of the radio signal transmitted between the wireless communication device of the vehicle and the wireless communication unit of the roadside antenna apparatus.
[0015] The roadside narrowband wireless communication apparatus according to this invention performs data transmission to and from the roadside antenna apparatus by using a baseband signal, not a radio frequency. Therefore, a frequency at which the transmission is performed is reduced to realize an extended communication distance and a reduced production cost. Also, the roadside narrowband wireless communication apparatus has an effect of realizing remote maintenance work of the roadside antenna apparatus by connecting the adjustment tool adjusting or controlling the roadside antenna apparatus without stopping ordinary signal transmission.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a block diagram showing a road-to-vehicle wireless communication system using a narrowband wireless communication apparatus of this invention;
[0017] FIG. 2 is a block diagram showing a narrowband wireless communication apparatus according to a first embodiment;
[0018] FIG. 3 is a block diagram showing a roadside antenna apparatus in the block shown in FIG. 2 ;
[0019] FIG. 4 is a block diagram showing a roadside apparatus in the block shown in FIG. 2 ;
[0020] FIGS. 5A-5D are diagrams illustrating an operation mode of the narrowband wireless communication apparatus shown in FIG. 2 ;
[0021] FIG. 6 is a diagram showing a structure of a packet signal communicated between the roadside antenna apparatus and the roadside apparatus;
[0022] FIG. 7 is a block diagram showing a narrowband wireless communication apparatus according to a second embodiment;
[0023] FIG. 8 is a block diagram showing a narrowband wireless communication apparatus according to a third embodiment; and
[0024] FIGS. 9A-9D are diagrams showing a narrowband wireless communication apparatus according to fourth embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
[0025] FIG. 1 is a block diagram to be used for illustrating a road-to-vehicle narrowband wireless communication system as a whole, the system performing a road-to-vehicle narrowband wireless communication according to the first embodiment of this invention. An on-vehicle wireless communication apparatus (not shown) is mounted on a vehicle 500 , and roadside antenna apparatuses 1 (hereinafter denoted by 1 - 1 to 1 -n) are installed on a road 501 at an interval of several kilometers, so that data communication is performed between the vehicle 500 and the roadside antenna apparatuses 1 by wireless communication line 499 .
[0026] The roadside antenna apparatuses 1 are divided into several groups each including several roadside antenna apparatuses 1 to be connected to a roadside apparatuses 3 (hereinafter sometimes denoted by 3 - 1 to 3 -n) via a connection cable 2 .
[0027] The roadside apparatus 3 is provided with plural base stations (only one base station is shown in the drawing for brevity) for various services, such as an ETC base station 47 , a data terminal equipment of a bank (not shown). Each of the base stations is connected to a network suitable for performing the service, such as an ETC network 201 and an internet network 202 , via a wire communication network such as a telephone network and an optical communication network.
[0028] The roadside narrowband wireless communication apparatus of the first embodiment includes the roadside antenna 1 , the roadside apparatus 3 , and the connection cable 2 . The communication between the roadside antenna apparatus 1 and the roadside apparatus 3 is not limited to the wire communication, and wireless communication is usable. In the case of the wireless communication, it is of course possible to omit the connection cable 2 .
[0029] Hereinafter, details of the roadside antenna apparatus 1 , the connection cable 2 , the roadside apparatus 3 , and the like will be described.
[0030] Shown in FIG. 2 is a detailed structure of a part of the roadside antenna apparatus 1 , the connection cable 2 , and the roadside apparatus 3 .
[0031] Though only 2 roadside antenna apparatuses 1 are shown in FIG. 2 , plural roadside antenna apparatuses may be connected to one roadside apparatus 3 as described in FIG. 1 . The roadside antenna apparatus 1 includes a vehicle 500 , an antenna 11 for wireless communication, a wireless communication unit 12 connected to the antenna 11 , and a first multiplexing unit 13 connected to the wireless communication unit 12 to perform data transmission. The roadside apparatus 3 includes a second multiplexing unit 31 , a wireless communication control unit 32 , a network controller 34 for controlling data transmission to and from a wired network, and a network connection unit 36 to be connected to the wired network. Also, a setting tool 100 may be connected to the roadside apparatus 3 via an interface 99 . The setting tool 100 is an appliance capable of inputting signals for adjusting and controlling the roadside antenna apparatus 1 , such as a personal computer.
[0032] Hereinafter, main functions of the components will be described.
[0033] The antenna 11 performs transmission of wireless communication signal to and from the vehicle 500 and decides a communication area on the road 501 by appropriate radiation directivity. The wireless communication unit 12 supplies a radio signal modulated into a send baseband signal to the antenna 11 . The wireless communication unit 12 demodulate the radio signal supplied from the antenna 11 into a receive baseband signal. The first multiplexing unit 13 performs serial/parallel conversion of the baseband signal and wireless communication unit control data from the wireless communication unit 12 to generate packet data having a predetermined length and then converts the packet data into that having a level according to specification of a predetermined signal line to send the data.
[0034] The second multiplexing unit 31 receives the signal of the level according to the specification of the predetermined connection cable 2 from the wireless communication control unit 32 and replays the packet data of the predetermined length to perform parallel/serial conversion of the transmission baseband signal and the wireless communication unit control data. Since the packet data have a frequency lower than that of the wireless communication signal, both an optical cable and a coaxial cable can be used as the connection cable. In this specification, the connection cable 2 of the first embodiment 1 is the optical cable.
[0035] Since the first multiplexing unit 13 of the roadside antennal apparatus 1 and the second multiplexing unit 31 of the roadside apparatus 3 are connected to each other by the connection cable 2 , the wireless communication unit 12 and the wireless communication control unit 32 are mutually connected to each other by at least one arbitrary signal line. It is necessary to assign a unique address to each of the roadside antenna apparatuses 1 in order to identify each of the plural roadside antenna apparatuses 1 .
[0036] The setting tool 100 is a serially connected personal computer, for example, and setting/maintenance of the roadside antenna apparatus 1 is achieved by performing various inputs described later in this specification using the setting tool 100 .
[0037] Structures of the wireless communication unit 12 and the first multiplexing unit 13 of the roadside apparatus 1 will be described in detail with reference to FIG. 3 . Since the components shown in FIG. 3 have a shared part such as microcomputer, they are not separated perfectly as the wireless communication unit 12 and the multiplexing unit 13 shown in FIG. 2 . Therefore, a function is indicated in a block in FIG. 3 .
[0038] As described in the foregoing, an optical fiber is used as the connection cable 2 for connecting the first multiplexing unit 13 to the second multiplexing unit 31 in this embodiment 1 . The specification of the communication is selected from full duplex communication and semi duplex communication depending on a transmission quantity of the signals. In the case of the full duplex communication, 2 optical fibers must be used for achieving 2 optical transmission systems. In the case of the semi duplex communication, one optical fiber is used since only one optical transmission system is required. However, it is possible to use 2 transmission systems separately for sending and receiving in the semi duplex communication; in this case, 2 optical fibers are required. A connection signal line of the multiplexed signal transmission is not limited to the optical fiber, and a twisted pair wire, a coaxial cable, or the like may be used in wired communication. A radio signal such as an optical space propagation signal and a radio wave propagation signal may be used in the multiplexed signal transmission.
[0039] A modem unit includes a wireless modulation demodulation circuit and a high frequency circuit.
[0040] A setting circuit forms a circuit selecting setting data from a wireless communication unit frequency setting table for frequency synthesizer (not shown) or the like used in the high frequency circuit and supplying the setting data via the wireless communication unit frequency setting circuit.
[0041] A control circuit includes a circuit for performing a series of controls inside the wireless communication unit.
[0042] Hereinafter, the circuit configuration of this embodiment will be described in detail.
[0043] Functions and structures of the second multiplexing unit 31 of the roadside apparatus 3 and a part of the wireless communication control unit 32 will be described with reference to FIG. 4 . The structures shown in FIG. 4 are almost the same as those of the wireless communication unit 12 of the roadside antenna apparatus 1 and the function block diagram of the first multiplexing unit 13 shown in FIG. 3 . The control circuit is provided with an interface 99 , so that the control circuit can exchange information with a man-machine setting tool 100 (ex. personal computer) to be connected externally.
[0044] Hereinafter, operation of a send circuit 31 A of the second multiplexing unit 31 of FIG. 4 will be described. Values of the frequencies used in the following description are examples and not limitative.
[0045] Information generated by using 65.536 MHz system, for example, is synchronized with a sending clock 155.52 MHz (indicated as XMHz in FIGS. 3 and 4 ) by the use of a synchronizing circuit (not shown) incorporated into a send unit. Address information and parity information are added to the synchronized information to generate a packet 600 . The thus-generated packet 600 is sent to the connection cable 2 via the parallel-serial conversion circuit (not shown) incorporated into the send circuit. A structure of the packet is shown in FIG. 5 .
[0046] Since operation of a receiving circuit 31 B of the second multiplexing unit 31 shown in FIG. 4 is substantially the same as this operation except for the direction of signals, the explanation is omitted in this specification.
[0047] The roadside apparatus 3 can perform communication with an arbitrarily selected roadside antenna apparatus 1 by inputting a command to the connected setting tool or operating a switch (not shown) in the following 2 modes.
[0048] 1) Remote normal mode;
[0049] 2) Remote loop back mode.
[0050] The roadside antenna apparatus 1 is provided with a switchboard (not shown), so that it is possible for a user to go to the roadside antenna apparatus 1 and perform setting in the following 2 modes.
[0051] 3) Automatic mode;
[0052] 4) Automatic loop back mode.
[0053] Hereinafter, details of operation of each of the above modes will be described.
[0054] 1) Remote Normal Mode
[0055] The wireless communication unit 12 performs a predetermined operation in accordance with control by the wireless communication control unit 32 . For instance, the wireless communication unit 12 sends an RF signal (status signal) at a constant interval (at 4.096 MHz cycle, for example) A frequency of the wireless communication unit 12 is set by referring to a table in accordance with command information received from the wireless communication control unit 32 (the setting is performed only after receiving the signal from the wireless communication control unit 32 ).
[0056] Of course, other settings of the roadside antenna apparatus 1 can be performed. A flow of signals in the remote normal mode is shown in FIG. 5 ( a ).
[0057] After the completion of the frequency setting, a modem output signal and a signal of a wireless communication unit output system are sent to the connection cable 2 at the constant cycle (The transmission is not performed during a period from the completion of the wireless communication unit frequency setting to recognition of a PLL lock signal by the wireless communication unit).
[0058] 2) Remote Loop Back Mode
[0059] When the wireless communication unit 12 recognizes that header information of data sent from the wireless communication control unit 32 is a loop back code, the wireless communication unit 12 sends signals sent from the wireless communication control unit 32 by loop back transmission at a constant interval (at the above described constant cycle, for example). That is, the control on the wireless communication unit is not performed. A flow of signals in the remote loop back mode is shown in FIG. 5 ( b ).
[0060] 3) Automatic Mode
[0061] This mode is used for performing an operation test on a wireless communication unit and an operation test in cooperation with a dedicated access point. As in the remote normal mode, a frequency of the wireless communication unit is set first after inputting the power (the frequency setting in the automatic mode is designated by a digital switch (not shown) provided in each of the roadside antenna apparatuses
[0062] 4) Automatic Loop Back Mode
[0063] This mode is used for performing a communication test between the first multiplexing unit 13 of the roadside antenna apparatus 1 and fold back point of the connection cable 2 of the second multiplexing unit 31 of the roadside apparatus 3 . A test pattern is continuously sent to be continuously compared with those received on the loop back path.
[0064] Hereinafter, a structure of a packet exchanged between the roadside antenna apparatus 1 and the roadside apparatus 3 will be described with reference to FIG. 6 . A structure of the packet 600 is shown in FIG. 6 , and the packet 600 includes a header 601 , an ANT address 602 for specifying the roadside antenna apparatus 1 , a COM address 603 for specifying the roadside apparatus 3 , a signal for setting/adjusting and controlling the roadside antenna apparatus 1 input from the adjustment tool 100 , data 604 of an original application handled by the road-to-vehicle communication system (for example, toll data of ETC), and a parity 605 . The ANT address 602 and the COM address 603 are used as the above-described control signal.
[0065] The packet 600 is sent as its header 601 being leading edge to be received as the header 601 being leading edge. Since the data 604 is a mixture of the control signal and data, it is compressed in the region of 604 in order to prevent loss of the original communication speed. That is, the wireless communication transmission baseband signal, the wireless communication transmission reference clock signal, and the control signal from the wireless communication unit 12 are multiplexed at a signal speed faster than the wireless transmission signal speed.
[0066] According to the above described structure, the narrowband roadside communication apparatus of this invention selects an arbitrary roadside antenna apparatus 1 by the remote operation and performs settings and maintenance with the remote control by inputting a command to the setting tool 100 such as a personal computer connected to the roadside apparatus 3 .
Second Embodiment
[0067] In actual maintenance work, an identical operation (maintenance) is performed on plural roadside antenna apparatuses 1 in many cases. Such maintenance work, i.e., repetition of the same key operation for each of the apparatuses, is a waste of time though the maintenance work can be performed remotely. In order to solve such problem, a structure shown in FIG. 7 may be adopted. Referring to FIG. 7 , a serial data control apparatus (for example, a serial I/F 4 such as a personal computer 101 ) connected to the roadside apparatus 3 transmits control contents from the personal computer 101 into multiplexed data, as serial data to be multiplexed, to control the wireless communication unit 12 . A control result is multiplexed and sent as serial data from the wireless communication unit 12 to the setting tool (personal computer) 100 , so that the control result is obtained by the setting tool 100 .
Third Embodiment
[0068] FIG. 8 is a block diagram showing a structure wherein, after demodulating the wireless transmission signal from the multiplexed data sent from the roadside apparatus 3 in the roadside antenna apparatus 1 , the demodulated signal is converted into an optical signal by an optical transmission unit 15 in the roadside antenna apparatus 1 to perform optical communication. In this case, since the wireless transmission signal is identical to the optical signal, it is possible to switch between electric wave and optical communication by including a switching signal in the multiplexing signal packet 600 , so that it is possible to select either one of the wireless communication unit 12 or the optical transmission unit 15 as the communication unit. Also, by including an optical transmission signal separately from the wireless transmission signal by the electric wave in the multiplexing data 600 , it is possible to operate the electric wave and the optical communication simultaneously without the switching.
[0069] The optical transmission unit 15 is usable for various wireless information services such as traffic information, and one example of simple usage thereof may be an optical signal for performing monitoring of a radio signal in the roadside antenna apparatus 1 .
Fourth Embodiment
[0070] FIG. 9 is a diagram showing various connection methods for connecting the roadside antenna apparatus 1 to the roadside apparatus 3 . Shown in FIGS. 9A to 9 C are examples of wired connection, wherein shown in FIG. 9A is an example of using an optical fiber as the connection cable 2 . A coaxial cable is used as the connection cable 2 in the example shown in FIG. 9B , and a twisted pair cable is used as the connection cable 2 for interconnection in the example shown in FIG. 9C . Of course, a single wire cable is used depending on a connection distance and a noise signal environment.
[0071] One example of wireless connection is shown in FIG. 9D , where optical communication, millimeter wave communication, or microwave communication is employed for interconnection.
[0072] Though two lines for sending and receiving are indicated in FIGS. 9A to 9 D under the assumption of full duplex communication, the plural transmission lines may not be required in the semi duplex communication since it is possible to use one line for sending and receiving by switching operation.
[0073] As described in the foregoing, it is apparent that the narrowband wireless communication apparatus of this invention is usable for road-to-vehicle communication in highways, road-to-vehicle communication in general roads, and road-to-vehicle communication in tunnels and underground roads, and on top of the above usages, the narrowband wireless communication apparatus of this invention is also usable for communication between a railroad line and a train.
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Since transmission between a roadside antenna unit and a roadside apparatus is performed by optical communication wherein a radio frequency is transmitted as an optical signal, the system has undesirably been expensive, and teletransmission has not been offered by the system. Also, there has been another problem that workers have to go to each of the roadside antenna apparatuses installed along a road in order to perform maintenance work of the apparatuses. A baseband signal is used for transmission between the roadside antenna apparatus and the roadside apparatus. A setting tool such as a personal computer is connected to the roadside apparatus so that operations of adjustment/setting of the roadside antenna apparatus are remotely performed with the wetting tool. The baseband signal and the remote control signal are compressed to be transmitted on an ordinary transmission signal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process of feeding at least two drawn rovings to respective ring spinning stations and to an apparatus for carrying out the process.
2. Description of the Prior Art
Each spinning station of known ring spinning machines is preceded by a drawing frame, from which a drawn fine roving is withdrawn through an eyelet and through a traveller revolves on a ring is fed to a bobbin which is non-rotatably mounted on a driven spindle. In such machines each revolution of the traveller will result in a turn of the yarn and the difference between the speeds of the leading bobbin and the trailing traveller will determine the velocity at which the yarn is wound up. Fine yarns cannot be made in such case unless the rovings supplied to the drawing frames are sufficiently light in weight per unit of length. For this reason said rovings must be subjected to a relatively expensive pretreatment to form a fine roving if the strength and uniformity which are required for ring spinning are to be achieved.
SUMMARY OF THE INVENTION
For this reason it is an object of the invention to provide a process in which the spinning stations of a ring spinning machine can be supplied with drawn rovings without a need for supplying expensive fine rovings which are light in weight.
This object is accomplished in accordance with the invention in that a primary roving which is used to feed both ring spinning stations is drawn and the drawn primary roving is divided into at least two separate rovings to be fed to respective ring spinning stations.
Because a drawn primary roving is divided into two separate rovings, it is not necessary to supply expensive fine rovings. As a result, rovings may be supplied which have a correspondingly higher weight per unit of length and this will not adversely affect the spinning conditions adjacent to each spinning station. Besides, the drawing of a roving will depend on the frictional resistance between the individual fibers of the fibrous structure so that a primary roving which is relatively heavy in weight can be drawn without a need for special measures. Nevertheless, the rovings into which the drawn primary roving is divided will meet all requirements also for the making of very fine yarns. Whereas it will generally be recommendable to divide the drawn primary roving into two rovings, a further division may be adopted if this is desired.
The process may be carried out with an apparatus comprising a drawing frame for drawing the primary roving and at least two ring spinning stations, which succeed the drawing frame. That apparatus is characterized in that the ring spinning stations are preceded by conveying means for conveying the common drawn primary roving, which conveying means comprise a revolving conveying surface including at least two separate suction zones, which extend one beside the other in the direction of conveyance and serve to divide the primary roving into separate rovings to be fed to respective ring spinning stations. The primary roving which enters the range of said two suction zones will be divided into two separate rovings because the fibrous structure disposed between the two suction zones will be pulled apart toward said suction zones to form two strands.
To be divided, the primary roving must be constrained to move adjacent to at least two juxtaposed suction zones so that a conveyor having a revolving conveying surface is provided. That conveying surface may be constituted by a revolving belt or a rotating disk. Particularly desirable conditions will be obtained if the conveying means comprise a rotating feed roller having at least two axially juxtaposed suction zones, which extend over a part of the periphery of the roller and along which the drawn primary roving is divided into two separate rovings. In such case the length in which the drawn primary roving moves without a constraint should be minimized. To that end the feed roller may be constituted by one of the delivery rollers of the drawing frame used to draw the primary roving. In that case the primary roving will be divided into two separate rovings immediately after the primary roving has been drawn.
A blast nozzle which is directed against the conveying surface may be provided. In that case the two separate rovings will be urged apart also by the air blast from the blast nozzle and this will not adversely affect the conveyance of the separate rovings on the conveying surface and will not disturb the alignment of the fibers of the separate rovings in the latter. Because the fibers of the separate rovings will be retained on the conveying surface by the suction zones, the air blast which urges the two separate rovings apart will also tend to condense the rovings.
Favorable conditions regarding the spreading of the two separate rovings will be provided if the blast nozzle consists of a slot nozzle, which extends in the direction of conveyance and spreads the separate rovings along a relatively large conveying path.
The dividing of the common primary roving into separate rovings may be assisted in that a suction-free intermediate zone, which flares in the direction of conveyance, is provided between the suction zones and the latter taper in the direction of conveyance. In that case the distance between the two separate rovings will be increased and the suction-free intermediate zone which is disposed between the suction zones and flares in the direction of conveyance will desirably constitute a deflecting surface for the air blast from any blast nozzle which may be provided. As a result, such air blast will be divided into two oppositely directed separate streams, which flow transversely to the separate rovings and are sucked off in the suction zones and assist the spreading of the separate rovings and ensure that the separate rovings will desirably be condensed. The suction zones which taper in the direction of conveyance conform to the course of the separate rovings and ensure also that the suction stream will be distributed in accordance with existing conditions along the length in which the suction zones extend in the direction of conveyance. Relatively strong suction forces for dividing the drawn primary roving into two separate rovings will be required in the receiving portions of the suction zone and only guiding functions are to be performed by the suction forces adjacent to the blast nozzle. For this reason the change of the width of the suction zones and the blast nozzle directed toward the suction-free intermediate zone between the suction zones will ensure also a desirable utilization of energy because a suction stream requires a much higher energy than a blast.
In order to ensure a uniform division of the roving into at least two separate rovings without a risk that the separate rovings may influence each other when the division has been effected, a blast zone for delivering a blast of air that has flown through the conveying surface may be provided also in the suction-free intermediate zone which is disposed between the suction zones and said air blast will then properly be divided by and sucked through the suction zones of the conveying surface. In that case the primary roving which has entered the range of said air streams will desirably be divided.
The actions which are exerted by the air blast on the separate rovings will be varied if the blasting zone is shifted in the direction of conveyance. An air blast from a blasting zone adjacent to the delivery end of the suction zones will hardly influence the dividing of the primary roving, which in that case will be divided substantially by the suction stream produced by the suction zones. But the air blast in the delivery part of the suction zones may assist the spreading of the separate rovings which have been formed. For this reason, desirable conditions for the dividing will be obtained if the blast zone extends close to the receiving end of the suction zones.
If a blast zone for delivering an air blast which has flown through the conveying surface is combined with a blast nozzle that is directed toward the conveying surface, particularly desirable conditions for the dividing of the primary roving will be provided if the blast nozzle is directed to the intermediate zone which in the direction of conveyance succeeds the delivery end of the blasting zone because different actions, which supplement each other, will be produced in that case by the blasts from the blasting zone and from the blast nozzle. In such an arrangement the air blast from the blasting zone will assist the division of the primary roving into two separate rovings and the air blast from the blast nozzle will assist the spreading and condensing of the separate rovings which have been formed from the primary roving.
Because the energy required to divide the drawn primary roving into two separate rovings is to be minimized, the suction zones should be as short as possible. To that end the suction zones may terminate at a distance before the delivery end of the conveying means. Surprisingly it has been found that when the two separate rovings have been moved sufficiently apart they will be guided on the conveying surface even when they are not sucked thereto.
The separate rovings may be guided on the conveying surface by means of a roller which is associated with the conveyor and applies pressure to the separate rovings. In that case the points of departure of the separate rovings will be defined and the condensing of the rovings will effectively be assisted. The transverse forces exerted by the divided air blast will act on rovings, which toward the delivery end are retained against a transverse displacement. Whereas clamping forces for a high-draft drawing of the primary roving are required in the nip between the delivery rollers of the drawing frame, such forces need not be exerted in the guiding gap defined by the pressure applying roller, where it is merely necessary to exert guiding forces which prevent a lateral wandering. For this reason the width of the condensed separate rovings will not appreciably be increased as they are conveyed through said guiding gap and because the separate rovings substantially correspond in their cross-sectional shape to the yarns which are to be made, the separate rovings can conveniently be twisted by the respective succeeding ring spinning stations.
If the pressure-applying roller is spaced before the delivery end of the conveying means, the twist which is imparted to the separate rovings by the ring spinning stations will extend along the conveying means as far as to the guiding gap between the pressure-applying roller and the conveying surface so that the fiber ends which protrude from the separate rovings will be wound around the separate rovings as they are rotated. This is due to the fact that the rotation of the roving will cause the protruding fiber ends to be deflected by the conveying surface transversely to the axis of the roving and will cause said fiber ends to be wound around the associated roving. That additional winding of the protruding fiber ends around the separate rovings will improve the alignment of the fibers owing to the condensing of the fibers and will appreciably increase the strength of the yarn.
As the primary roving is divided into at least two separate rovings, the fibers of the primary roving will be pulled apart and individual fibers may be sucked at one end toward one suction zone and at the other end toward the other suction zone so that such fibers may form bridges between the separate rovings adjacent to the suction zones. Such bridges may tend to move the separate rovings toward each other. A formation of such bridges by individual transverse fibers will be prevented if a fiber stripper is associated with the conveying surface in the suction-free intermediate zone between the suction zones and/or in the succeeding peripheral portion because such fiber stripper will permit transverse fibers to be conveyed only to one of the separate rovings.
The fiber stripper may be of any of several types and may consist, e.g., of an elastic pressure-applying member. But particularly simple conditions will be obtained if the fiber stripper consists of at least one stripping brush, which is moved into engagement with the conveying surface and prevents a further conveyance of fiber bridges between the separate rovings.
For an advantageous result of the spinning operation the drawn primary roving must be divided into the separate rovings with a constant fiber ratio. That ratio will depend on the position of the drawn primary roving relative to the two suction zones and on the distribution of fibers over the cross-section of the roving. If the roving guide associated with those drawing elements of the drawing frame which directly precede the delivery rollers is mounted to be adjustable in the direction of the width of the gap defined thereby, this will permit an exact adjustment of the distribution of ratio of the fibers contained in the two separate rovings because the distribution of the fibers of the primary roving over the cross-section thereof can be influenced by a displacement of that roving guide. In that manner a desired distribution of fibers over the width of the drawn primary roving can be enforced so that the desired division of the primary roving will be ensured if the position of the primary roving relative to the dividing means is properly selected.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified front elevation showing an apparatus in accordance with the invention for feeding two drawn rovings to respective ring spinning stations.
FIG. 2 is a side elevation showing that apparatus partly broken away.
FIG. 3 is a sectional view taken on line III--III in FIG. 2.
FIG. 4 is an enlarged sectional view taken through the high-draft field of the drawing frame on the feeding plane.
FIG. 5 is an enlarged sectional view which is similar to FIG. 2 and shows a portion of a modified apparatus in accordance with the invention.
FIG. 6 is a sectional view taken on line VI--VI in FIG. 5.
FIG. 7 illustrates another modification in a view which is similar to FIG. 5.
FIG. 8 is a sectional view taken on line VIII--VIII in FIG. 7.
FIG. 9 is a still further enlarged sectional view taken on line IX--IX in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is illustrated by way of example on the drawing.
In the illustrative embodiment shown in FIGS. 1 to 4, two ring spinning stations 3 are preceded by a common drawing frame 1 for drawing a primary roving 2. Each ring spinning station is of conventional type and comprises a ring rail 4 that is provided with a ring, a traveller 5 movably mounted on the ring 5, and a bobbin 8, which is adapted to be driven by a spindle wharve 7.
One delivery roller 9 of the pair of delivery rollers 9, 10 of the drawing frame 1 constitutes a feed roller associated with the succeeding ring spinning stations 3 and is larger in diameter than the other delivery roller 10 to constitute conveying means 11 for conveying the drawn primary roving 2. The conveying means 11 comprise two suction zones 12a and 12b, which extend one beside the other in the direction of conveyance and to which a suction is applied via a corresponding suction insert 13 of the feed roller 9. This is particularly apparent from FIG. 3.
Because the drawn roving 2 is moved on the feed roller 9 into the region of the two suction zones 12a and 12b and said suction zones are only closely spaced apart at least at their receiving end, the fibrous structure which is constituted by the primary roving 2 will be broken apart between the two suction zones 12a and 12b and will be pulled apart toward said suction zones so that the primary roving 2 will be divided into two separate rovings 2a and 2b, which are conveyed along the conveying means 11 first as far as to a pressure-applying roller 14, which together with the feed roller 9 defines a guiding gap, which prevents a lateral wandering of the separate rovings 2a and 2b. That guiding gap will control the deflection of the separate rovings 2a and 2b from the direction of conveyance of the conveyor means 11 toward the entrance eyelets 15 of the ring spinning stations 3.
The two suction zones 12a and 12b enforce a division of the primary roving 2 into two separate rovings 2a and 2b, which are fed to respective ring spinning stations 3. That division will afford the considerable advantage that only a common drawing frame 1 is required to be associated with both ring spinning stations 3 and the primary roving which is fed to that drawing frame may have a weight which is twice the weight of the roving which is required for the making of the ring-spun yarn. As a result, the expensive making of a fine roving otherwise required may be omitted and that omission will not adversely affect the result of the spinning operation because the fineness of the yarn will depend on the weight of the separate rovings 2a and 2b rather than on the weight of the primary roving 2.
In order to assist the division of the primary roving 2 into two separate rovings 2a and 2b, a blast nozzle 16 is provided between the separate rovings 2a and 2b and is directed toward the conveying surface so that the air blast which is directed by the blast nozzle 16 against the suction-free intermediate zone 17 will urge the two separate rovings 2a and 2b apart so as to increase the distance between them. The suction-free intermediate zone desirably flares in the direction of conveyance and the suction zones 12a and 12b have a corresponding taper so that the separate rovings 2a and 2b will be condensed, particularly because the pressure-applying roller 14 will prevent a lateral shifting of the separate rovings 2a and 2b. As a result, the rovings can be given a cross-sectional shape which is similar to the cross-sectional shape of the yarn that is to be made so that the twisting of the separate rovings by the ring spinning stations 3 will greatly be facilitated. This is due to the fact that the wide roving strip which has left the high-draft field of the drawing frame need no longer be condensed in a triangular region to the round cross-section of the yarn as the roving strip is twisted and the alignment of the fibers will thus be improved and a stronger yarn will be made. Besides, the pressure applying roller 14 is spaced before the delivery end 18 of the conveying means 11 and the guidance of the rovings on the feed roller behind the pressure-applying roller 14 will ensure that roving fibers which protrude from the separate rovings 2a, 2b will be wound around said rovings because the twist which is imparted to the rovings by the ring spinning stations will extend as far as to the guiding gap defined by the pressure-applying roller 14 and the feed roller 9 so that the protruding fiber ends engaging the surface of the feed roller 9 will be wound around the rotating separate rovings 2a and 2b.
An exact division of the primary roving 2 into the two separate rovings 2a and 2b will require a predetermined position of the drawn roving 2 relative to the two suction zones 12a, 12b and a proper distribution of the fibers over the cross-section of the roving. To that end a roving guide 20 may be associated with those drawing elements of the drawing frame 1 which directly precede the delivery rollers 9 and 10 and consist of drawing belts 19 and said roving guide 20 may be mounted to be adjustable in the direction of the width of the gap that is defined by said guide and may be arranged to be displaced by means of an adjusting mechanism 21, such as a screw drive. Such a displacement will highly sensitively influence the alignment of the drawn primary roving 2 relative to the suction zones 12a and 12b and the distribution of fibers over the cross-section of the roving.
The illustrative embodiment shown in FIGS. 5 and 6 differs from the illustrative embodiment shown in FIGS. 1 to 4 essentially only in that a stripper 22, which succeeds the blast nozzle 16 in the direction of rotation of the feed roller 9, is disposed in the suction-free intermediate zone 17 between the suction zones 12a and 12b, which intermediate region 17 flares in the direction of conveyance. In the illustrated embodiment that stripper 22 is constituted by a brush 23, which prevents a formation of fiber bridges between the two separate rovings 2a and 2b. Behind the pressure-applying roller 14 such fiber bridges might otherwise cause the two separate rovings 2a and 2b to influence each other as they are twisted. Each of the fibers which have been transversely stretched as the fibers of the primary roving 2 were pulled apart will be permitted by the brush to move only to one of the two separate rovings 2a and 2b. Because the separate rovings have been condensed so that the fibers need not be moved toward each other in the configuration of a triangle having a wide base when the separate rovings have left the guiding gap, the separate rovings 2a and 2b which leave the guiding gap between the pressure-applying roller 14 and the feed roller 9 can be uniformly twisted without influencing each other and this is achieved in spite of the fact that the rovings lie on the feed roller 9 until they are close to that guiding gap.
The illustrative embodiment shown in FIGS. 7 to 9 comprises in addition a blasting zone 24 in the intermediate zone 17 between the two suction zones 12a and 12b, which taper in the direction of conveyance. That blasting zone 24 extends close to the receiving end of the suction zones and is supplied with compressed air via a pressure line 25. The air blast which emerges from the feed roller 9 adjacent to the blasting zone 24 is deflected toward the suction zones 12a and 12b and is divided into two partial streams and is then sucked off. By that air stream the fibrous structure of the primary roving 2 which is fed to the feed roller 9 will be broken up and pulled apart toward the two suction zones 12a and 12b so as to form two separate rovings 2a and 2b. The enforced division of the primary roving 2 by the two suction zones 12a, 12b and the blasting zone 24 between them into two separate rovings 2a and 2b, which are fed to respective ring spinning stations 3, may be assisted by a succeeding blast nozzle 16, which discharges an air blast that is directed against the suction-free intermediate zone and urges the separate rovings 2a and 2b apart.
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In order to avoid the need for providing expensive fine rovings, a process is proposed in which two rovings are supplied to respective ring spinning stations (3). A common primary roving (2) is drawn and is subsequently divided into two separate rovings (2a, 2b) for feeding respective ring spinning stations (3). The primary roving (2) is divided into two separate rovings (2a and 2b) by conveying means (11), which comprise two juxtaposed suction zones (12a, 12b), which extend in the direction of conveyance.
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BACKGROUND OF THE INVENTION
The present invention relates to an engine control apparatus for marine use, and more particularly, to an apparatus for controlling both engine revolution (throttle control) and change of "ahead(forward)"-"neutral"-"astern(reverse)" (clutch control) of a small craft or boat, for example motorboat and so on, which are remotely operated by a single operational lever in a cockpit.
As a conventional engine control apparatus for marine use, there has been known a device shown in Japanese Unexamined Patent Publication No. 114197/1984.
In the device, as shown in FIG. 6 for example, when a driving disc 52 supported with an axis on a housing 51 is rotated by means of an operational lever 53 in a certain domain (a certain angular range) including neutral position, only a clutch arm 54 rotates and a change operation of "ahead"-"neutral"-"astern" of a clutch is performed through a clutch operation cable 55 (including a cable end rod, and so forth).
Further, when the driving disc 52 is rotated over the above-mentioned domain, only a throttle arm 56 rotates and power of the engine is governed through a throttle operational cable 57. In this case, when the throttle cable 57 is pushed, the engine is accelerated. That is, the engine is a "push-type-engine". However, the device is designed such that the device can also be applied to a "pull-type-engine" which is accelerated when the throttle cable 57 is pulled.
When the device is applied to a "pull-type-engine", an operating plate 61 which has a cam roller 60 engaged with a cam groove 59 of the above-mentioned driving disc 52 is removed, the inside of the plate 61 is turned out, and is attached to the device again. And further, the plate 61 is pin-jointed to another engaging hole 62 of the throttle arm 56.
Therefore, in the above-mentioned conventional device (Japanese Unexamined Patent Publication No. 114197/1984), when the device adapted for a push-type-engine (or a pull-type-engine) is applied to a boat having another type engine i.e. the pull-type-engine (the push-type-engine), the work of re-assembling is very troublesome.
Further, the device of FIG. 6 has a free throttle lever 63 for independently operating the throttle when the operating lever 53 is in the neutral position.
That is, a link 64 is laid between the free throttle lever 63 and the throttle arm 56 so as to rotate around a pin 67, and an arc-shaped cam groove 65 is formed in the link 64.
The cam groove 65 slidably receives a cam roller 66 fixed to the top end of the free throttle lever 63, and the cam roller 66 engages with the cam groove 65 with, so to speak, linear-contact. Therefore, a disadvantageous abrasion occurs in the contacting part. Moreover it is necessary to rotate widely the operating plate 61, when the engine is accelerated through the free throttle lever 63. Therefore, there are some problems that the mechanism is complicated, and assembling and adjusting works and maintenance of the mechanism are troublesome.
The object of the present invention is to provide an engine control apparatus for marine use, in which the same operability as the above-mentioned conventional device is held, mechanism is simple, and assembling and adjusting and maintenance are easy.
Another object of the present invention is to provide a device which can be easily applied to a different type of engine, i.e. an engine having a different operating direction of a throttle cable.
SUMMARY OF THE INVENTION
The engine control apparatus of the present invention comprises an operating plate, a transmission link, and a throttle arm. The operating plate is driven by pushing/pulling operation through a cam which is attached to a driving disc. The transmission link extends in a moving direction of the operating plate and is movable in the same direction. Moreover, the link is driven by pushing/pulling operation according to the operation of the free throttle lever.
The throttle arm is connected to a top end or the neighborhood of the transmission link (a first rotation center), and is further connected to the top end or the neighborbood of the operating plate (a second rotation center). When a throttle is operated through the operating plate, the throttle arm rotates around the first rotation center, and on the other hand, when the throttle is operated through the free throttle lever, the throttle arm rotates around the second rotation center.
In the apparatus as mentioned above, during a general run, the free throttle lever is in the idling position and the throttle arm is rotated such that the first rotation center serves as a fulcrum.
On the contrary, when the engine is operated in order to warm up, the throttle arm is rotated such that the second rotation center serves as another fulcrum. That is to say, the first and second rotation centers perform as a force point and a fulcrum of a lever altenately in accordance with situation.
Since, in the above-mentioned operations, the contact portion is only the rotating surface of the pin joints, durability of a rotating mechanism portion of the free throttle arm is improved, and a total mechanism of the device becomes simple.
Further, in the motions of the transmission link and the operating plate, rotating motion is fundamentally not required. In addition, for example, if a structure allowing some vertical motions of the operating plate is employed, the operating plate can be formed as a member linearly moving in the housing. In such case, the mechanism of the device becomes more simple, and the motion of the throttle arm becomes more smooth. And besides, during the rotation of the throttle arm, the throttle cable sweeps less degrees in swing angle.
In addition, when the driving disc has two types of cams, i.e. a cam for pull-type-engine and another cam for push-type-engine, and both cams are formed in the same driving disc such that the cams are opposed to each other, the device can be easily applied to not only a pull-type-engine but also a push-type-engine by changing a cam roller position of the operating plate and by changing a connecting position between the rotating link and the transmission link.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 and FIG. 2 are perspective views showing a housing cover side and a housing body side, respectively, of an embodiment of the device of the present invention;
FIG. 3 and FIG. 4 are interior front views of the mechanisms shown in FIG. 1 and FIG. 2, respectively;
FIG. 5 is a front view showing the device shown in FIG. 1, in the re-assembled state for pull-type-engine; and
FIG. 6 is a front view showing an inner part of an example of conventional engine control apparatuses for marine use.
DETAILED DESCRIPTION
Referring to FIG. 1, a cover-side half body of an engine control apparatus is explained.
A housing cover 1 has two projecting block-like guides portions 2 and 3, i.e. a main guide 2 and a secondary guide 3.
The main guide 2 has a shaped hole 4 at the center or the neighborhood thereof. A guide bush 6 made of bearing metal or synthetic resin is securely inserted into the hole 4, and the guide bush 6 has a joggled flange with a rectangular shape to be engaged with the outer surface of the main guide 2. The guide bush 6 also has a cylindrical hole with an inner surface 7 for rotatably supporting a boss 9 of a driving disc 8 of FIG. 2.
An operating plate 10 is mounted on the guide bush 6 in a slidable state. That is to say, the inside parallel edges of the rectangular hole 11 of the operating plate 8 and the reverse surface of the operating plate 10 are engaged with the peripheral surface and the front surface of the joggled flange 5 in a slidable state. Therefore, the operating plate 10 can be guided with the guide bush 13 so as to linearly slide in a longitudinal direction of the rectangular hole 11.
A sliding bush 13 having a flange is slidably engaged with another rectangular hole 12 formed in the secondary guide 3. Further, the operating plate 10 has a flanged pin 15 inserted through a hole formed in the forward end portion and is projected to the reverse side of the plate 10, and the flanged pin 15 is connected to the sliding bush 13.
Therefore, by means of both guide portions 2 and 3, the linear motion of the operating plate 10 is certainly retained with a long span over the right side and left side.
A throttle arm 18 is attached rotatably around the above-mentioned pin 15, and is sandwitched between the sliding bush 13 and the operating plate 10.
In an upper side of the above-mentioned main guide portion, a disc-like rotating link 19 is rotatably attached to the housing cover 1. The rotating link 19 is fixed to the base part or the axis of the free throttle lever 20 such that the rotating link is rotated together with the free throttle lever 20 arranged on the outside of the housing cover. Two screw holes 22 and 23 are formed in order to selectively attach a transmission link 21. The two positions are symmetrical with respect to the rotation center of the rotating link 19.
Further, in case of FIG. 1, another end of the transmission link 21 is pin-jointed to the hole located in the upper end of the throttle arm 18. An end of the transmission link 21 is pin-jointed concentrically with the screw hole 22 located in the fore side of the rotating link 19. Therefore the transmission link 21 is arranged almost parallel to the operating plate 10, and the transmission link 21 and the operation plate 10 are constructed in an parallel arrangement in mechanism so as to move in almost the same direction. The operating plate 10 has two holes 26 and 27 for selectively attaching a cam roller 25 to be engaged with the cam groove of the driving disc 8. The attaching holes 26, 27 are arranged on the both sides of the rectangular hole 11 of the operating plate 10. In case of FIG. 1, the cam roller 25 is attached to an attaching hole 27 (referring to FIG. 5) located in the aft side.
Hereinafter, construction of the main body side of the housing is explained referring to FIG. 2.
A driving disc 8 is rotatably mounted in the central portion 28 of the housing and is connected to the operational lever 29 which is located in the outside of the main body 28 of the housing, such that the driving disc 8 is rotated through the lever 29.
Two cam grooves each of which has a "C" like shape 30 and 31 are formed in the driving disc 8 on the opposite sides with respect to the boss 9 so as to oppose to each other. Each cam groove 30 and 31 has a rest zone Ro with an arc shape of which a center is the rotating center of the driving disc 8 and operating zones Rf and Rr which extend from the both ends of the rest zone in a circumferential direction with somewhat inward to the center of rotation i.e. as the operating zone extends from the end of the rest zone, the operating zone extends inner side in the radial direction. One operating zone Rf is made to be long or than the other in order that the engine can be operated to the full throttle state i.e. the operating zone for "ahead (forward)", and another operating zone Rf is for "astern (reverse)".
The back side of the driving disc 8 is provided with one tooth 32 and a slidably contacting portion with a cylindrical slidable surface 33 as a one body as shown with a broken line in FIG. 4. The tooth 32 and the slidable surface 33 construct a clutch operating mechanism together with two teeth 34a and a inwardly curved slidable surface 36 formed in the position opposing a clutch arm 34 rotatably mounted on the main body 28 of the housing, and the both cooperate to perform the clutch mentioned after operation which is the same as the conventionally known operation.
The two halves of FIG. 1 and 2 are mately superposed in such state that the cam roller 25 is engaged with the cam groove 30 of the driving disc 8, and are assembled with using screws or the like.
Hereinafter, operation of the device constructed as mentioned above is explained referring to FIGS. 3 and 4.
Firstly, the clutch operation is explained referring to FIG. 4.
When the operational lever 29 points just "upper side", the clutch arm 34 points "down side" which is the "neutral" position on account of an engagement of teeth 32, 34a. Next, when the operational lever 29 is turned forward (in an arrow A direction), the down end of the clutch arm 34 rotates forward on account of an engagement of teeth 32, 34a, and the clutch cable 35 is pulled in an arrow A1 direction to chang the clutch into "ahead".
On the contrary, when the operational lever 29 is turned in an arrow B direction, the clutch arm 34 rotates backward and the clutch cable 35 is pulled in an arrow A2 direction.
When the above-mentioned clutch operation is performed, the cam roller 35 moves in the rest zone Ro, therefore the operating plate 10 and the throttle arm 18 of FIG. 3 do not move.
When the clutch operation is finished, the inwardly curved slidable surface 36 located in the base part of the clutch arm 34 comes in contact with the cylindrical surface of the driving disc. Therefore, though widely the operational lever is swung, the clutch arm 34 does not rotate and is locked with keeping the angle. Such a clutch operation is almost the same as operation of a conventional device, including a lock mechanism.
When the operational lever is moved further in an arrow A direction, the cam roller 25 is admitted in the forward zone Rf of the cam groove 30, and the operating plate 10 is slided in the direction of an arrow C according to the rotating angle.
Therefore, the throttle arm 18 is rotated around the connecting point P in an arrow E direction, and the engine is accelerated through pulling the throttle cable 37 (referring to two-dot chain line S). And besides, during all that time, another connecting point Q connecting the throttle arm 18 with the operating plate 10 moves linearly, and the connecting point P moves somewhat up and down with respect to a point connecting the rotating link 19 with transmission link 21 (the position of the screw hole 22). For this reason, the down end of the throttle arm 18 has a narrow or range of up and down motion (the range for the same operating stroke) compared with the case of merely turning around the connecting points P or Q. Therefore, there is an advantage that a connecting rod 37a and a guiding pipe attached to an end part of the throttle cable 37 moves with a narrow angle.
The operation to return the operational lever to the original "neutral" position and the operation to rotate the lever in the aft side direction are the same as the above-mentioned "forward operation" except that the direction is inverse. Hereinafter, the free throttle operation in case of an idling running is explained referring to FIG. 1.
When the operational lever 29 is let to be in the state of neutral and the clutch is let to be in "neutral", the operating plate is in a regular position or a rest position (a position shown at right side of FIG. 1 with a real line).
Under the situation, when the throttle lever 20 is pulled in an arrow U direction, the rotating link 19 turns in the same direction and the transmission link 21 is pulled in the aft side direction (in an arrow T direction) as shown in an imaginary line. Then, the lower side of the throttle arm 18 rotates forward around the connecting point Q to pull the throttle cable 37. As a result, an idling running of the engine can be performed.
Though, the case that the device is mounted on a "pull-type-engine" is mentioned above, the device of FIGS. 1 and 2 can be easily applied to the "push-type-engine" by re-assembling as mentioned below.
Firstly, the connecting point of the transmission link 21 with the rotating link 19 is changed to the side of the screw hole 23. For that reason, the device becomes to a type that when the free throttle lever 20 is pulled and raised, the transmission link 21 is pushed forward.
Further, the cam roller 25 of the operating plate 10 is removed and is attached to a attaching hole (26 in FIG. 1) to be engaged with a cam groove 31 of the driving disc 8 of FIG. 2. For that reason, the operating plate 10 and connecting point Q are located in the left side in the neutral position. Therefore, when the transmission link 21 is pushed forward, the lower side of the throttle lever 18 is rotated backward and the throttle cable 37 is pushed. Then the engine can be accelerated.
Next, in relation to the throttle operation by means of the operational lever 29, when the operational lever 29 is operated so as to be turned forward, the cam roller 25 comes into the ahead zone Rf and the operating plate 10 is pulled backward to the full throttle position. Then the throttle arm 18 is rotated in the aft direction.
Therefore, in case that the device is re-assembled as shown in FIG. 5, the throttle cable 37 can also be pushed either pushed to the accelerating side or pulled to the decelerating side operation by means of the operational lever 29 and the free throttle lever 20 through the same manner as the explanation in case of FIG. 3.
Also in the device of the present invention, it is preferable that the device has a braking means (40 in FIG. 4) for giving a feeling of a suitable resistance against the motion of the operational lever as are in the conventional device and has a known interlocking mechanism 41 in FIG. 3 for preventing an errorneous simultaneous operation of the operational lever 29 and the free throttle lever 20, as are provided in the conventional device.
Further, the device may preferably have a suitable detent mean for announcing a certain angle position (the end of rotating and so on) of the driving disc 8 and the rotating link 19 to the operator.
Besides, if a through hole is formed in the housing cover 1, a boss part of the operational lever 29 can be advantageously fixed to the top end of the boss 9 of the driving disc 8 through the hole. For that reason, the operational lever can also be easily attached to the housing cover side.
When the device of which the operational lever is attached to the housing cover side and another type of device of which the operational lever is attached to the housing body side are superposed together, the device can be employed as an operating apparatus for a motorboat having two engines so as to speak a "twin-type-motorboat".
Moreover, the numeral 43 of FIG. 4 shows an ignition key switch, and the numeral 44 shows a terminal for the purpose of connecting to electric apparatuses, for example, a limit switch for detecting an angular position of the driving disc, a trim switch (a switch for operating a trim angle of an outboard engine) attached to the operational lever.
Further, the numeral 29a of FIG. 1 shows a lever connected to a trigger which is attached to a grip of the operational lever 29. The lever 29 allows itself to turn (or change to an operating position) only when the trigger is pulled with a finger, and is used for the purpose of releasing an interlock of the operational lever.
The device of the present invention retains the operatability to change the clutch and to operate the throttle with a single operational lever at the same time that a conventional device has. In addition, in the device of the present invention since the mechanism is simple, assembling and maintenance are easy. Further, the device is also selectively applied to "pull-type-engine" and "push-type-engine" by re-assembly some parts.
Though several embodiments of the invention are described above in detail, it is to be understood that the present invention is not limited to the above-mentioned embodiment, and various changes and modifications may be made in the invention without departing from the spirit and scope thereof.
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An engine control apparatus for marine use comprising an operating plate which is driven by pushing/pulling operation through a cam attached to a driving disc, a transmission link which is arranged so as to extend in the moving direction of the operating plate and to be movable in the direction, and moreover, which is driven by pushing/pulling operation according to the operation of a free throttle lever, and a throttle arm which is connected to the transmission link at a first rotation center and connected to the top end of the operating plate at a second rotation center which is apart from the first center of rotation. In the device, when a throttle is operated through the operating plate, the throttle arm rotates around the first center of rotation, and on the other hand, when the throttle is operated through the free throttle lever, the throttle arm rotates around the second center of rotation.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a radiation therapy devices and a method of radiation therapy, and more particularly, to radiation therapy devices and radiation therapy methods that use predictive organ dynamics data.
[0003] 2. Discussion of Related Art
[0004] Conventional radiation therapy typically involves directing a radiation beam at a tumor in a patient to deliver a predetermined dose of therapeutic radiation to the tumor according to an established treatment plan. This is typically accomplished using a radiation therapy device such as the device described in U.S. Pat. No. 5,668,847 issued Sep. 16, 1997 to Hernandez, the contents of which are incorporated herein for all purposes.
[0005] The radiotherapy treatment of tumors involves three-dimensional treatment volumes which typically include segments of normal, healthy tissue and organs. Healthy tissue and organs are often in the treatment path of the radiation beam. This complicates treatment, because the healthy tissue and organs must be taken into account when delivering a dose of radiation to the tumor. While there is a need to minimize damage to healthy tissue and organs, there is an equally important need to ensure that the tumor receives an adequately high dose of radiation. Thus, the goal of radiation is to administer a treatment that has a high probability of tumor control while providing an acceptably low probability of complications in normal tissue.
[0006] With new image guided and adaptive radiotherapy techniques, a wealth of information about the patient geometry is obtained, and it is desirable to use this information to tailor the treatment for complication-free tumor control at every step in the treatment. This is difficult because the three-dimensional treatment volumes for the tumor typically also include normal organs. Thus healthy tissue and organs must be taken into account when delivering a dose of radiation to the tumor, and each type of tissue has a different type of response to varying degrees of radiation. While there is a need to minimize damage to healthy tissue and organs, there is an equally important need to choose a prescription in which the tumor receives an adequately high dose of radiation. Cure rates for many tumors are a sensitive function of the dose they receive, just as complication rates in normal organs are a function of the dose that they receive. Therefore, it is useful to have as much information as possible to understand how a certain type of tumor and certain normal structures have responded to radiation in other patients. It would be essential to monitor these quantities both during treatment during the follow up process.
[0007] Another factor that adds complexity to the planning process is the fact that many organs change size, shape and position from day to day. This also affects the prescription because margins must be added to these structures to account for the likely extent of the changes. A better understanding of the likely effect of these factors could result in a more accurate plan and higher probability of complication free tumor control.
[0008] [0008]FIG. 1 schematically shows a radiation therapy machine 10 that includes a gantry 12 which can be swiveled around a horizontal axis of rotation 14 in the course of a therapeutic treatment. A treatment head 16 is fastened to a projection of the gantry 12 . A linear accelerator (not shown) is located inside gantry 12 to generate the high energy radiation required for the therapy. The axis of the radiation bundle emitted from the linear accelerator and the gantry 12 is designated by beam path 18 . Electron, photon or any other detectable radiation can be used for the therapy.
[0009] During a course of treatment, the radiation beam is trained on treatment zone 20 of an object 22 , for example, a patient who is to be treated and whose tumor lies at the isocenter of the gantry rotation. Several beam shaping devices are used to shape radiation beams directed toward the treatment zone 20 . For example, a multileaf photon collimator and a multileaf electron collimator can be arranged to shape the radiation beams. Each of these collimators may be separately controlled and positioned to shape beams directed at treatment zone 20 .
[0010] Accordingly, it is an object of the present invention to tally informative statistics on the amount of dose required to treat specific types of tumors, and on the tolerance levels of specific normal tissues.
[0011] It is another object of the present invention to compile changes in the size and shape for each type of tissue and tumor and use the compiled changes with informative statistics to predict how organs will respond throughout the course of therapy.
SUMMARY OF THE INVENTION
[0012] One aspect of the present invention regards a method of treating an region of interest with radiation by identifying a region of interest of a patient. The method includes determining a treatment plan for the region of interest based on a statistical analysis between one or more metrics of the identified region of interest and a previously determined predictive dynamics database that includes information regarding the one or more metrics for corresponding regions of interest for a population of patients. Thereafter, a dose of radiation is delivered to the region of interest of a patient based on the determined treatment plan.
[0013] A second aspect of the present invention regards a radiation therapy device that includes a radiation source positioned to direct a beam of radiation along a beam path toward a region of interest of a patient and a treatment planning system connected to a control console, which is connected to the radiation source. The treatment planning system includes a memory that stores a predictive dynamics database that includes one or more metrics associated with the region of interest and probability distribution functions for the one or more metrics. The treatment planning system generates a treatment plan based on the stored predictive dynamics database and sends the treatment plan to the radiation source so as to control a dose of radiation generated by the beam of radiation at the region of interest.
[0014] A third aspect of the present invention regards a method of generating a predictive dynamics database used for treating a region of interest with radiation. The method includes taking a three-dimensional image volume of a region of interest of a patient, defining the three-dimensional image volume and determining one or more metrics of the defined three-dimensional image volume, forming probability distribution functions for each of the one or more metrics, and storing the one or more metrics and the formed probability distribution functions to form a predictive dynamics database.
[0015] Each aspect of the present invention increases the probability of tumor control and decreases the probability of complications in normal tissue.
[0016] Further characteristics and advantages of the present invention ensue from the following description of exemplary embodiments by the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 shows an embodiment of a radiation therapy machine;
[0018] [0018]FIG. 2 shows an embodiment of a radiation therapy machine in accordance with the present invention;
[0019] [0019]FIG. 3 shows a block diagram illustrating portions of the radiation therapy machine of FIG. 2;
[0020] [0020]FIG. 4 schematically shows a collimator system to be used with the radiation therapy machine of FIG. 2; and
[0021] [0021]FIG. 5 shows a flow chart that shows a mode of a method of treating a region of interest with radiation in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] A radiation therapy machine 100 that incorporates a number of the elements of the radiation therapy machine 10 of FIG. 1 is shown in FIGS. 2 - 4 . The radiation therapy machine 100 includes a gantry 102 which can be swiveled around a horizontal axis of rotation 104 during the course of a therapeutic treatment. A beam source 106 is used to generate radiation beams in any of a number of ways well-known to those skilled in the art. For example, the beam source 106 may include a dose control unit 108 used to control a trigger system generating injector trigger signals fed to an electron gun in a linear accelerator (not shown) located inside the gantry 102 to produce the high energy radiation, such as an electron beam or photon beam, required for the therapy. The beam source 106 may include separate sources of radiation for photons and electrons. The axis of the radiation bundle emitted from the linear accelerator and the gantry 102 is designated by beam path 110 .
[0023] During a course of treatment, the radiation beam is trained on treatment zone 112 of an object 114 , for example, a patient who is to be treated and whose tumor lies at the isocenter of the gantry rotation. Several beam shaping devices are used to shape radiation beams directed toward the treatment zone 112 . In particular, a multileaf photon collimator 116 and a multileaf electron collimator 118 are provided. Each of these collimators, as will be described further below, may be separately controlled and positioned to shape beams directed at the treatment zone 112 .
[0024] The plates or leaves of the collimators 116 and 118 are made of a material, such as brass, tungsten or lead, substantially impervious to the emitted radiation. The collimator leaves or plates are mounted between the radiation source and the patient and positioned in order to delimit (conform) the field. Areas of the body, for example, healthy tissue, are therefore subject to as little radiation as possible and preferably to none at all.
[0025] Note that the plates or leaves of the collimators 116 and 118 are movable such that the distribution of radiation over the field need not be uniform (one region can be given a higher dose than another). In particular, the leaves of each collimator are individually driven by a drive unit 120 , 122 and are positioned under the control of electron collimator control 124 , photon collimator control 126 and sensor(s) 128 and 130 . Drive units 120 , 122 move the leaves of each collimator in and out of the treatment field to create a desired field shape for each type of beam. In one embodiment, where an electron beam is to be generated and primary electrons are to be used in a treatment, photon collimator control 126 operates to retract individual leaves of photon collimator 116 , while electron collimator control 124 operates to position individual leaves of electron collimator 118 across the path of the electron beam to generate a desired electron field shape at the isocenter.
[0026] Note that while the radiation therapy machine 100 described above has the capability of providing either photon beam or electron beam treatments, the present invention is equally applicable to radiation therapy machines that have only one radiation source.
[0027] Radiation therapy machine 100 also includes a central treatment processing or control unit 132 that controls an adaptive radiation treatment process in accordance with the present invention. One mode of a possible adaptive radiation treatment process 200 is shown in FIG. 5. In this mode, a predictive organ dynamics database is established and updated per steps 202 , 204 , 206 and 208 to be described below. In particular, the predictive organ dynamics database includes information taken from N three-dimensional (3D) image volumes taken of a particular region of interest for a population of patients that may include a particular patient to be treated. The three-dimensional image volumes are taken in a well known manner, such as magnetic resonance imaging, CT or x-ray imaging, per step 202 . The 3D image volume may be obtained at a different site or at the site of the radiation therapy machine 100 by an imaging system, such an x-ray imaging system 134 or a magnetic resonance imaging system 136 . In the case of an x-ray imaging system, an imaging radiation source 138 , such as an x-ray source, subjects the treatment zone 112 to radiation that is imaged by detector 140 in a well known manner. The image information is then fed from the detector 136 to a computer 142 of the central treatment planning unit 132 .
[0028] Each time a 3D image volume of the patient is taken, the target for treatment and normal structures are defined in the 3D image volume in the central treatment planning or (virtual) simulation unit 132 by a known process called segmentation per step 204 . It is important that each segmentation of the 3D image volume be done as consistently as possible, using automatic techniques if they are available. Note that the segmentation process preferably includes consistently naming and defining the organs shown in the 3D image volume so that they can be compared with other like named and defined organs of the patient and the entire patient population. Similarly, tumors and targets need to be adequately characterized or identified in the 3D image volume to ensure that they can be pooled or grouped with tumors and targets of similar type and stage of development.
[0029] After an image is appropriately segmented per step 204 , a number of metrics, i.e., measurable quantities or qualities, are recorded based on the 3D image volume data sent to the central treatment processing unit 132 per step 206 . For each organ, the position, size and shape and other organ parameters are determined and recorded. Examples of such organ parameters are:
[0030] 1) The position of the organ—the x,y,z coordinates of the centroid of the organ of interest relative to other anatomical landmarks
[0031] 2) The size of the organ—the volume of the organ of interest in cubic centimeters;
[0032] 3) The shape of the organ—various metrics that quantify the shape of the organ of interest. Such metrics may include, but are not limited to, a symmetry index, number of inflection points, or ideally a variation of its generalized mid-line representation, such as defined in the article “Multi-scale Deformable Model Segmentation and Statistical Shape Analysis Using Medial Descriptions,” by S. Joshi, S Pizer, P T Fletcher, P. Yushkevich, A Thall, and J S Marron, accepted for publication in: IEEE-Transaction on Medical Imaging, 2002;
[0033] 4) The dose applied to the organ—the equivalent uniform dose (EUD) applied to the organ of interest at the time the 3D image volume is recorded; (could also be the average/mean dose with a standard deviation or homogeneity index; or other way of recording the dose)
[0034] 5) The time of the image—the date and time of day the 3D image volume is recorded, and the amount of time elapsed since the therapy began;
[0035] 6) The medical outcomes in the volume resulting from radiation—such as the grade of any complications for normal tissue or tumor response for the target at the time the 3D image volume is recorded;
[0036] 7) The radiation sensitivity—the reaction a patient has to being treated with a particular type of radiation. Such a metric can be measured by performing a pre-treatment assay on skin or hair cells of the patient that can be used to rank where the patient falls with respect to the general patient population with regard to radiosensitivity. The metric will also be assessed throughout the course of therapy by the patient's physician; and
[0037] 8) The identity of the patient—the identity of the patient associated with the 3D image volume. Such information may include a patient's past motion data to predict his future motion, for example. Also the age and sex of the patient would be important when seeking to apply the data to other patients who may be considered in the same class.
[0038] After the image is taken, segmented and its metrics are recorded per steps 202 , 204 , 206 , the process is repeated as shown in FIG. 4. One 3D dataset may be obtained each day of treatment, or once a week during the approximately 6 weeks of therapy, and at each follow-up session after therapy is completed.
[0039] Once sufficient data entries have been made into each of these categories, probability distribution functions for each quantity as a function of dose and time are made in the central treatment processing unit 132 per step 208 . Examples of probability distribution functions made in unit 132 are the probability of a tumor “kill” as a function of dose and the probability of a tumor “kill” as a function of time past therapy completion. Note that even if there is initially a correlation between dose and time (especially for the tumor), the distributions may eventually diverge during a follow up treatment, so it is important to categorize the data in both ways.
[0040] The metrics of step 206 and the probability distribution functions of step 208 are determined by the central treatment planning unit 132 and are stored in a mass storage memory 144 of the central treatment processing unit 132 . The combination of one or more of the metrics of step 206 and probability distribution functions of step 208 are collectively deemed a predictive organ dynamics database. The predictive organ dynamics database includes metrics and probability distribution functions determined for images of other patients using the process 200 described above. In addition, the predictive organ dynamics database is not limited to a single region of interest but may include data regarding multiple regions of interest, such as different organs of a patient. The above described database functions in two ways: for intra-patient comparison and for inter-patient comparison that will be explained later. In radiation therapy, it is assumed that many quantities, such as organ motion and radiation response (on a cellular level) have a relatively narrow distribution intrinsic to the individual patient, and a wider distribution when these quantities are pooled over all similar patients.
[0041] Once a predictive organ dynamics database has been initially established based on data from a number of patients, the database can be applied to a patient during his or her treatment. At the beginning of the treatment there is typically little or no data on the individual patient stored in the database. In this case, a clinician may use expectation values from a larger patient population to prescribe a treatment for the patient. Accordingly, the initial treatments will be based on a treatment that would be effective for a majority of the population represented by the database. The initial treatment may be determined from the predictive organ dynamics database or by published clinical trials of similar patients.
[0042] After each of the initial treatments, a three-dimensional image volume of the region of interest of the patient is taken and added to the database per steps 202 , 204 , 206 and 208 . Once the patient has undergone several treatment sessions, the database contains enough information that the treatment can be modified based on the previous data of the patient placed in the database. In this situation, the patient is positioned on table 152 for a therapy session. The identity of the patient is entered at the console 154 which results in the treatment planning system 146 performing a statistical analysis of one or more metrics of the previously accumulated data for the region of interest of the patient present in the database in conjunction with the probability distributions within the database. From that analysis, the patient is assigned a “rank” for each variable per step 210 and it is used to understand where the patient fits on the probability distribution function for each of the metrics determined in step 206 . This rank predicts approximately the future status of one or more regions of interest of the patient, such as an organ, that is being treated by radiation. For example, if the patient after the first week of treatment shows that he has a widely varying prostate position compared to other patients in the first week of treatment (perhaps he's ranked in the 70-75% percentile), the clinician can sample the same probability distribution function at the same percentile or rank (70-75%) to predict what the motion of the prostate will be for subsequent treatments performed one or more days after the treatment. The prediction is for subsequent treatment days and the remainder of the course of therapy.
[0043] The above described predictive organ dynamics database may alone reveal interesting trends or may be further analyzed with deterministic methods or a Monte Carlo algorithm to sample all the probability distribution functions per step 210 and feed back their composite effect on planning to the treatment planning system 146 , ultimately yielding a prediction of complication free survival probability for a given patient plan based on real patient data. The sampling of the probability distribution functions by the computer program can model the likely behavior of the organ or region of interest as a function of dose and time. The treatment planning system 146 is typically used to define and simulate a beam shape required to deliver an appropriate therapeutic dose of radiation to treatment zone 112 . The sampling of each probability distribution function may be constrained to the narrow range indicated by the patient's rank for each variable.
[0044] This sampled information is used by the treatment planning system 146 of the central treatment processing or control unit 132 to influence the choice between various treatment plans or to modify a selected treatment plan applied to a particular patient's region of interest, such as an organ, per step 214 to optimize the outcome of the treatment. For example, if the sampled information shows that the organ being treated is likely to move a lot in the superior direction, the treatment planning system 146 will develop a treatment plan with a large margin in the superior direction.
[0045] As another example, if a sensitive structure in the field has a high probability that its physiology will fail even with a low dose, a plan that is very conservative with respect to the dose to that organ will be chosen, even at the expense of dosing other, less sensitive, organs or perhaps even at the expense of dosing the tumor. Note that the treatment plan determined by step 214 includes controlling the radiation strength, duration and shape as well as the position of the radiation source and the patient. For example, a patient is placed in proper position by having the computer 144 send signals to a gantry control 148 , and a table control 150 that controls table 152 .
[0046] After the patient is properly positioned the electron radiation beam is applied to the treatment region to generate a desired dosage. The computer 144 is also operatively coupled to the dose control unit 108 which includes a dosimetry controller and which is designed to control the beam source 106 to generate a desired beam achieving desired isodose curves. After a treatment plan is implemented, the predictive organ dynamics database is updated by imaging the region of interest during a patient follow up phase and entering metric data via the process 200 explained previously.
[0047] As the predictive organ dynamics database is enlarged by the number of patients entered and the time spans from which particular regions of interest are enlarged, the sampled information ultimately can be used to predict future complications and survival rates for a particular patient's treatment plan based on other patient data.
[0048] Those skilled in the art will appreciate that various adaptations and modifications of the just described preferred embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
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A method of treating a region of interest with radiation by taking a three-dimensional image volume of a region of interest of a patient, defining the three-dimensional image volume, determining one or more metrics of the defined three-dimensional image volume and delivering a dose of radiation to the region of interest of a patient based on the one or more metrics.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. national stage application of International Application No. PCT/EP2005/005699 filed May 27, 2005, which designates the United States of America, and claims priority to German application number DE 10 2004 027 291.3 filed Jun. 4, 2004 the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to a method and device for controlling a valve. The valve has a valve drive, which is configured as a piezoactuator, a valve member, a valve body and a valve seat.
BACKGROUND
[0003] Such a valve is used for example in a pump/nozzle device for supplying fuel to the combustion chamber of a cylinder of an internal combustion engine, in particular a diesel internal combustion engine. In the case of a pump/nozzle device a pump, a control unit with the valve and a nozzle unit form an assembly. A pump piston is preferably driven by way of a camshaft of an internal combustion engine by means of a toggle.
[0004] The pump can be coupled hydraulically to a low-pressure fuel supply facility by way of the valve. It is coupled hydraulically to the nozzle unit on the output side. The start of injection and the quantity injected are determined by the valve and its valve drive. The compact structure of the pump/nozzle device results in a very small high-pressure volume and a large degree of hydraulic rigidity. This allows very high injection pressures of around 2,000 bar to be achieved. This high injection pressure combined with the ease of control of the start of injection and the quantity injected allows a significant emissions reduction whilst at the same time keeping fuel consumption low when the internal combustion engines are in use.
[0005] A pump/nozzle device is known from DE 198 35 494 C2 having a pump and a valve with a valve member, which controls the hydraulic coupling of a shut-off chamber to a run-off channel. The run-off channel is coupled hydraulically to the pump and a nozzle unit. A supply channel is provided, which is coupled hydraulically to the shut-off chamber. A piezoelectric valve drive is assigned to the valve member, by way of which the valve member can be moved between two end positions. In a first end position of the valve member the run-off channel is coupled hydraulically to a shut-off chamber and this in turn is coupled to the supply channel. In a second end position of the valve member the run-off channel is decoupled hydraulically from the shut-off chamber and the valve member is in a valve seat of the valve.
[0006] In the first end position of the valve member, during a delivery stroke of the pump, fluid is taken in by the pump from the supply channel by way of the shut-off chamber and the run-off channel. During a working stroke of a pump piston of the pump, in the first end position of the valve member, fluid is pushed back from the pump by way of the run-off channel, the shut-off chamber into the supply channel. In the second end position of the valve member, during the delivery stroke of the pump piston, the absence of any hydraulic coupling between the run-off channel and the shut-off chamber and the supply channel means that no fluid is pushed back and the pump piston generates high pressure. When a predetermined pressure threshold is exceeded, a nozzle needle of the nozzle unit opens a nozzle of the nozzle unit and fluid is injected. The end of injection is determined in that the valve member is controlled by means of the actuator unit into its first end position such that fluid can flow back by way of the run-off channel into the shut-off chamber and the supply channel, with the result that the pressure in the pump and therefore also in the nozzle unit drops, which in turn causes the nozzle unit to close.
[0007] Low pollutant emissions of an internal combustion engine, in which the pump/nozzle device is disposed, a precise control of the internal combustion engine require the precise measuring in of fuel by the pump/nozzle device. This in turn requires reproducible activation of the piezocontrolled valve of the pump/nozzle device, said activation having long-term stability.
SUMMARY
[0008] The object of the invention is to create a method and device for controlling a valve, by means of which it is possible to ensure precise control of the valve over a long operating period.
[0009] A method for controlling a valve with a valve drive, which is configured as a piezoactuator, with a valve member, a valve body and a valve seat, may comprise the steps of: determining and generating an actuating signal to load the piezoactuator such that the valve member is controlled from a position away from the valve seat into the valve seat, as a function of a pilot control value, which is a function of at least one operating variable, and an output value of a regulator; determining a first value, which is characteristic of the electrical energy supplied to the piezoactuator on arrival of the valve member on the valve seat; determining a second value, which is characteristic of the electrical energy supplied to the piezoactuator on completion of the loading process of the piezoactuator; determining an actual value, which is characteristic of a sealing force, with which the valve member is pressed onto the valve seat as a function of the first and second values; supplying the actual value and a predetermined setpoint value to the regulator, which generates the output value as a function thereof, and adjusting a pilot control value assignment instruction as a function of the output value and at least one operating variable and, when a predetermined condition is met, the pilot control value assignment instruction is used to determine the pilot control value.
[0010] In an embodiment, a basic pilot control value can be determined as a function of the at least one operating variable, an adaptation value can be determined as a function of the at least one operating variable, the pilot control value can be determined as a function of the basic pilot control value and the adaptation value and an adaptation value assignment instruction can be adjusted as a function of the output value and at least one operating variable and, when the predetermined condition is met, the adaptation value assignment instruction can be used to determine the adaptation value. In an embodiment, the predetermined condition can be configured such that it is met, when operation resumes after a break in the operation of the valve. In an embodiment, the pilot control value assignment instruction can be adjusted as a function of the output value and a rotation speed of a crankshaft of an internal combustion engine.
[0011] In another embodiment, a device for controlling a valve comprises a valve drive, which is configured as a piezoactuator, with a valve member, a valve body and a valve seat, wherein the device being operable to determine and generate an actuating signal to load the piezoactuator, such that the valve member is controlled from a position away from the valve seat into the valve seat, as a function of a pilot control value, which is a function of at least one operating variable, and an output value of a regulator, determine a first value, which is characteristic of the electrical energy supplied to the piezoactuator on arrival of the valve member on the valve seat, determine a second value, which is characteristic of the electrical energy supplied to the piezoactuator on completion of the loading process of the piezoactuator, determine an actual value, which is characteristic of a sealing force, with which the valve member is pressed onto the valve seat, as a function of the first and second values, supply the actual value and the predetermined setpoint value to the regulator, which generates the output value as a function thereof, and adjust a pilot control value assignment instruction as a function of the output value and at least one operating variable and, when a predetermined condition is met, use the pilot control value assignment instruction to determine the pilot control value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Exemplary embodiments of the invention are described in more detail below based on the schematic drawings, in which:
[0013] FIG. 1 shows a pump/nozzle device with a valve and a device for controlling the pump/nozzle device and the valve and
[0014] FIG. 2 shows a block diagram for determining an actuating signal in the device for controlling the valve.
[0015] Elements with the same structure or function are shown with the same reference characters in all the figures.
DETAILED DESCRIPTION
[0016] In a method and a corresponding device for controlling a valve, a valve drive can be configured as a piezoactuator, with a valve member, a valve body and a valve seat. An actuating signal to load the piezoactuator is determined and generated as a function of a pilot control value and an output value of a regulator. The pilot control value is a function of at least one operating variable. The actuating signal is used to load the piezoactuator such that the valve member is controlled from a position away from the valve seat into the valve seat. A first value is determined, which is characteristic of the electrical energy supplied to the piezoactuator, as the valve member arrives on the valve seat. A second value is determined, which is characteristic of the electrical energy supplied to the piezoactuator, when the process of loading the piezoactuator is completed. An actual value, which is characteristic of a sealing force, with which the valve member is pressed on the valve seat, is determined as a function of the first and second values. The actual value and a predeterminable setpoint value are supplied to the regulator, which generates an output value as a function thereof. A pilot control value assignment instruction is adjusted as a function of the output value and at least one operating variable. When a predetermined condition is met, the pilot control value assignment instruction is used to determine the pilot control value.
[0017] Therefore precise activation is simple to achieve even with highly dynamic activation of the valve, as is particularly the case when the valve is used for a pump/nozzle device, as the correspondingly adjusted pilot control value assignment instruction relieves the burden on the regulator and said regulator only has to compensate for minor deviations around the operating point, with the result that such deviations can be compensated for quickly. It is also possible in this manner to adjust the sealing force of the valve precisely over a long operating period of the valve. The pilot control value assignment instruction here refers to the formula used to determine the pilot control value as a function of the at least one operating variable. It can for example be converted by means of a corresponding analytical function but is reproduced particularly simply by means of a suitable characteristic map.
[0018] The valve force, with which the valve is pushed into the valve seat by the valve drive, can be adjusted in a manner that is very exact and can be reproduced very easily, when it is in contact with the valve seat. The valve seat force is indicative of the degree of sealing of the valve, when the valve member is in contact with the valve seat. This allows the mechanical strain of the valve member and also the valve seat to be reduced specifically over a long operating period of the valve and at the same time ensures that the valve seat force, in other words the sealing force, remains the same over said long operating period. It is therefore also possible to minimize tolerances during the opening and closing process of the valve in a simple manner.
[0019] The embodiments therefore also utilize the knowledge that the first value is largely a function of a force, which is produced by the pressure of the fluid acting on the valve member, and a force of a regularly present reset means. The embodiments also utilize the knowledge that the second value is largely a function of the sealing force and also the force, which is produced by the pressure of the fluid acting on the valve, and the force of the reset means. An actual value for the sealing force can thus be determined in a simple manner as a function of the two values. The piezoactuator can therefore also be used as a sensor at the same time.
[0020] According to an embodiment a basic pilot control value is determined as a function of the at least one operating variable. An adaptation value is determined as a function of the at least one operating variable and an adaptation value assignment instruction is adjusted as a function of the output value and at least one operating variable and, if the predetermined condition is met, the adaptation value assignment instruction is used to determine the adaptation value. The pilot control value is determined as a function of the basic pilot control value and the adaptation value. It is possible in this manner, for example in the case of a number of valves, to determine the respective basic pilot control value by means of the same basic pilot control value assignment instruction, which in some instances does not even have to be adjusted, and it is simply possible to adjust to adapt the adaptation value assignment instruction individually for every valve. This then allows very precise activation of the individual valve and the basic pilot control value assignment instruction can be used in a common manner at the same time.
[0021] It may be particularly advantageous, if the predetermined condition is configured such that it is met when operation resumes after a break in the operation of the valve. A break in operation is characterized in that the valve member is not moved for a significantly longer period than is the case during typical operation of the valve. Where the valve is used in an internal combustion engine, such a break in operation can for example be the time period between the deactivation of the internal combustion engine and a subsequent engine start. It is possible thus to ensure in a simple manner that the largest possible number of output values are captured to adjust the pilot control value assignment instruction, before it is actually used to determine the pilot control value. This makes it possible to prevent unwanted coupling effects, in particular direct feedback effects. It also enhances the quality of the pilot control in a simple manner.
[0022] It may be particularly simple for the pilot control value assignment instruction to be a function of the output value and a rotation speed of a crankshaft of an internal combustion engine, when the valve is used in an internal combustion engine, for example in a pump/nozzle device. It has surprisingly proven in this context that sufficiently precise adjustment of the pilot control value assignment instruction is made possible by simply taking into account the rotation speed. In particular it is possible to take dynamic influences simply into account in this manner.
[0023] The pump/nozzle device ( FIG. 1 ) comprises a pump unit, a control unit and a nozzle unit. The pump/nozzle device is preferably used to feed fuel into the combustion chamber of a cylinder of an internal combustion engine. The internal combustion engine is preferably configured as a diesel internal combustion engine. The internal combustion engine has an intake duct to take in air, it being possible to couple said intake duct to cylinders by means of gas inlet valves. The internal combustion engine also has an exhaust gas duct, which is controlled by way of the outlet valve to remove the gases to be ejected from the cylinders. The cylinders are respectively assigned pistons, which are coupled respectively to a crankshaft by way of a connecting rod. The crankshaft is coupled to a camshaft.
[0024] The pump unit comprises a piston 11 , a pump body 12 , a working space 13 and a pump reset means 14 , which is preferably configured as a spring. When integrated in an internal combustion engine, the piston 11 is coupled to a camshaft 16 , preferably by means of a toggle, and is driven by said camshaft 16 . The piston 11 is guided in a recess of the pump body 12 and determines the volume of the working space 13 as a function of its position.
[0025] The pump reset means 14 is configured and disposed such that the volume of the working space 13 defined by the piston 11 has a maximum value, when no external forces are acting on the piston 11 , in other words forces, which are transmitted by way of the coupling with the camshaft 16 .
[0026] The nozzle unit comprises a nozzle body 51 , in which a nozzle reset means 52 , which is configured as a spring and in some instances also as a damping unit, and a nozzle needle 53 are disposed. The nozzle needle 53 is disposed in a recess of the nozzle body 51 and is guided in the region of a needle guide 55 .
[0027] In a first state the nozzle needle 53 is in contact with a needle seat 54 , thereby sealing a nozzle 56 , which is provided to feed fuel into the combustion chamber of the cylinder of the internal combustion engine. The nozzle unit is preferably configured as an inward opening nozzle unit, as shown.
[0028] In a second state the nozzle needle 53 is disposed at a slight distance from the needle seat 54 , towards the nozzle reset means 52 , thereby releasing the nozzle 56 . In this second state fuel is measured into the combustion chamber of the cylinder of the internal combustion engine. The first or second state is adopted as a function of a force balance between the force exerted by the nozzle reset means 52 on the nozzle needle 53 and the force countering this, produced by the hydraulic pressure in the region of the needle shoulder 57 .
[0029] The control unit comprises a supply channel 21 and a run-off channel 22 . The supply channel 21 and the run-off channel 22 can be coupled hydraulically by means of a valve. The supply channel 21 is guided to the valve by a low-pressure side connection of the pump/nozzle device. The run-off channel 22 is coupled hydraulically to the working space 13 and is guided to the needle shoulder 57 and can be coupled hydraulically to the nozzle 56 as a function of the current state of the nozzle needle 53 .
[0030] The valve comprises a valve member 231 , which is preferably configured as what is known as an A-valve, in other words it opens outward counter to the flow direction of the fluid. The valve also comprises a shut-off chamber 232 , which is coupled hydraulically to the supply channel 21 and can be coupled hydraulically by means of the valve member 231 to a high-pressure chamber. The high-pressure chamber is coupled hydraulically to the run-off channel 22 .
[0031] When the valve member 231 is in the closed position, the valve member 231 is in contact with a valve seat 234 of a valve body 237 . A valve reset means is also provided, which is disposed and configured such that it pushes the valve member 231 into an open position, in other words at a distance from the valve seat 234 , when the forces exerted by an actuating drive 24 on the valve member are smaller than the forces produced by the pressure of the fluid, in this instance the fuel, and acting on the valve member 231 by way of the valve reset means. The actuating drive 24 is configured as a piezostack.
[0032] The actuating drive 24 is preferably coupled by means of a transmission unit, which preferably amplifies the lift of the actuating drive 24 , to the valve member 231 . A connector is preferably also provided on the actuating drive 24 to receive electric contacts to activate the actuating drive 24 .
[0033] A device 60 is provided to control the pump/nozzle device, generating an actuating signal SG for the valve.
[0034] With the valve member 231 in the open position, when the piston 11 is moved upward, in other words away from the nozzle 56 , fuel is taken into the working space 13 by way of the supply channel 21 . As long as the valve member 231 remains in its open position during a subsequent downward movement of the piston 11 , in other words toward the nozzle 56 , the fuel in the working space 13 and the run-off channel 22 is pushed back again into the shut-off chamber 232 and in some instances into the supply channel 21 by way of the valve.
[0035] If however the valve member 231 is controlled into its closed position during the downward movement of the piston 11 , the fuel in the working space 13 and therefore also in the run-off channel 22 and in the high-pressure chamber is compressed, as a result of which the pressure in the working space 13 , the high-pressure chamber and the run-off channel 22 increases as the piston 11 continues its downward movement. As the pressure in the run-off channel 22 rises, so does the force produced by the hydraulic pressure, said force acting on the needle shoulder 57 in the direction of an opening movement of the nozzle needle 53 to release the nozzle 56 . When the pressure in the run-off channel 22 exceeds a value, at which the force produced on the needle shoulder 57 by the hydraulic pressure is greater than the force of the nozzle reset means 52 counter to this, the nozzle needle 53 moves away from the needle seat 54 , thereby releasing the nozzle 56 for the supply of fuel to the cylinder of the internal combustion engine. The nozzle needle 53 then moves back into the needle seat 54 , thereby sealing the nozzle 56 , when the hydraulic pressure in the run-off channel 22 drops below the value, at which the force produced at the needle shoulder 57 by the hydraulic pressure is smaller than the force produced by the nozzle reset means 52 . The time when the force drops below said value and fuel ceases to be measured in can be influenced by controlling the valve member 231 from its closed position to an open position.
[0036] Controlling the valve member from its closed position to its open position produces the hydraulic coupling between the high-pressure chamber and the shut-off chamber 232 and the supply channel 21 . The large pressure difference between the fluid in the high-pressure chamber and the run-off channel 22 and the fluid in the shut-off chamber 232 and the supply channel 21 during the opening process causes the fuel to flow from the high-pressure chamber at very high speed, generally the speed of sound, into the shut-off chamber 232 and on into the supply channel 21 . This then rapidly reduces the pressure in the high-pressure chamber and the run-off channel 22 so significantly that the forces exerted by the nozzle reset means 52 on the nozzle needle 53 cause the nozzle needle 53 to move into the needle seat 54 , thereby sealing the nozzle 56 .
[0037] The process of determining an actuating signal SG to load the piezoactuator of the valve drive 24 is described below with reference to the block diagram in FIG. 2 .
[0038] At a predeterminable first time the valve member 231 is controlled from its position away from the valve seat 234 into the valve seat. The predeterminable first time is preferably selected such that the piston 11 is in its top dead center and remains there until the anticipated arrival of the valve member 231 on the valve seat 234 . This allows the arrival time to be detected particularly precisely. The predeterminable first time can however also be selected such that the piston 11 has left its top dead center by the anticipated arrival of the valve member 231 on the valve seat 234 .
[0039] In a block B 1 a basic pilot control value EGY_PRE of the electrical energy to be supplied is determined as a function of a fuel temperature T_FU and/or a rotation speed N and the predeterminable first time. The predeterminable first time is dependent on the time SOI when the nozzle needle 53 moves away from its contact with the nozzle body 51 , in other words the start of injection, and, if the piston is partially outside its top dead center, while the valve member 231 is in contact with the valve seat 234 . The pilot control value EGY_PRE of the electrical energy to be supplied is determined for example by means of a characteristic map, the characteristic map values of which were determined beforehand by experimentation.
[0040] A setpoint value EGY_D_SP of an electrical differential energy is also determined in the block B 1 . The setpoint value EGY_D_SP of the electrical differential energy is characteristic of the sealing force, exerted by the valve member 231 on the valve seat 234 of the valve body 237 , when the valve member 231 is in contact with the valve seat 234 . The setpoint value EGY_D_SP of the electrical differential energy is determined in the block B 1 as a function of the fuel temperature T_FU, the speed N and/or the predeterminable first time. It can also be done by means of a corresponding characteristic map for example. Alternatively or additionally it can also be done as a function of a coolant temperature.
[0041] In a block B 2 the energy supplied until the arrival of the valve member 231 on the valve seat 234 is determined as a function of actual values EGY_AV of the electrical energy supplied to the piezoactuator during the loading process. This can be done for example by evaluating actual values V_AV of the piezovoltage or corresponding variables characterizing it, for example the actual current through the piezoactuator or the load or electrical energy supplied to the piezoactuator. The arrival of the valve member 231 results in a characteristic pattern of said variables, which can be used to identify the time of arrival of the valve member 231 . An actual value EGY_AV of the electrical energy supplied on arrival of the valve member 231 in the valve seat 234 is then also determined in the block B 2 based on the determined time of arrival of the valve member 231 in the valve seat 234 and the actual value EGY_AV of the energy supplied assigned to this time.
[0042] In a block B 3 the actual values EGY_AV of the electrical energy supplied are also read in and the actual value EGY_AV at the end of the loading process of the piezoactuator is assigned to an actual value EGY_CHA of the electrical energy supplied on completion of the loading process. Completion of the loading process can for example be identified when the actual values EGY_AV of the electrical energy supplied reach a maximum or by corresponding information to a further controller function for the pump/nozzle device.
[0043] In a block B 4 the difference between the actual value EGY_CHA of the electrical energy supplied on completion of the loading process and the actual value EGY_DET of the supplied electrical energy on arrival of the valve member 231 in the valve seat 234 is determined and routed to a block B 5 , which comprises a low-pass filter and provides an actual value EGY_D_AV of the electrical differential energy at its output.
[0044] In a block B 6 the difference is formed between the setpoint value EGY_D_SP and the actual value EGY_D_AV of the electrical differential energy. In a simpler embodiment the actual value EGY_D_AV of the electrical differential energy can also be determined directly without the low-pass filter in block B 5 .
[0045] The output of the block B 6 is connected to the input side of a block B 7 , which comprises a regulator, which is preferably configured as a PI regulator. The manipulated variable of the regulator, which in this exemplary embodiment is a regulating value EGY_FBC of the electrical energy to be supplied, which can also be referred to as the output value, is then supplied to a block B 8 .
[0046] In a block B 9 an adaptation value EGY_D_PRE of the electrical differential energy to be supplied is determined as a function of one or more of the following variables. The variables are for example the fuel temperature T_FU or the coolant temperature or the rotation speed or the time SOI of the start of injection.
[0047] To this end an adaptation value assignment instruction is stored in the block B 9 , said adaptation value assignment instruction being processed during operation of the valve to determine the adaptation value EGY_D_AD. To this end a characteristic map is preferably stored for every individual pump/nozzle device in the block B 9 , with values of the adaptation value EGY_D_AD being stored therein as a function of one or more input variables of the block B 9 . A predeterminable number of characteristic map points are preferably stored in said characteristic map. The respective adaptation value EGY_D_AD is then determined, as is usual with characteristic maps, by means of corresponding interpolation between the stored characteristic map points. The characteristic map of the block B 9 is updated when a predetermined condition is present. The predetermined condition is preferably met, when the internal combustion engine, to which the pump/nozzle device is assigned, is restarted after the engine has stopped. The updating of the characteristic map is described in more detail below.
[0048] The adaptation value EGY_D_PRE of the electrical differential energy to be supplied and the basic pilot control value EGY_PRE of the electrical energy to be supplied are added together in the block B 8 and thereby form a pilot control value of the electrical energy to be supplied. The regulating value EGY_FBC of the electrical energy to be supplied is also added in the block B 8 and the resulting sum is the required electrical energy EGY_THRUST to be supplied to the piezoactuator.
[0049] The value EGY_THRUST of the required electrical energy to be supplied is fed to a block B 10 , in which a corresponding actuating signal SG is generated to activate the valve drive 24 configured as a piezoactuator. The actuating signal SG is preferably a pulse-width-modulated signal and the required electrical energy to be supplied EGY_THRUST is preferably split into a predetermined number of energy sub-quantities, each being supplied to the piezoactuator in a period of the pulse-width-modulated or pulse-amplitude-modulated signal.
[0050] The block B 10 also preferably comprises a further lower-order regulator, in which the actual supply of electrical energy to the piezoactuator is regulated, with the manipulated variable being the respective pulse width or pulse height of the actuating signal SG. The current loading at the time or the actual values V_AV of the piezovoltage or the actual values EGY_AV of the electrical energy supplied for example can also serve as the manipulated variables.
[0051] If the actuating signal SG is to be determined for a loading process subsequent to a second predeterminable time, which can also be selected such that the piston 11 has left its top dead centre before the anticipated arrival of the valve member 231 on the valve seat 234 , the regulating value EGY_FBC of the electrical energy to be supplied is preferably adopted from a loading process, which took place subsequent to the first predeterminable time. Only the basic pilot control value EGY_PRE of the electrical energy to be supplied and the adaptation value EGY_D_AD of the electrical energy to be supplied are then re-calculated. This has the advantage of reducing the computation load and, if the predeterminable first time is selected such that the piston 11 is at its top dead center and remains there until the anticipated arrival of the valve member 231 on the valve seat 234 , the valve sealing force is then also set precisely for the predeterminable second time.
[0052] A block B 12 is also provided, to which the regulating value EGY_FBC of the regulator of the block B 7 is fed. The regulating value EGY_FBC of the electrical energy to be supplied is representative of an error of the pilot control value of the electrical energy to be supplied in the current operating point, which is determined by one or more of the variables fuel temperature T_FU, coolant temperature, rotation speed N, start of injection SOI.
[0053] The block B 12 preferably comprises an intermediate characteristic map, which is re-initialized in each instance after the characteristic map of the block B 9 has been updated. The regulating values EGY_FBC occurring during operation of the pump/nozzle device are stored in the intermediate characteristic map of the block B 12 . This takes place as a function of the respectively assigned current variables, in other words one or more of the input variables of the block B 12 .
[0054] The intermediate characteristic map preferably comprises a predetermined number of discrete points for storing the regulating value EGY_FBC. The corresponding characteristic map values can preferably be “learned” by way of a surface weighting, a filter or by means of similar methods. It is thus possible to take into account by means of the surface weighting method how far the current operating point is in each instance from a corresponding checkpoint of the intermediate characteristic map and the one or more checkpoints of the intermediate characteristic map are then updated with a corresponding weighting.
[0055] As far as determining the output variables of the blocks B 9 , B 1 , B 12 is concerned, it can also be advantageous to take into account the current capacity of the piezoactuator as an input variable.
[0056] When the predetermined condition is met, in other words for example when the internal combustion engine is restarted after an engine stop, the characteristic map of the block B 9 is updated by means of the intermediate characteristic map of the block B 12 . It is particularly advantageous in this context, if the intermediate characteristic map is smoothed beforehand by means of a suitable filter. In the simplest instance the checkpoints of the intermediate characteristic map are added to the corresponding checkpoints of the characteristic map B 9 . Alternatively this can also be done by means of a predeterminable weighting, etc.
[0057] The regulating values EGY_FBC occurring since the last update of the characteristic map B 9 , which are representative of an error of the pilot control value in the current operating point, are thus used effectively to improve the quality of the respective pilot control value. It is possible in this manner to restrict the regulator of the block B 7 to compensating only for extremely small differences between the setpoint value EGY_D_SP and the actual value EGY_D_AV of the electrical differential energy, thus ensuring very precise activation of the actuating drive 24 , which is the piezoactuator, even during extremely highly dynamic operation of the pump/nozzle device.
[0058] Because the characteristic map of the block B 9 is only updated when the predetermined condition is met, it is possible to prevent undesirable direct feedback effects. Alternatively the predetermined condition can also be configured such that it is met after a predeterminable number of engine runs, for example two, three, four or five engine runs, or that it is met after a predeterminable operating period, for example five or ten operating hours.
[0059] Alternatively, instead of the adaptation value EGY_DAD, the updating of the assignment instruction there can take place directly in the block B 1 as a function of the intermediate characteristic map of the block B 12 . In this instance the basic pilot control value EGY_PRE can also be identical to the pilot control value.
[0060] As an alternative the output variables of the blocks B 1 , B 2 , B 3 , B 4 , B 5 , B 6 , B 7 , B 8 , B 9 , B 10 can also be corresponding electrical voltages or currents or loads. In the case of an internal combustion engine with a number of cylinders, to which a number of pump/nozzle devices are then assigned, it is particularly preferable for the block B 1 to be implemented in an identical manner for all pump/nozzle devices, while the block B 9 is then preferably provided in an individual manner for every individual pump/nozzle device.
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An piezo actuator loading signal is determined and generated according to an output value and a pilot control value which depends on at least one operational parameter. The loading signal causes that a valve member moves into a valve seat. A first value characteristic of the electric power fed to the actuator when the valve member hits the valve seat is determined while a second value characteristic of the energy delivered to the actuator is determined when the loading process of the actuator has been completed. A real value characteristic of a sealing force with which the valve member is pressed onto the valve seat is determined according to the first and second value. The real value and a predefined setpoint value are fed to the controller which accordingly adjusts a pilot control value assignment instruction which is used for determining the pilot control value if a predefined condition is met.
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This application is a continuation-in-part of U.S. patent application Ser. No. 08/910,202, filed Aug. 13, 1997, which is a continuation-in-part of allowed U.S. patent application Ser. No. 08/383,404, filed Feb. 3, 1995, (now U.S. Pat. No. 5,667,394).
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improvement to a night light of the type having an electro-luminescent lighting element, as disclosed in parent U.S. patent application Ser. No. 08/910,202, in which large area electrodes on the electro-luminescent lighting element directly engage a specially designed connection member to facilitate electrical connection of the lighting element to a metal plug. The improvement involves the use of a multiple-piece housing which provides a curved surface while minimizing the amount of plastic required.
2. Discussion of Related Art
The present invention utilizes the basic electro-luminescent lighting fixture connector principles disclosed in copending allowed U.S. patent application Ser. No. 08/383,404, (now U.S. Pat. No. 5,667,394) applied to a night light of the type disclosed in parent U.S. patent application Ser. No. 08/910,202, by utilizing a non-penetrative contact arrangement which limits damage to the electro-luminescent element(s) used in the night light and reduces the risk of electrical shocks and short circuits, and in addition addresses a problem with prior electro-luminescent night lights, such as the one disclosed in U.S. Pat. No. 5,662,408, that if the two-piece housing of the prior night lights is designed with a curved electro-luminescent panel, so as to provide a greater viewing angle and a more attractive housing configuration, while still providing a flat back surface to permit the night light to be flush with an electrical outlet when plugged in, the amount of plastic material required by the back piece of the housing must be increased in order to provide the necessary curved electro-luminescent element supporting surface. As a result, the prior two-piece housing construction is not practical for an electro-luminescent night light having a curved surface.
Except for the arrangement of the housing, the night light of the present invention is similar to that disclosed in the parent application. Since the advantages of the non-penetrative or sandwich type contact termination arrangement are described in detail in the parent application, they will not be repeated herein, except to note that non-penetrative contact termination, and in particular the use of resilient conductive members to provide the electrical connection between the prongs and large area electrodes provided on the surface of the electro-luminescent element, serves to simplify assembly and tooling by increasing the tolerances necessary to effect a good electrical connection, while increasing reliability and decreases risks of short-circuiting or electrical shock hazards.
The only prior disclosure of non-penetrative contact techniques to an electro-luminescent night light known to the Inventor is found in the above-cited U.S. Pat. No. 5,662,408, issued on Sep. 2, 1997. This patent discloses a low profile night light which relies on direct engagement between the outlet prongs and terminals extending from the electro-luminescent element.
While in one embodiment, shims are used to bias the prongs against the terminals, with the terminals being positioned between the shims and the terminals, none of the embodiments uses resilient conductive elements positioned between the prongs and large area terminals or electrodes on the surface of the electro-luminescent element, as in the present invention or that described in the parent application. As a result, in addition to failing to provide a practical way to support the electro-luminescent element to provide a curved surface, the night light disclosed in U.S. Pat. No. 5,662,408 provides a less secure higher impedance electrical connection, greater risk of short-circuits and electrical shock, and decreased assembly tolerances, particularly in view of the delicate nature of the terminal extensions required to effect the electrical connection to the outlet prongs.
SUMMARY OF THE INVENTION
It is accordingly an objective of the invention to provide a night light utilizing an electro-luminescent element having simplified assembly, low materials costs, increased reliability, and a reduced risk of short circuits and electric shock, and which includes a housing having a curved surface for enhanced visibility and a more attractive configuration.
This objective of the invention is achieved, in accordance with the principles of a preferred embodiment of the invention, by providing a night light in which an electrical connection between electrodes on the electro-luminescent element and a source of electric power is optionally provided by resilient conductive elements which provide a self-biased electrical connection to the electrodes without the need for penetrative elements or movable elements, and which includes, in an especially preferred embodiment of the invention, a two-part housing, at least one part being curved, and at least one intermediate housing member in the form of at least one inner plate, the inner plate serving as a fixture means for causing the electro-luminescent element to maintain a curved shape, supporting the plug assembly, and biasing the prongs of the plug assembly against conductive members which serve to ensure a good electrical connection between the prongs and contacts on the electro-luminescent element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view illustrated the basic principle of utilizing a non-penetrative contact arrangement in a night light.
FIG. 2 is an exploded perspective view showing a variation of the night light illustrated in FIG. 1 .
FIG. 3 is an exploded perspective view of an electro-luminescent light assembly suitable for use in the night lights of FIGS. 1 and 2.
FIG. 4 is an exploded perspective view of a further variation of the night lights illustrated in FIGS. 1 and 2.
FIG. 5 is a perspective view of an assembled night light corresponding to the night lights illustrated in FIGS. 1 and 4.
FIG. 6 is a perspective view of an assembled night light corresponding to the night light of FIG. 2 .
FIG. 7 is a perspective front view of a night light which utilizes the principles illustrated in FIGS. 1 - 6 , but which incorporates a curved surface in accordance with the principles of an especially preferred embodiment of the invention.
FIG. 8 is an exploded perspective rear view of a front portion of the night light illustrated in FIG. 7 .
FIG. 9 is an exploded perspective rear view showing both the front and rear portions of the night light illustrated in FIG. 7 .
FIG. 10 is an exploded perspective rear view of a variation of the night light illustrated in FIG. 7 .
FIG. 11 is a perspective view of a variation of the contact arrangement utilized in the night lights of FIGS. 7 - 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIG. 1, a night light constructed in accordance with the principles described in the parent application, and which is disclosed herein in order to illustrate the basic connector arrangement used by the present invention, includes an electro-luminescent element 14 made up of multiple phosphor segments 15 and electrode contact areas 16 (which are actually on the rear side of elements 16 extending from panel 14 ). The housing for the night light includes a rear section 17 containing an indentation for receiving the electro-luminescent element 14 and openings 18 for prongs 19 , and a front section 20 having an opening or window 21 through which the electro-luminescent element is to be viewed. An optional frontsheet 22 may be positioned between the electro-luminescent element 14 and window 21 .
In order to greatly simplify assembly of the night light of FIG. 1, contact areas 16 and prongs 19 are electrically connected together by means of resilient conductive elements 23 which are compressed between the contact areas and prongs when the housing is assembled together. Compression of the conductive elements 23 ensures that electrical continuity between the electrodes of the electro-luminescent element and the prongs is maintained, with the resilience of the conductive elements also compensating for tolerances in the construction of the prongs or contact areas of the electrodes of the electro-luminescent element, for example in the case where the prongs and electrodes have facing surfaces that are not completely parallel, or not completely flat.
The conductive elements 23 may be in the form of flexible or elastic conductive rubber elements, or conductive elements of similarly flexible and conductive plastic or metal material. Prongs 19 are UL-listed standard plugs, or equivalent plugs arranged to meet the requirements of countries other than the United States.
Preferably, rear housing section 17 and front housing section 20 are sealed together to prevent the night light from being opened and the electrical connections exposed. As will be explained in more detail below, additional housing pieces such as an inner plate can also be added for this purpose. The indentation in which the electro-luminescent element is received may of course have any desired configuration, or may be eliminated in favor of alternative electro-luminescent element holding means, and the means by which the housing sections are held together and/or sealed may include any suitable holding or sealing means, including glue, double-sided tape, press-fit posts, screws, melting, ultra-sonic sealing, hot melt adhesives, etc., resulting in an attractive and compact night light assembly similar to the one illustrated in FIG. 9 .
The electro-luminescent panel 14 may be of the type disclosed in U.S. Pat. No. 5,572,817 and copending U.S. patent application Ser. No. 08/729,408 (now U.S. Pat. No. 5,752,337), Ser. No. 08/734,872 (now U.S. Pat. No. 5,883,508), and Ser. No. 08/746,706 (now U.S. Pat. No. 5,806,960), in which attractive designs are obtained by including logos, figures, cartoon characters, words, on either the frontsheet 22 or the electro-luminescent element itself, either by printing, silk-screening, stencilling, or the like, and/or by appropriately arranging the phosphor segments of the electro-luminescent element. Alternatively, or in addition to electro-luminescent panel 14 the night light may include a three-dimensional tube 14 ′ arranged in an attractive pattern in the manner described in copending U.S. patent application Ser. No. 08/758,393. In the embodiment illustrated in FIG. 8, for example, a single color panel 14 ″ provides background for the illumination effect provided by the three-dimensional electro-luminescent element 14 ′, the other elements of the night light being the same as described in connection with FIG. 1, except that additional conductive resilient elements, for example having the configuration illustrated in parent U.S. patent application Ser. No. 08/383,404 (now U.S. Pat. No. 5,667,394), must be included in order to provide the necessary electrical connections. Further details of either the electro-luminescent panel or three-dimensional electro-luminescent element may be found in the above-cited patent and patent applications.
While in the arrangement of FIG. 1, the electro-luminescent panel is directly connected to the prongs of the night light outlet, it is also within the scope of the invention to use conductive member(s) 23 ′ to connect one or more electrodes of the panel to an inverter, control circuit, function interface, or the like, which can be in the form of a conventional circuit or an integrated circuit. Numerous suitable circuits are known and it is intended that the invention encompass any circuitry to which the electro-luminescent element might be connected, or no circuitry at all, with the electrodes of the electro-luminescent element being directly and exclusively connected to the prongs of the night light. By circuitry is meant any electrical component, including wires, resistors, capacitors, transistors, inductors, and so forth, as well as switches such as the illustrated photo-sensor 27 .
As shown in FIGS. 2 and 6, for example, the additional circuitry might be housed in an extension 36 of the rear housing member 25 . FIG. 2 also illustrates the variation in which the electro-luminescent element 26 does not have multiple segments, the decorative pattern being obtained instead by appropriate decoration of the frontsheet 27 .
Alternatively, in the variation shown in FIG. 3, the effects obtained by electro-luminescent element 28 and frontsheet 29 are enhanced by including an optical effects device 30 similar to the one described in copending U.S. patent application Ser. No. 08/841,624 and its parent U.S. patent application Ser. No. 08/489,160 (now abandoned), in which the image of the electro-luminescent element is enhanced by passage through a transparent transmission medium such as water, a gel, a solid transparent medium, epoxy, silicone, PVC, PC, acrylic, or the like to increase the apparent brightness of the element. The optical device can form a convex or concave lens, and can magnify the image, change the image location, change the focus, or change the color of emitted light in a simple and inexpensive yet effective manner.
The principles illustrated in FIGS. 1 - 6 are applied to a night light having a curved surface, as follows:
As illustrated in FIG. 7, the night light of the especially preferred embodiment of the invention differs from the night lights illustrated in FIGS. 1 - 6 in that, instead of a planar front surface, the front housing part 100 includes a curved surface 101 having a window or opening 102 through which one or more electro-luminescent elements may be viewed, with prongs 103 and 104 extending from a rear housing 105 and connected by means illustrated in FIGS. 8 - 11 to the electro-luminescent elements. In order to support an electro-luminescent element behind window or opening 102 , and also support prongs 103 and 104 and bias them relative to electrodes on the electro-luminescent element, the invention provides an additional housing piece, hereinafter referred to as an inner plate (not shown in FIG. 7, but illustrated as element 107 in FIGS. 8 - 10 ). It will be appreciated that other terms such as press-board would also be descriptive of the inner plate, and that members other than plates or boards could also be substituted in order to perform the same function.
FIG. 8 illustrates the assembly of the front portion of the night light shown in FIG. 7 . In this embodiment, the electro-luminescent element 106 , which may include any of the electro-luminescent elements disclosed in the prior patent documents cited above so long as they are sufficiently flexible to conform to the curved surface 101 of housing part 100 , is pressed flush against the rear of the front housing part by an inner plate 107 and positioned between posts 108 so as to be visible through window or opening 102 . The dimensions of window or opening are such that at least a portion of the electro-luminescent element extends beyond the edges of the window or opening to be supported by the front housing part in the area 128 denoted in FIG. 8 by hatching.
Pressing of the electro-luminescent element 106 against the front housing part 100 is accomplished by securing the inner plate 107 to the front housing part, with the electro-luminescent element sandwiched between the front surface of the inner plate and the rear surface of the front housing part using screws 109 or other fastening means, which pass through openings 110 and are threaded into posts 108 . While it is within the scope of the invention to secure the inner plate to the front housing by fasteners other than screws, such as an adhesive fastener, the use of screws is particularly advantageous because it permits the inner plate 107 to be disassembled from the front housing in order to replace a defective or damaged lighting element.
The inner plate 107 serves not only to press the electro-luminescent element against the front housing part 100 , but also to bias contact extensions 111 and 112 of prongs 103 and 104 against respective resilient conductive elements 113 and thereby bias the conductive elements against large area electrodes 114 on the electro-luminescent element in order to establish an electrical connection between the prongs and the electrodes. This is accomplished by providing slots 115 and 116 in the inner plate having an area sufficient to allow passage of the rear portions 117 and 118 of the prongs, but not of the contact extensions 111 and 112 , which as a result are engaged by the front surface of the inner plate and pressed against the resilient conductive elements 113 upon securing the inner plate to the front housing part. As a result, the arrangement of this embodiment greatly reduces the required thickness of the back housing piece and reduces the overall weight of the night light, and in addition permits the prong length from the back housing to the inner plate to be varied so that other devices can be connected, such as a power fail switching circuit or other functional components.
As illustrated in FIG. 9, the housing of this preferred embodiment of the invention is completed by securing rear housing part 105 to the front housing part 100 following attachment of the inner plate 107 to thereby capture the electro-luminescent element 106 and press the contact extensions 111 and 112 of prongs 103 and 104 against resilient conductive elements 113 , in turn pressing resilient conductive elements 113 against electrodes 114 of the electro-luminescent element. Rear housing part 105 includes, in this embodiment, slots 119 and 120 through which rear portions 117 and 118 of prongs 103 and 104 extend to the exterior of the housing for engagement with contacts of a standard electrical outlet, and openings 119 for screws 120 which are used to removably fasten the rear housing part to the front housing part by means of threaded posts 121 in the front housing part (these posts are omitted from FIG. 8 ). As with the screws 109 , it is within the scope of the invention to substitute other fastening means, including adhesive fasteners, but screws are especially preferred because they enable disassembly of the night light in order to replace defective or damaged electro-luminescent elements.
In the variation of the especially preferred embodiment of the invention illustrated in FIG. 10, the electro-luminescent element is indirectly connected to the prongs of the night light outlet by circuitry housed within an extension or attachment 122 to the inner plate 107 in a manner similar to that illustrated in FIGS. 2 and 6. Again, the circuitry can be in the form of one or more elements selected from the group consisting of an inverter, control circuit, function interface, or the like, which can be in the form of a conventional analog or digital circuit, or an integrated circuit, numerous examples of which are known, the extension or attachment 122 including appropriate terminals or contacts for engaging the 103 and 104 and respective conductive members 113 in order to establish an electrical connection therewith. Of course, the embodiments illustrated in FIGS. 7 - 10 can also be used with an optical effects device similar to device 30 illustrated in FIG. 3 and described above.
The contact arrangement shown in FIGS. 7 - 10 may be modified to provide additional receptacles in the manner described in copending application Ser. No. 08/925,122, filed Sep. 8, 1997, and incorporated herein by reference. An example of a multiple receptacle contact arrangement is illustrated in FIG. 11, in which the prongs are connected to, or integral with, conductive strips 123 and 124 , which in turn are provided with multiple receptacle contacts 125 .
Finally, it will be appreciated by those skilled in the art that the front housing may include decorations or design features in addition to the illustrated simple curved surface, and that additional pieces may be added to the front housing part 100 in order to enhance the design.
Having thus described a preferred embodiment of the invention and a number of different variations and modifications of the preferred embodiment, it is anticipated that still further variations and modifications will undoubtedly occur to those skilled in the art upon reading the above description, and it is therefore intended that the invention be interpreted solely in accordance with the appended claims.
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A night light includes an electro-luminescent element connected to an electrical plug by conductive elements compressed between electrodes of the electro-luminescent element and prongs of the electrical plug. The electro-luminescent element is captured between an inner plate and a front part of the housing so as to cause the electro-luminescent element to conform to a curved surface of the housing without the need for additional plastic housing material, the inner plate also serving to apply a biasing force against the conductive elements.
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The present patent application claims priority from a Japanese Patent Applications Nos. 2003-296787 filed on Aug. 20, 2003 and 2004-216537 filed on Jul. 23, 2004, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a liquid seal and a liquid ejection apparatus. More particularly, the present invention relates to a liquid seal which is used for the liquid ejection apparatus and is capable of maintaining quality of the liquid and also relates to a liquid ejection apparatus employing the liquid seal.
2. Description of the Related Art
A liquid ejection apparatus, such as an ink-jet recording apparatus, performs recording on a recording medium, such as a recording paper, by ejecting liquids, such as ink, from a fluid ejection head, such as a recording head. The liquid ejection apparatus includes a liquid accommodating container, such as an ink cartridge, which is detachably mounted with a main body of the liquid ejection apparatus. The liquid accommodating container supplies the liquid therein to a fluid ejection head through a liquid guide member, e.g., a liquid supplying tube as disclosed in Japanese Patent Laid-Open No. 2001-212974.
If viscosity of the liquid increases due to evaporation of the liquid or if air bubbles is generated in the liquid, performance of the fluid ejection head may deteriorate. In order to prevent a liquid evaporation and the increase of the viscosity, it is necessary to lessen the evaporation through a liquid accommodating chamber, the liquid guide member, and the fluid ejection head. Moreover, in order to prevent generating air bubbles in the liquid, it is necessary to lessen the amount of air being entered into the fluid through the liquid accommodating chamber, the liquid guide member, and the fluid ejection head.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a liquid seal used for a liquid ejection apparatus which performs recording by ejecting a liquid. At least a part of the liquid seal is formed from a layer compound mixture material including a high molecular compound and an inorganic layer compound. The liquid seal seals the liquid. According to the liquid seal, compared with a case if it does not include the inorganic layer compound, the amount of the ink solvent and atmospheric air permeating the liquid seal can be lessened. Therefore, the quality of the liquid is maintainable.
When the content of the inorganic layer compound in the layer compound mixture material is more than or equal to 1 percent of the weight and less than or equal to 50 percent of the weight, the amount of the ink solvent and atmospheric air permeating the liquid seal can be lessened while the characteristic of the high molecular compound is maintained.
The liquid seal may be a resin case in which the liquid is accommodated. In this way, the amount of the ink solvent and atmospheric air permeating the liquid accommodating container can be lessened.
When the liquid ejection apparatus includes: a liquid accommodating container for accommodating the liquid; and a liquid ejection unit for ejecting the liquid, the liquid seal may be a liquid guide member for supplying the liquid from the liquid accommodating container to the liquid ejection unit by allowing communication between the liquid ejection unit and the liquid accommodating container. In this way, the amount of the ink solvent and atmospheric air permeating the liquid guide member can be lessened.
When the liquid ejection apparatus includes: a liquid accommodating container for accommodating the liquid; a liquid ejection unit for ejecting the liquid; and a liquid guide member for supplying the liquid from the liquid accommodating container to the liquid ejection unit by allowing communication between the liquid ejection unit and the liquid accommodating container, the liquid seal may be a container holding member for detachably holding the liquid accommodating container and for connecting the liquid accommodating container to the liquid guide member by connecting the liquid guide member. In this way, the amount of the ink solvent and atmospheric air permeating the container holding member can be lessened.
When the liquid ejection apparatus includes: a liquid accommodating container for accommodating the liquid; a liquid ejection unit for ejecting the liquid; and a liquid guide member for supplying the liquid from the liquid accommodating container to the liquid ejection unit by allowing communication between the liquid ejection unit and the liquid accommodating container, and when the liquid ejection unit includes: a head body for ejecting the liquid outside according to a signal input from a body of the liquid ejection apparatus; a base member for holding the head body, where the base member includes a channel unit for guiding the liquid to the head body; and a joint member connecting with each of the liquid guide member and the base member for guiding the liquid supplied from the liquid guide member to the base member, the liquid seal may be the joint member. In this way, the amount of the ink solvent and atmospheric air permeating the joint member can be lessened.
The liquid seal may include a surface layer which prevents peeling of the inorganic layer compound. Thereby, even if the liquid seal is flexed, the peeling of the inorganic layer compound from the front surface can be prevented. In this case, the surface layer may be unitedly formed by the high molecular compound which does not include the inorganic layer compound. Thereby, the layer including the inorganic layer compound and the surface layer which does not include the inorganic layer compound can be unitedly formed.
The liquid seal may be formed by extrusion, and the inorganic layer compound may be allotted in the liquid seal along a direction of the extrusion. Thereby, the inorganic layer compound can be densified in a direction perpendicular to the direction of the extrusion, so that the amount of the ink solvent and atmospheric air permeating in the direction perpendicular to the direction of the extrusion can be lessened.
According to a second aspect of the present invention, there is provided a liquid ejection apparatus which performs recording on a recording medium by ejecting a liquid. The liquid ejection apparatus includes: a liquid accommodating chamber for accommodating the liquid; a liquid ejection unit for ejecting the liquid to the recording medium; a liquid seal for sealing the liquid. The liquid seal is essentially made of layer compound mixture material including a high molecular compound and an inorganic layer compound. According to the second aspect, the same effectiveness as the first aspect can be attained.
The summary of the invention does not necessarily describe all necessary features of the present invention. The present invention may also be a sub-combination of the features described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an ink-jet recording apparatus where a cover is removed.
FIG. 2 is a perspective view of an ink feed system included in the ink-jet recording apparatus.
FIG. 3 is an exploded perspective view of the ink cartridge.
FIG. 4 is a sectional view of the ink sealing film.
FIG. 5 is a top view of the cartridge holder.
FIG. 6 is a sectional view of the cartridge holder in the A—A cross section of FIG. 5 .
FIG. 7 is a perspective view of the ink guide member.
FIG. 8 is a sectional view of the cross direction of the ink guide member.
FIG. 9 is an exploded perspective view of the recording head unit.
FIG. 10 is a flowchart illustrating a manufacturing process of the bottom case 410 , etc.
FIG. 11 is an expanded sectional view in which the cross section of the base is expanded to illustrate the outline of the configuration.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described based on the preferred embodiments, which do not intend to limit the scope of the present invention, but exemplify the invention. All of the features and the combinations thereof described in the embodiment are not necessarily essential to the invention.
FIG. 1 is a perspective view illustrating an ink-jet recording apparatus 10 using an embodiment of the present invention where a cover is removed, and FIG. 2 is a perspective view of an ink feed system included in the ink-jet recording apparatus 10 . As shown in FIG. 1 and FIG. 2 , the ink-jet recording apparatus 10 includes: a carriage 42 reciprocally moving along with a main scanning direction above a recording medium 11 , such as a recording paper; a recording head unit 300 mounted with the carriage 42 ; a plurality of ink cartridges 400 accommodating a plurality of colors of ink, respectively; a cartridge holder 200 for detachably fixing the plurality of ink cartridges 400 to the body of the ink-jet recording apparatus 10 ; and a rectangular-shaped ink guide member 100 which connects the recording head unit 300 to the cartridge holder 200 . The ink in the ink cartridges 400 is supplied to the recording head unit 300 through the cartridge holder 200 and the ink guide member 100 . The recording head unit 300 reciprocally moves with the carriage 42 along a guide shaft 48 to perform recording by the ink ejection to the recording medium 11 . The cartridge holder 200 is an example of a container holding member.
At least a part of each of the ink cartridges 400 , the cartridge holder 200 , the ink guide member 100 , and the recording head unit 300 , i.e., the part being in contact with the ink, is essentially made of layer compound mixture material, which is a mixture of high molecular matter and an inorganic layer compound. For this reason, it is hard to transmit atmospheric air through the ink cartridges 400 , the cartridge holder 200 , the ink guide member 100 , and the recording head unit 300 .
Although the inorganic layer compound is montmorillonite, which is preferably an example of smectite, it may be another smectite, mica, vermiculite, halloysite, or their synthetic analog. Moreover, although the content of the inorganic layer compound in the layer compound mixture material is preferably more than or equal to 1 percent of the weight and less than or equal to 50 percent of the weigh, it is more preferable that it is more than or equal to 5 percent of the weight and less than or equal to 30 percent of the weight. In this case, the layer compound mixture material can maintain the characteristic of the high molecular matter. Moreover, the ink cartridges 400 , the cartridge holder 200 , the ink guide member 100 , and the recording head unit 300 can be formed by ejection molding.
FIG. 3 is an exploded perspective view of the ink cartridge 400 . The ink cartridge 400 includes a bottom case 410 , a top case 420 , and an ink sealing film 430 . The bottom case 410 includes recess 412 a on a surface joined to the top case 420 , and further includes an ink supply port 414 at a surface for supplying the ink outside. The ink sealing film 430 is welded on the perimeter of the recess 412 a to form an ink accommodating chamber 412 which accommodates the ink in the lower case 410 . The top case 420 is connected to the bottom case 410 to form a resin case of the ink cartridge 400 . The bottom case 410 and the top case 420 are essentially made of the layer compound mixture material. When forming the bottom case 410 and the top case 420 , the layer compound mixture material includes polypropylene as the high molecular matter.
FIG. 4 is a sectional view of the ink sealing film 430 . The ink sealing film 430 includes a welding film 432 , a mixture film 434 , and a heat-resistant film 436 in this order from a side to be welded to the bottom case 410 . The welding film 432 includes material similar to the bottom case 410 , and welded to the bottom case 410 . When the bottom case 410 includes polypropylene, the welding film 432 is formed with cast polypropylene. The mixture film 434 is essentially made of the layer compound mixture material, and prevents the ink solvent and the atmospheric air permeating the ink sealing film 430 . When forming the mixture film 434 , the layer compound mixture material includes polypropylene as the high molecular matter. The heat-resistant film 436 is essentially made of material of which a softening point higher than the welding film 432 , and when welding the welding film 432 , it maintains shape of the ink sealing film 430 .
FIG. 5 is a top view of the cartridge holder 200 , and FIG. 6 is a sectional view of the cartridge holder 200 in the A—A cross section of FIG. 5 . As shown in FIG. 6 , the cartridge holder 200 includes a plate-like member 202 and a sealing film 204 welded to a surface of the plate-like member 202 . As shown in FIG. 5 , the plate-like member 202 has a substantially rectangular shape, and includes a plurality of cylindrical cartridge connection units 210 to which the ink supply ports 414 of ink cartridges 400 are connected, a plurality of conveying member communicating pores 220 to which the ink guide member 100 is connected, and a plurality of slot units 230 which connect the plurality of cartridge connection units 210 to the conveying member communicating pores 220 , respectively. The slot units 230 are formed over the surface of the plate-like member 202 , and form the channels for the liquid by sealed by the sealing film 204 . The plate-like member 202 is essentially made of the layer compound mixture material. When forming the plate-like member 202 , the layer compound mixture material includes polypropylene as the high molecular matter. In addition, although the sealing film 204 is formed by inserting the mixture film between the welding film and the heat-resistant film like the ink sealing film 430 shown in FIG. 4 in the present embodiment, the configuration is not limited to it.
FIG. 7 is a perspective view of the ink guide member 100 . The ink guide member 100 has a rectangular shape, and includes a plurality of cylindrical holder side connection units 102 at one end. The holder side connection units 102 are inserted to the conveying member communicating pores 220 of the cartridge holder 200 . The ink guide member 100 further includes a plurality of cylindrical head side connection units 104 at the other end. The head side connection units 104 are connected to the recording head unit 300 . The holder side connection units 102 and the head side connection units 104 are formed with the base 110 (to be described hereinafter) of the ink guide member 100 shown in FIG. 8 by two colors.
FIG. 8 is a sectional view of the cross direction of the ink guide member 100 . The ink guide member 100 includes a base 110 and the ink sealing film 120 . The base 110 is essentially made of the layer compound mixture material, and includes a plurality of slot units 112 a , which extend along the longitudinal direction and are spaced apart from each other. The ink sealing film 120 is welded to whole surface of the base 110 , and openings of the plurality of slot units 112 a are sealed to form a plurality of channel units 112 . As shown in FIG. 1 , the ink guide member 100 connects the recording head unit 300 to the cartridge holder 200 . The recording head unit 300 moves with the carriage 42 . For this reason, the ink guide member 100 needs to have flexibility. When forming the base 110 of the ink guide member 100 , the layer compound mixture material includes thermoplastic elastomer, for example, SEPS (polystyrene-polyethylene-polypropylene-polystyrene) polymer as the high molecular matter. In addition, although the ink sealing film 120 is formed by inserting the mixture film between the welding film and the heat-resistant film like the ink sealing film 430 shown in FIG. 3 and FIG. 4 in the present embodiment, the configuration is not limited to it.
FIG. 11 is an expanded sectional view in which the cross section of the base 110 is expanded to illustrate the outline of its configuration. FIG. 11 illustrates the base 110 being cut in the thickness direction along the longitudinal direction of the base 110 . For purposes of description, scale of the inorganic layer compounds 142 is magnified in the Figure.
The base 110 shown in FIG. 11 includes an central layer 132 including a inorganic layer compound 142 and a high molecular compound 140 , and the surface layers 130 and 134 arranged on surfaces of the central layer 132 . The central layer 132 and the surface layers 130 and 143 are formed by extruding the layer compound mixture material, which is a mixture of the inorganic layer compound 142 and the high molecular compound 140 , towards a predetermined direction. In FIG. 11 , the direction of the extrusion is right (or left) direction. By the force of the extrusion, the inorganic layer compound 142 is aligned along the direction of the extrusion of the central layer 132 . Thereby, the inorganic layer compound 142 can be densified in a direction perpendicular to the direction of the extrusion. Therefore, in the base 110 , the amount of the ink solvent and atmospheric air passing in the direction perpendicular to the direction of the extrusion (the vertical direction in FIG. 11 ) can be lessened.
At the time of the extrusion molding, the high molecular compound 140 in the surfaces being in contact with open air is cured faster than a central area. In this case, since the high molecular compound 140 is cured from the front surfaces towards the center pushing the inorganic layer compound 142 to the central area, the surface layers 130 and 134 are essentially made of the high molecular compound 140 which do not include the inorganic layer compound 142 . Therefore, the surface layers 130 and 134 which do not include the inorganic layer compound 142 and the central layer 132 which includes the inorganic layer compound 142 can be formed unitedly and easily. Moreover, since the central layer 132 and the surface layers 130 and 134 are unitedly formed including the same high molecular compound 140 , peeling between these layers can be prevented.
The above-mentioned surface layers 130 and 134 prevent peeling of the inorganic layer compounds 142 provided in the central layer 132 . Thereby, even if the base 110 is flexed, the peeling of the inorganic layer compound 142 on its front surfaces can be prevented. Moreover, since the inorganic layer compound 142 does not appear on the front surfaces of the base 110 , the inorganic layer compound 142 can be prevented from hooking other components on the front surfaces of the base 110 .
FIG. 9 is an exploded perspective view of the recording head unit 300 . The recording head unit 300 includes a joint member 302 , a base member 304 , and a head body 306 . The head body 306 ejects the ink onto the recording medium 11 shown in FIG. 2 according to the signal input from the body of the ink-jet recording apparatus 10 . The base member 304 holds the head body 306 , and supplies ink to the head body 306 .
The joint member 302 includes a sealing film 320 , which is welded to the whole surface of the connection base 310 , and the connection base 310 . The connection base 310 has a plurality of conveying member connection unit 312 , head side connection units 314 , and a plurality of channel grooves 316 . The conveying member connection unit 312 is exposed from film ports 322 formed in the sealing film 320 , and receives a plurality of kinds of ink respectively by inserting the head side connection units 104 of the ink guide member 100 . Sealing of the head side connection units 314 is accomplished by the sealing film 320 , and it is connected to the base member 304 and supplies the plurality of kinds of ink to the base member 304 , respectively. The channel grooves 316 guides the plurality of kinds of ink received by the conveying member connection units 312 to the head side connection units 314 , respectively. The connection base 310 is essentially formed of the layer compound mixture material. When forming the connection base 310 , the layer compound mixture material includes the polyphenylene ether resin as the high molecular matter. The composition of the sealing film 320 is similar to the ink sealing film 430 shown in FIGS. 3 and 4 except for the composition of the welding film 432 . In the sealing film 320 , a layer corresponding to the welding film 432 is essentially made of the material similar to polyphenylene ether resin. However, it should be noted that the sealing films 320 is not limited to it.
FIG. 10 is a flowchart illustrating a manufacturing process of the bottom case 410 and the top case 420 of the ink cartridge 400 , the plate-like member 202 of the cartridge holder 200 , and the base 110 of the ink guide member 100 . First, the pellet of the layer compound mixture material, which is the mixture of the inorganic layer compound and the high molecular matter, is prepared (S 10 ). Then, the pellet is melted (S 20 ), and placed into a die. Then, the bottom case 410 , the top case 420 , the plate-like member 202 , and the base 110 are ejection molded (S 30 ). In this way, the bottom case 410 , the top case 420 , the plate-like member 202 , the base 110 , and the connection base 310 can be formed by ejection molding.
As mentioned above, as for the ink-jet recording apparatus 10 , since the bottom case 410 and the top case 420 of the ink cartridge 400 , the plate-like member 202 of the cartridge holder 200 , and the base 110 of the ink guide member 100 are essentially made of the layer compound mixture material, which is the mixture of the inorganic layer compound (e.g., montmorillonite) and the high molecular matter, it is hard for the atmospheric air to dissolve into the ink. For this reason, gas ejection from the recording head unit 300 instead of the ink, or so called “dot defect”, is reduced, and even if it performs continuation recording, recording quality does not deteriorate so easily. Moreover, frequency of ink ejection for the restoration from the dot defect, i.e., frequency of cleaning, is reduced. Therefore, the quantity of the ink that is used for the recording purpose can be increased. Moreover, since the ink solvent cannot evaporate easily until the ink reaches the recording head unit 300 , the viscosity of the ink does not increase so easily.
Moreover, as for the member conventionally formed by the ejection molding, it can be manufactured by the same process as the former method except that the process of making the layer compound mixture material is added. Therefore, the increase in manufacturing cost is avoidable.
In addition, the ink-jet recording apparatus 10 is an example of a liquid ejection apparatus. Moreover, the ink cartridge 400 is an example of an ink accommodating container, and the recording head unit 300 is an example of a liquid ejection unit. However, the liquid ejection apparatus is not limited to it. Other examples of a liquid ejection apparatus are a color filter manufacturing apparatus for manufacturing a color filter of a liquid crystal display. In this case, the cartridge accommodating coloring material is an example of a liquid accommodating container. Yet another example of the liquid ejection apparatus is an electrode forming apparatus for forming electrodes of an organic EL display, an FED (field luminescence display), and the like. In this case, a cartridge accommodating electrode material (conduction paste) of the electrode forming apparatus is an example of the liquid accommodating container. Yet another example of the liquid ejection apparatus is a biochip manufacturing apparatus for manufacturing a biochip. In this case, the cartridge of the biochip manufacturing apparatus accommodating organic substance and a sample is an example of the liquid accommodating container. The liquid ejection apparatus of the present invention further includes another liquid ejection apparatus having an industrial application. The recording medium is an object onto which the recording is performed by ejecting the liquid, and includes a circuit board on which circuit patterns such as display electrodes are formed, a CD-ROM on which a label is printed, and a prepared slide on which a DNA circuit is recorded, as well as the recording paper.
Although the present invention has been described by way of exemplary embodiments, it should be understood that those skilled in the art might make many changes and substitutions without departing from the spirit and the scope of the present invention which is defined only by the appended claims.
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The liquid ejection apparatus is capable of reducing the increase of the viscosity of a liquid due to evaporation of the liquid and also for reducing the quantity of the atmospheric air dissolving into the ink. A liquid seal used for a liquid ejection apparatus which performs recording by ejecting a liquid, at least a part of the liquid seal is formed from a layer compound mixture material including a high molecular compound and an inorganic layer compound. The liquid seal seals the liquid. For example, the liquid seal is an ink cartridge accommodating the liquid therein, or an ink guide member for supplying the ink in the ink cartridge to a recording head unit.
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BACKGROUND OF THE INVENTION
Technical Field of the Invention
The present invention relates to ribbon cartridges for printers and more specifically to systems for mounting such cartridges on the printer.
Art Discussion
Ribbon cartridges greatly facilitate the mounting of a ribbon on a printer by eliminating all or most of the unpleasant tasks of threading the ribbon along the ribbon path. This advantage is quickly compromised, however, if ribbon pulls loose from the cartridge during handing to produce a frustrating tangle. For printers that cause electrodes to sweep across the ribbon during printing, there is, additionally, raised the possibility of damaging the printhead if a crimp or twist is inadvertently formed in the ribbon as a result of handling.
To avoid problems that might arise if a ribbon threading loop is accidentally pulled, it is desirable to prevent ribbon release during handling while nonetheless allowing normal movement during printing. Such restraining of the ribbon is desirably achieved with little cost added to the cartridge and should be easily disabled upon mounting of the cartridge.
BRIEF SUMMARY OF THE INVENTION
In a ribbon cartridge with first and second coaxial ribbon reels, flexible blades formed in the floor of the cartridge urge the reels together and against a top cover to constrain the reels from moving.
Preferably, a reel surface adjacent the top cover includes shaped projections that mate with corresponding projections of the inner top cover surface to restrain rotational reel movement. By so constraining the reels, shifting of the reels within the reel container of the cartridge is prevented and there is reduced likelihood of breakage if the cartridge is dropped or otherwise abused.
During mounting to a support frame, hook-like arms of a rotatable loading member enter apertures in the base of the cartridge and engage the resilient blades with camming edges that, upon rotation of the loading member to a clamping position, drive the projecting portions of the blades toward the cartridge floor, thereby releasing the reels to drop to their normal operative positions where they rotate freely. By so controlling the resilient blades, the arms serve not only to release the reels but also hold the cartridge firmly against the support frame.
For a preferred implementation of the invention, the loading member is also connected through linkages so that, when rotated to the load position, tension control and ribbon drive instrumentalities that nip the ribbon during printer operation are drawn to locations where they do not interfere with the ribbon threading path defined by guide arms of the cartridge. Upon rotation of the loading member to the operating position, the tension and drive instrumentalities are freed to redefine the ribbon path for normal printing operation.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be described in detail with reference to the drawing wherein:
FIG. 1 is a perspective view of a cartridge according to the invention mounted on a support;
FIG. 2 is a cross-sectional view taken as indicated by the line 2--2 in FIG. 1;
FIG. 3 is a cutaway perspective view emphasizing instrumentalities cooperating with resilient blades according to the invention;
FIG. 4 is a cutaway perspective view emphasizing the mating cover and reel surfaces according to the invention;
FIG. 5 is a partial plan view indicating the position of loading arms in apertures defined in the floor of a cartridge according to an aspect of the invention; and
FIG. 6 is a simplified view taken from under the support for the cartridge and serves to emphasize linkages to the load lever that serve to drive ribbon nipping devices to withdrawn positions to facilitate ribbon insertion.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, a ribbon cartridge generally denoted 10 includes a container 12 that is preferably molded of high impact strength polystyrene. The container 12 has a base section 14 that includes a generally planar floor 16 and a sidewall 18. A ribbon chamber 20 is defined by the base section 14 in conjunction with a cover 22 that is received on the sidewall 18.
To permit access to the ribbon chamber 20, the cover 22 may be hinge mounted by hinge members 24 and 26, so as to be fastenable to the sidewall 18 using cooperating latch members 28 and 30. Alternatively, the cover 22 may be bonded or fixed by other permanent means to be integral with the sidewall 18 to provide a substantially sealed container 12.
A drive aperture 32 is defined in the floor 16 by a cylindrical bearing projection 34 having a collar 36 adjacent the floor 16. Arranged to slip over and rotate on the cylindrical bearing projection 34 is a core 38 of a first reel 40 for a ribbon 42 (preferably a supply reel). Also arranged in the chamber 20 is a second reel 44 (preferably a takeup reel) that includes flange 46 and a core 48 that is coaxial with and is rotatable on the core 38. Extending axially from the center of the core 48 is a cylindrical knob 50 that projects through the cover 22 at an aperture defined by the edge 52 to permit operator access for manually rotating the second reel 44.
Projecting guide structures 60, 61, 62 and 63 (see FIG. 1) are molded into the container 12 in rigid channel-like shapes and serve to guide the ribbon 42 along a threading path extending from reel 40 to reel 44. Supported on the arms 60-63 are plural rounded guide surfaces 66 that contact the ribbon to define the threading path which includes apertures 64 in the sidewall 18 that allow a loop of the ribbon 42 to extend externally of the ribbon chamber 20. The arms 60-63 define three ribbon access windows 68, 70 and 72 along the ribbon threading path at which the ribbon 42 is exposed on all sides, for example, to interact with printer instrumentalities such as a tension brake 74 (with cooperating shock roller 73 and pressure roller 75), a printhead 76, and a pair of drive rollers 78 (these elements are not shown in FIG. 2) which are mounted to a support frame 80.
According to the invention, one or more resilient blades 82 are arranged on the floor 16 of the container 12 (see also FIG. 3) to enter the ribbon chamber 20 with an inclination toward the bearing projection 34 so as to urge against the core 38 of the first reel 40. A pad 84 on each blade 82 is located to establish engagement with the core 38 at the outer periphery. Preferably, a pair of resilient blades 82 are provided to balance forces about the axis of the core 38 and, to achieve low cost, the resilient blades 82 are molded as a part of the base section 14.
At the surface of core 48 adjacent the cover 22 a circular ridge 86 coaxial with the core 48 is provided with a series of irregularities such as projections 100 (see FIG. 4) that are shaped to mate with corresponding projections 102 formed on the inner surface of the cover 22.
The projections 100 and 102 are preferably asymmetrical angled teeth that, when mating, offer moderate resistance to rotation of the core 48 for a rotation direction to wind the ribbon 42 onto the reel 44 (counterclockwise as viewed in FIG. 1). For the direction corresponding to unwinding of the ribbon 42 from reel 44, the projections 100 and 102 interfere, for the preferred implementation, preventing rotation.
Now considering mounting of the cartridge 10 on the support 80, two tabs 200 are positioned to cooperate in two sets of guide ridges 202 to promote a proper orientation. A ribbed drive key 204 (see FIG. 2) is positioned relative to tabs 200 for entering the drive aperture 32 and extends into a mating recess (not shown) of the core 48 to establish a drive connection. The ribbed drive key 204 is mounted to a shaft 206 that is supported in a bearing 208.
For mounting, the bearing 208 is preferably formed (e.g. using an acetal plastic) to be integral with a flange 210 that is constrained in tabs 212 of the support frame 80. Rotational motion is provided by a drive system (not shown) through a cable 214 that wraps around a pulley 216 which is connected to rotate with the shaft 206. The flange 210 has a recess 218 that encircles the bearing 208 and receives a washer-like pivot section 220 (see also FIG. 6) of a loading member 222 that includes a handle 224 and preferably two projecting arms 226 (one for each resilient blade 82).
For a "load" position of the loading member 222, the arms 226 are positioned (see also FIG. 5) to enter a pair of corresponding apertures 228 formed in the floor 16 of the base section 14 adjacent the collar 36. Referring again to FIG. 3, interaction results when the arms 226 are rotated from the "load" position (phantom) to a "clamp" position to cause a camming edge 230 to drive the resilient blades 82 toward the floor 16. With the resilient blades 82 depressed, the reels 40 and 44 are free to move toward the floor 16 reducing the friction therebetween and disengaging the projections 100 and 102 to allow free rotation relative to the cover 22. To further reduce friction between the two spools, reel 44 comes to rest atop bearing projection 34 while reel 40 rests against collar 36, the spacing being such that the spools are separated from one another. Also, shoulder projections 19 are formed in the chamber 20 to prevent the ribbon 42 from slipping over the edge of the flange 46.
According to a special aspect of the invention, a compact cartridge 10 is achieved by arranging the arms 226 to enter a channel 236 formed in the core 38. It will be appreciated that upon returning the arms 226 from the clamp position to the load position, the resilient blades 82 are released to urge the reels 40 and 44 toward the cover 22 for restraining movement.
For a further aspect of the invention that is best understood with reference to FIG. 6, the loading member 224 is provided with a cam projection 400 and a bent tab 402 for coupling motion to linking members 404 and 406 to be used in opening nip points that occur along the path for the ribbon 42. Rotation of the loading member 224 causes the link member 404 to rotate counterclockwise (as viewed) about the pivot pin 403 to couple motion through a fork section 405 to the pin 408 mounted to a linking member 410, thereby causing rotation about a pivot pin 412. Such rotation about pivot pin 412 results in contact with a pin 414 to drive a pivot arm 416, supported at pivot pin 418, counter-clockwise (as viewed) against the biasing force of a spring 420. (Note the flange 210 has been cut away to better illustrate the loading member 224.)
The pivot pins 403, 412 and 418 are mounted to the support frame 80 (shown cutaway). Attached to pivot member 416 to extend above support frame 80 is one of the drive rollers 78 (see FIG. 1) and the motion transmitted from the cam projection 400 causes the drive rollers 78 to separate, thereby facilitating ribbon threading as the cartridge 10 is loaded.
The linking member 406 is moved by the bent tab 402 along a path defined in part by a pin 421 that is mounted to the support frame 80 and is arranged in a guide slot 422. A finger 424 engages a pivot member 426 that pivots about a pivot pin 428 and provides force opposite the bias of a spring 430 to cause counter-clockwise rotation (as viewed). This motion is transmitted to a pivot member 434 through a set of bent tabs 432 to cause rotation about a pin 435 against the bias of a spring 436. Motion transmitted by the linking member 406, when the loading member 222 is transferred to the load position, separates the brake member 74 and the pressure roller 75. Such separation facilitates threading of the ribbon 42 during loading and shifts the shock roller 73 to come within the opening 68 (see FIG. 1).
The invention has been described in detail with reference to a presently preferred implementation thereof. It will be appreciated, however, that variations and modifications within the scope of the claimed invention will be suggested to those skilled in the art.
For example, the invention could be adapted to various kinds of printers and both moveable printhead carrier printers or moveable platen printers may use the invention.
Also, the ribbon could be an ink ribbon or a lift-off tape or possibly a magnetic tape.
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A ribbon loading system for a printer utilizes a ribbon cartridge that includes a container enclosing two coaxially arranged ribbon reels. By providing flexible blades in the floor of the container, the reels are urged toward a top cover where relative movement is restrained. Upon loading of the cartridge, camming arms enter apertures in the container and are moveable to a clamping position to draw the blades from the ribbon reels and allow free rotational movement.
For a presently preferred implementation, the structure including the camming arms is coupled through linkages to clear the ribbon threading path and thereby facilitate ribbon insertion.
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TECHNICAL FIELD
[0001] The present invention relates to an electronic data encryption and decryption system and its method.
BACKGROUND ART
[0002] At present, electronic data is often encrypted for transmission in order to prevent the content thereof from being leaked.
[0003] For data encryption, two basic encryption methods, a symmetric encryption method (secret key encryption method) and an asymmetric encryption method (public key encryption method), are generally used.
[0004] The symmetric encryption method uses a common secret key for both encryption and decryption.
[0005] The asymmetric encryption method uses a pair of asymmetric keys.
[0006] More specifically, the asymmetric encryption method uses one secret key and one public key. Data encrypted by the public key can be decrypted only by the corresponding secret key.
[0007] Organizations such as companies and public offices retain confidential information and need to manage the confidential information.
[0008] However, there is a danger that an organization insider may encrypt confidential information and transmit it to others.
[0009] In this case, since the data has been encrypted, it is difficult to determine whether the transmitted data is confidential information or not.
[0010] Thus, there is a possibility that the organization may be unaware of the leakage of confidential information, if occurs.
[0011] In order to avoid this, a system needs to be established in which a confidential information manager (hereinafter, referred to as “privileged user”) of an organization can decrypt encrypted data irrespective of the intentions of a transmitter and a receiver and confirm whether the content of transmitted data includes confidential information or not.
[0012] Examples of a conventional method for the privileged user to decrypt encrypted electronic data are disclosed in PTL 1 and PTL 2.
[0013] Use of the method disclosed in PTL 1 allows the privileged user to decrypt encrypted electronic data.
[0014] However, in the method disclosed in PTL 1, it is necessary for the privileged user to retain and manage all information concerning the secret keys of users of the encryption system, making the key management work cumbersome and complicated.
[0015] The reason for the above is that the privileged user needs to mange information of individual secret keys of the users of the encryption system.
[0016] Use of the method disclosed in PTL 2 allows the privileged user to decrypt encrypted electronic data without a need to manage the secret keys of the users of the encryption system.
[0017] However, the privileged user needs to manage his own secret key. In addition, each of the encryption system users needs to manage two secret keys. Further, for electronic data encryption, each of the encryption system users needs to acquire four public keys.
[0018] The reason for the above is that since there does not exist a key for decrypting encrypted data but a pair of secret and public keys, it is necessary to create a pair of secret and public keys every time required.
CITATION LIST
Patent Literature
[0000]
{PTL 1} JP-A-11-055244
{PTL 2} JP-A-11-085015
SUMMARY OF INVENTION
Technical Problem
[0021] As described above, in order to transmit electronic data without allowing a third party to access the content thereof, a method that encrypts electronic data and then transmits it is effective.
[0022] However, there is a danger that any company insider may encrypt confidential information by using an encryption technique for the wrong purpose and transmit it to others.
[0023] Therefore, a confidential information manager of a company or the like needs to decrypt data encrypted by the company insider so as to confirm the content thereof.
[0024] In this regard, although there is known a method for the privileged user to decrypt the encrypted data, a plurality of encryption and decryption keys are required, making the key management work cumbersome and complicated.
[0025] An object of the present invention is therefore to provide an electronic data encryption and decryption system and its method allowing the privileged user to decrypt all encrypted data without using a plurality of secret keys but only by using a single secret key that the privileged user himself has.
Solution to Problem
[0026] According to the present invention, there is provided an electronic data encryption and decryption system that includes: a privileged user device including, a privileged user key generation means for generating a privileged user secret key x and a privileged user public key x·P (P is a generator), a first session key generation means for generating a session key K, and a first decryption means for decrypting encrypted data by using the session key K generated by the first session key generation means; a user device including, a user key generation means for generating a user secret key r, a user public key r·P, and a public key rx·P, a second session key generation means for generating the session key K, and a second decryption means for decrypting the encrypted data by using the session key K generated by the second session key generation means; and an encrypted data generation device including, a third session key generation means for generating a session key K by using the public key rx·P, session key generation information s and a random point Q, and a means for encrypting input electronic data using the session key K generated by the third session key generation means.
[0027] Further, according to the present invention, there is provided a privileged user device that includes: a privileged user key generation means for generating a privileged user secret key x and a privileged user public key x·P (P is a generator); a session key generation means for generating a session key K; and a decryption means for decrypting encrypted data by using the session key K generated by the session key generation means.
[0028] Further, according to the present invention, there is provided a user device that includes: a user key generation means for generating a user secret key r, a user public key r·P (P is a generator), and a public key rx·P (x is a privileged user secret key); a session key generation means for generating a session key K; and a decryption means for decrypting the encrypted data by using the session key K generated by the session key generation means.
[0029] Further, according to the present invention, there is provided an encrypted data generation device that includes: a session key generation means for generating a session key K by using a public key rx·P (r is a user secret key, x is a privileged user secret key, and P is a generator), session key generation information s and a random point Q; and a means for encrypting input electronic data using the session key K generated by the session key generation means.
[0030] Further, according to the present invention, there is provided a program allowing a computer to function as a privileged user device, the privileged user device including: a privileged user key generation means for generating a privileged user secret key x and a privileged user public key x·P (P is a generator); a session key generation means for generating a session key K; and a decryption means for decrypting encrypted data by using the session key K generated by the session key generation means.
[0031] Further, according to the present invention, there is provided a program allowing a computer to function as a user device, the user device including: a user key generation means for generating a user secret key r, a user public key r·P (P is a generator), and a public key rx·P (x is a privileged user secret key); a session key generation means for generating a session key K; and a decryption means for decrypting the encrypted data by using the session key K generated by the session key generation means.
[0032] Further, according to the present invention, there is provided a program allowing a computer to function as an encrypted data generation device, the encrypted data generation device including: a session key generation means for generating a session key K by using a public key rx·P (r is a user secret key, x is a privileged user secret key, and P is a generator), session key generation information s and a random point Q; and a means for encrypting input electronic data using the session key K generated by the session key generation means.
[0033] Further, according to the present invention, there is provided an electronic data encryption and decryption method that includes: a privileged user key generation step of generating a privileged user secret key x and a privileged user public key x·P (P is a generator); a first session key generation step of generating a session key K; a first decryption step of decrypting encrypted data by using the session key K generated by the first session key generation step; a user key generation step of generating a user secret key r, a user public key r·P, and a public key rx·P; a second session key generation step of generating the session key K; a second decryption step of decrypting the encrypted data by using the session key K generated by the second session key generation step; a third session key generation step of generating a session key K by using the public key rx·P, session key generation information s and a random point Q; and a step of encrypting input electronic data using the session key K generated by the third session key generation step.
ADVANTAGEOUS EFFECTS OF INVENTION
[0034] According to the present invention, it is possible to allow the privileged user to decrypt all encrypted data without using a plurality of secret keys but only by using a single secret key that the privileged user himself has.
BRIEF DESCRIPTION OF DRAWINGS
[0035] FIG. 1 A block diagram showing an electronic data encryption and decryption system according to an embodiment of the present invention.
[0036] FIG. 2 A block diagram showing a structure of an encryption system privileged user device shown in FIG. 1 .
[0037] FIG. 3 A block diagram showing a structure of an encryption system user device shown in FIG. 1 .
[0038] FIG. 4 A block diagram showing a structure of an encrypted data generation device in FIG. 1 .
[0039] FIG. 5 A flowchart showing operation of the encryption system privileged user device shown in FIG. 1 .
[0040] FIG. 6 A flowchart showing operation of the encryption system user device shown in FIG. 1 .
[0041] FIG. 7 A flowchart showing operation of an encrypted data generation device shown in FIG. 1 .
DESCRIPTION OF EMBODIMENTS
[0042] A preferred embodiment of the present invention will be described in detail below with reference to the accompanying drawings.
[0043] First, a structure of the present embodiment will be described with reference to FIG. 1 . An electronic data encryption and decryption system according to the embodiment of the present invention includes an encryption system privileged user device 2 , an encryption system user device 3 , and an encrypted data generation device 4 .
[0044] The encryption system privileged user device 2 is a device used by an encryption system privileged user.
[0045] The encryption system privileged user device 2 retains a privileged user secret key x and provides a privileged user public key x·P (P is a generator) to the encryption system user device 3 and encrypted data generation device 4 .
[0046] Further, the encryption system privileged user device 2 decrypts encrypted data generated by the encrypted data generation device 4 .
[0047] The encryption system user device 3 retains a user secret key r, a user public key r·P, a privileged user public key x·P, and a public key rx·P and provides the user public key r·P and public key rx·P to the encrypted data generation device 4 .
[0048] The encryption system user device 3 decrypts encrypted data generated by the encrypted data generation device 4 .
[0049] The encrypted data generation device 4 is a device used by a user who generates encrypted data.
[0050] The encrypted data generation device 4 retains the privileged user public key x·P provided from the encryption system privileged user device 2 and retains the user public key r·P and public key rx·P provided from the encryption system user device 3 .
[0051] The encrypted data generation device 4 generates a session key (temporary key) K and uses the session key K to encrypt electronic data.
[0052] Next, structures of the respective devices will be described with reference to the drawings.
[0053] First, with reference to FIG. 2 , a structure of the encryption system privileged user device 2 will be described.
[0054] The encryption system privileged user device 2 includes an input/output section 21 , a privileged user key generation section 22 , a key storage section 23 , a session key generation section 24 , and a decryption section 25 .
[0055] The input/output section 21 performs input of encrypted data and output of decrypted data and performs output of the privileged user public key x·P. Further, the input/output section 21 receives information from the privileged user through a keyboard or the like.
[0056] The privileged user key generation section 22 generates the privileged user secret key x and privileged user public key x·P. The privileged user secret key x is selected from one of the elements of a cyclic multiplicative group Zq of an order q.
[0057] A privileged user public key Ppub is one element of a cyclic multiplicative group G of an order q. The cyclic multiplicative group G is an elliptic curve or hyperelliptic curve Jacobian and is generated with a generator set as P. Further, the cyclic multiplicative group G has bilinear pairs e.
[0058] Here, the bilinear pairs e satisfy the following proposition.
[0000] G×G→Zq [Numeral Expression 1]
[0000] where G is a cyclic multiplicative group, × denotes a direct product, → denotes a mapping, and Zq is a mapping of G×G.
[0059] The privileged user public key Ppub is generated by multiplying the privileged user secret key x and generator P. The generated privileged user secret key x and privileged user public key Ppub are stored in the key storage section 23 .
[0060] Here, the bilinear pairs will be described.
[0061] Weil pairs and Tate pairs, which are algebraic curves, are very important in the study of algebraic geometry.
[0062] The initial application of the bilinear pairs was used for evaluating a discrete logarithm problem in an encryption system.
[0063] For example, MOV attack using the Weil pairs and FR attack using the Tate pairs have reduced a discrete logarithm problem in a specific elliptic curve or hyperelliptic curve to a discrete logarithm problem in a finite field.
[0064] In recent years, it has become clear that the bilinear pairs can be applied variously in cryptography.
[0065] The bilinear pairs e that satisfy the above proposition further satisfy the following conditions.
[0000] e ( P 1 +P 2 ,Q )= e ( P 1 ,Q ) e ( P 2 ,Q ) [Numeral Expression 2]
[0000] and
[0000] e ( P,Q 1+ Q 2)= e ( P,Q 1) e ( P,Q 2) [Numeral Expression 3]
[0000] or
[0000] e ( aP,bQ )=( eP,Q ) ab [Numeral Expression 4]
[0000] In addition,
[0000] e ( P,Q )≠1 [Numeral Expression 5]
[0000] PεG,QεG [Numeral Expression 6]
[0000] (where G is a cyclic multiplicative group)
existence of Numeral Expression 6 that satisfies Numeral Expression 5 is required.
[0066] The session key generation section 24 uses session key information sr·P (to be described later) added to encrypted data, a privileged user secret key x, and a random point Q (to be described later) to generate a session key K. The generated session key is provided to the decryption section 25 .
[0067] The decryption section 25 uses the session key K provided from the session key generation section 24 to decrypt encrypted data.
[0068] Next, with reference to FIG. 3 , a structure of the encryption system user device 3 will be described.
[0069] As shown in FIG. 3 , the encryption system user device 3 includes an input/output section 31 , a user key generation section 32 , a key storage section 33 , a session key generation section 34 , and a decryption section 35 .
[0070] The input/output section 31 performs input of encrypted data, output of decrypted data, output of the user public key r·P, input of the privileged user public key x·P, and output of the public key rx·P. Further, the input/output section 31 receives information from the user through a keyboard or the like.
[0071] The user key generation section 32 generates the user secret key r and user public key r·P. As is the case with the privileged user secret key x, the user secret key r is selected from one of the elements of a cyclic multiplicative group Zq of an order q.
[0072] A broadly-defined user public key Upub is an element of a cyclic multiplicative group G of an order q and is generated as a set of a narrowly-defined user public key r·P and public key rx·P. r denotes a user secret key, P denotes a generator, and x denotes a privileged user secret key. rx·P can be obtained by multiplying the privileged user public key x·P by r from the left. Since the values of rx and x have been multiplied by “·P”, they cannot be decrypted by the encrypted data generation device 4 .
[0073] The generated user secret key r and user public key Upub are provided to the key storage section 33 .
[0074] The key storage section 33 stores the user secret key r and broadly-defined user public key Upub (a set of the narrowly-defined user public key r·P and public key rx·P) that has been generated by the user key generation section 32 .
[0075] The session key generation section 34 uses session key information sx·P (to be described later) added to encrypted data, a user secret key r, and a random point Q (to be described later) to generate a session key K. The generated session key K is provided to the decryption section 35 .
[0076] The decryption section 35 uses the session key K provided from the session key generation section 34 to decrypt encrypted data.
[0077] Next, with reference to FIG. 4 , a structure of the encrypted data generation device 4 will be described.
[0078] The encrypted data generation device 4 includes an input/output section 41 , an electronic data storage section 42 , a key storage section 43 , a session key generation section 44 , and an encryption section 45 .
[0079] The input/output section 41 performs input of electronic data, output of decrypted data, input of the broadly-defined user public key Upub, and input of the privileged user public key x·P. Further, the input/output section 41 receives information from the user through a keyboard or the like.
[0080] The electronic data storage section 42 stores electronic data provided from the input/output section 41 . Further, the electronic data storage section 42 provides the stored electronic data to the encryption section 45 .
[0081] The key storage section 43 has session key generation information s and a random point Q. The session key generation information s is an element of a cyclic multiplicative group Zq, and random point Q is an element of a cyclic group G. The session key generation information s and random point Q are provided to the session key generation section 44 .
[0082] Further, the key storage section 43 stores the privileged user public key Ppub (=x·P) and broadly-defined user public key Upub (a set of the narrowly-defined user public key r·P and public key rx·P) that have been provided from the input/output section 41 .
[0083] The session key generation section 44 uses the session key generation information s, random point Q, and public key rx·P that have been provided from the key storage section 43 to generate a session key K. The generated session key K is provided to the encryption section 45 .
[0084] The encryption section 45 uses the session key K provided from the session key generation section 44 to encrypt the electronic data provided from the electronic data storage section 42 .
[0085] The encrypted data is provided to the input/output section 41 .
Operation of Embodiment
[0086] With reference to FIGS. 2 to 7 , operation of the present embodiment will be described in detail.
[0087] First, with reference to FIGS. 4 and 5 , electronic data encryption operation performed by the encrypted data generation device 4 will be described in detail.
[0088] The input/output section 41 inputs therein electronic data (step S 201 ).
[0089] The input/output section 41 stores the input electronic data in the electronic data storage section 42 (step S 203 ).
[0090] The input/output section 41 inputs therein the privileged user public key Ppub and broadly-defined user public key Upub (step S 205 ).
[0091] The input/output section 41 stores the input privileged user public key Ppub and broadly-defined user public key Upub in the key storage section 43 (step S 207 ).
[0092] The key storage section 43 provides the session key generation information s, random point Q, privileged user public key Ppub and broadly-defined user public key Upub to the session key generation section 44 (step S 209 ).
[0093] The session key generation section 44 uses the provided session key generation information s, random point Q, privileged user public key Ppub and user public key Upub to generate a session key K (step S 211 ). The session key K is generated according to the following expression.
[0000] K=e ( rx·P,s·Q ) [Numeral Expression 7]
[0000] where e denotes bilinear pairs, r denotes a user secret key, x denotes a privileged user secret key, P denotes a generator of the above-mentioned privileged user public key Ppub, s is session key generation information, and Q is a random point.
[0094] The encryption section 45 acquires the electronic data from the electronic data storage section 42 , acquires the session key K from the session key generation section 44 , and encrypts the acquired electronic data using the acquired session key K (step S 213 ).
[0095] The encryption section 45 calculates sx·P and sr·P as session key information from the session key generation information s, user public key r·P, and privileged user public key x·P (step S 215 ).
[0096] The encryption section 45 provides encrypted data to which the session key information sx·P and sr·P and random point Q have been added to the input/output section 41 (step S 217 ).
[0097] The input/output section 41 provides the encrypted data to which the session key information sx·P and sr·P and random point Q have been added to the input/output sections 21 and 31 of the encryption system user device 3 and encryption system privileged user device 2 (step S 219 ).
[0098] Next, with reference to FIGS. 3 and 6 , encrypted data decryption operation performed by the encryption system user device 3 will be described in detail.
[0099] The input/output section 31 inputs therein the encrypted data to which the session key information sx·P and sr·P and random point Q have been added from the input/output section 41 and provides them to the decryption section 35 (step S 231 ).
[0100] The decryption section 35 extracts the session key information sx·P and sr·P and random point Q from the encrypted data to which the session key information sx·P and sr·P and random point Q have been added (step S 233 ).
[0101] The extracted session key information sx·P and sr·P and random point Q are provided to the session key generation section 34 .
[0102] The session key generation section 34 acquires the user secret key r from the key storage section 33 and uses the user secret key r, session key information sx·P and sr·P, and random point Q to generate a session key K (step S 235 ).
[0103] K is generated according to the following expression.
[0000] K=e ( sx·P,r·Q ) [Numeral Expression 8]
[0000] where e denotes bilinear pairs, s is session key generation information, x denotes a privileged user secret key, P denotes a generator of the above-mentioned privileged user public key Ppub, r denotes a user secret key, and Q is a random point.
[0104] The session key generation section 34 provides the generated session key K to the decryption section 35 .
[0105] The decryption section 35 uses the provided session key K to decrypt encrypted data (step S 237 ). The decrypted electronic data is provided to the input/output section 31 .
[0106] Next, with reference to FIGS. 2 and 7 , encrypted data decryption operation performed by the encryption system privileged user device 2 will be described in detail.
[0107] The input/output section 21 inputs therein the encrypted data to which the session key information sx·P and sr·P and random point Q have been added from the input/output section 41 and provides them to the decryption section 25 (step S 261 ).
[0108] The decryption section 25 extracts the session key information sx·P and sr·P and random point Q from the provided encrypted data (step S 263 ).
[0109] The extracted session key information sx·P and sr·P and random point Q are provided to the session key generation section 24 .
[0110] The session key generation section 24 acquires the privileged user secret key x from the key storage section 23 and uses the privileged user secret key x, session key information sx·P and sr·P, and random point Q to generate a session key K (step S 265 ).
[0111] K is generated according to the following expression.
[0000] K=e ( sr·P,x·Q ) [Numeral Expression 9]
[0000] where e denotes bilinear pairs, s is session key generation information, r denotes a user secret key, P denotes a generator of the above-mentioned privileged user public key Ppub, x denotes a privileged user secret key, and Q is a random point.
[0112] The session key generation section 24 provides the generated session key K to the decryption section 25 .
[0113] The decryption section 25 uses the provided session key K to decrypt encrypted data (step S 267 ). The decrypted electronic data is provided to the input/output section 21 .
[0114] The encryption system privileged user device 2 , encryption system user device 3 , and encrypted data generation device 4 each can be realized by hardware, software or a combination thereof.
[0115] Further, as another embodiment, the encryption system user device 3 and encrypted data generation device 4 may be embodied as one device.
EFFECTS
[0116] The first effect is that the privileged user can decrypt encrypted data.
[0117] The reason is that the public key of the privileged user and public key of a receiver of encrypted data are generated using a bilinear pairing technique, so that the secret key of the privileged user used for decryption can decrypt data that has been encrypted in any encrypted data generation device.
[0118] The second effect is to facilitate key management.
[0119] The encrypted data receiver can decrypt encrypted data only by using his secret key. Further, the privileged user can decrypt all encrypted data only by using his secret key.
[0120] Thus, the encrypted data receiver and privileged user each only need to manage one secret key for decryption.
[0121] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2007-160193 (filed Jun. 18, 2007) under the Paris Convention, the entire contents of which are incorporated in the present specification by reference.
[0122] Although the representative embodiment of the present invention has been described in detail, it should be understood that various changes, substitutions and alternatives can be made therein without departing from the sprit and scope of the invention as defined by the appended claims. Further, it is the inventor's intent to retain all equivalents of the claimed invention even if the claims are amended during prosecution.
INDUSTRIAL APPLICABILITY
[0123] The present invention can be applied for internal control of a company. In the case where an employee in a company transmits encrypted electronic data by mail, there is a possibility that he may encrypt confidential information of the company and improperly transmits it to others. In view of this, it is necessary to detect such an improper act of the employee of the company and prevent it. To this end, the encryption system according to the present invention has allowed all encrypted data to be decrypted with simple key management.
REFERENCE SIGNS LIST
[0000]
2 : Encryption system privileged user device
3 : Encryption system user device
4 : Encrypted data generation device
21 : Input/output section
22 : Privileged user key generation section
23 : Key storage section
24 : Session key generation section
25 : Decryption section
31 : Input/output section
32 : User key generation section
33 : Key storage section
34 : Session key generation section
35 : Decryption section
41 : Input/output section
42 : electronic data storage section
43 : Key storage section
44 : Session key generation section
45 : Encryption section
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An object of the present invention is to provide an electronic data encryption and decryption system allowing a privileged user to decrypt all encrypted data without using a plurality of secret keys but only by using a single secret key that the privileged user himself has. An electronic data encryption and decryption system includes: a privileged user device, a user device, and an encrypted data generation device. The privileged user device has: a privileged user key generation means for generating a privileged user secret key x and a privileged user public key x·P (P is a generator); a first session key generation means for generating a session key K; and a first decryption means for decrypting the encrypted data by using the session key K generated by the first session key generation means. The user device has: a user key generation means for generating a user secret key r, a user public key r·P, and a public key rx·P; a second session key generation means for generating the session key K; and a second decryption means for decrypting the encrypted data by using the session key K generated by the second session key generation means. The encrypted data generation device has: a third session key generation means for generating the session key K by using the public key rx·P, session key generation information s, and a random point Q; and a means for encrypting the input electronic data by using the session key K generated by the third session key generation means.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a regulating flap arrangement of an exhaust-gas turbocharger provided with a turbine housing.
Description of the Related Art
FIG. 5 shows a regulating flap arrangement 100 which is already known. The figure shows a bushing 110 which is inserted into a turbine housing. A flap shaft 105 is rotatably mounted in said bushing 110 . A flap shaft lever 109 is fastened to one end of the flap shaft 105 . Said flap shaft lever 109 is connected to a flap plate 104 , for example for opening and closing a wastegate duct. The sealing between the flap shaft 105 and the bushing 110 is realized by means of two piston rings 101 which are arranged centrally in the flap shaft 105 . The regulating flap arrangement 100 which is already known is only inadequately capable of compensating the gaps and play that arise during operation owing to running play, tilting and rotation, such that the escape of exhaust gas with soot as leakage gas into the surroundings of the engine cannot be satisfactorily prevented.
It is therefore an object of the present invention to provide a regulating flap arrangement which permits sealing between the bushing and the flap shaft in a reliable manner.
BRIEF SUMMARY OF THE INVENTION
The sealing according to the invention is realized in each case by means of a shaped sealing ring which is arranged on the face-side end of the bushing. The shaped sealing ring can be compressed axially and, in so doing, provide sealing between the face-side end of the bushing and the outer flap lever or the inner flap shaft lever. It is alternatively possible for the shaped sealing ring to be compressed radially. In the case of the radial arrangement, the shaped sealing ring provides sealing between the flap shaft and an inwardly directed wall of the bushing.
In both cases, use is made according to the invention of a shaped sealing ring which, as viewed in its cross section, has at least one cavity. In particular, the shaped sealing ring is of V-shaped or S-shaped form. Owing to said cavity, it is possible for the shaped sealing ring to be compressed or deformed to an adequate extent in the axial or radial direction. The deformation of the shaped sealing ring results in a stress in the shaped sealing ring which counteracts the deforming force and which thus causes the shaped sealing ring to impart its sealing action.
The outer flap lever or the inner flap shaft lever may also be manufactured in one piece with the flap shaft.
The shaped sealing ring is in particular manufactured from metal and arranged in the secondary force flux in order to avoid inadmissibly intense compression.
By means of the new design of the regulating flap arrangement, it is achieved that the gaps and play arising during operation are compensated, and the escape of exhaust gas and soot is substantially prevented. The problem of the contamination of adjacent components with soot and the ingress of exhaust gas into the driver's cab is thereby also solved. Emissions into the environment are eliminated, and the exhaust gas and the soot can pass into the atmosphere only via the catalytic converter and the particle filter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Further details, advantages and features of the present invention become apparent from the following description of exemplary embodiments with reference to the drawing, in which:
FIG. 1 shows a perspective, sectional illustration of an exhaust-gas turbocharger according to the invention,
FIG. 2 shows a detail view of a regulating flap arrangement according to the invention as per a first exemplary embodiment,
FIG. 3 shows a detail view of the regulating flap arrangement according to the invention as per a second exemplary embodiment,
FIG. 4 shows a detail view of the regulating flap arrangement according to the invention as per a third exemplary embodiment, and
FIG. 5 shows a regulating flap arrangement according to the prior art.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an exhaust-gas turbocharger 3 which has a turbine housing 2 in which a regulating flap arrangement 1 according to the invention, which will be explained in more detail with reference to FIGS. 2 to 4 , can be arranged.
FIG. 1 shows the basic design of the regulating flap arrangement 1 composed of a flap plate 4 for opening and closing a wastegate duct. The flap plate 4 is connected via an inner flap shaft lever 9 to a flap shaft 5 . Said flap shaft 5 extends through the turbine housing 2 to the outside. An outer flap lever 6 is fastened to the outer end of the flap shaft 5 . The flap lever 6 is in turn connected to a regulating rod 7 . The regulating rod 7 is moved by means of a drive 8 .
FIG. 2 shows the first exemplary embodiment of the regulating flap arrangement 1 in detail. According to FIG. 2 , a bushing 10 is situated in the turbine housing 2 . The flap shaft 5 is rotatably received in said bushing 10 . An axial direction 15 and a radial direction 16 are defined with reference to the flap shaft 5 . A groove 19 is formed on the face-side end of the bushing 10 . In this exemplary embodiment, the groove 19 is outwardly open in the radial direction 16 and is outwardly open in the axial direction 15 . A shaped sealing ring 13 is arranged in the groove 19 .
A face-side end of the bushing 10 constitutes a first sealing surface 11 . A second sealing surface 12 is situated opposite said first sealing surface 11 . The second sealing surface 12 is formed on the flap lever 6 . The shaped ring 13 provides sealing between said two sealing surfaces 11 , 12 .
In this exemplary embodiment, the shaped sealing ring 13 is of V-shaped form. The V-shaped form comprises a first leg 17 and a second leg 18 as viewed in cross section. Said two legs 17 , 18 are not parallel to one another, such that each leg 17 , 18 has a free end and the other ends of the legs 17 , 18 are connected to one another. The free ends of the legs 17 , 18 bear against the sealing surfaces 11 , 12 . The sealing action arises as a result of an axial compression and deformation of the shaped sealing ring 13 in the axial direction 15 . As a result of said deformation, a stress is generated in the shaped sealing ring 13 such that the shaped sealing ring 13 presses its legs 17 , 18 against the sealing surfaces 11 , 12 .
The groove 19 has a groove depth 20 in the axial direction 15 . The groove depth 20 is selected such that an excessively intense compression of the shaped sealing ring 13 is avoided. Specifically, before the shaped sealing ring 13 is destroyed, the flap lever 6 abuts against the bushing 10 and the shaped sealing ring 13 is securely received within the groove 19 .
The shaped sealing ring 13 has a cavity 14 . Owing to said cavity 14 , the shaped sealing ring 13 differs significantly from a simple seal of disk-shaped form. The cavity 14 is important for attaining an adequate deformation of the shaped sealing ring 13 when the latter is compressed, and thus also building up an adequate stress in the shaped sealing ring 13 .
FIG. 3 shows the regulating flap arrangement 1 as per the second exemplary embodiment. Identical or functionally identical components are denoted by the same reference numerals in all of the exemplary embodiments. The first two exemplary embodiments differ in that the shaped sealing ring is of S-shaped form in the second exemplary embodiment. As a result, the shaped sealing ring 13 has two cavities 14 . In the second exemplary embodiment, too, the shaped sealing ring 13 is compressed in the axial direction 15 .
FIG. 4 shows the regulating flap arrangement 1 as per the third exemplary embodiment. Identical or functionally identical components are denoted by the same reference numerals in all of the exemplary embodiments. In the third exemplary embodiment, the shaped sealing ring 13 is of V-shaped form with two legs 17 , 18 . By contrast to the first exemplary embodiment, however, the V shape of the shaped sealing ring 13 in the third exemplary embodiment opens in the axial direction 15 .
In the third exemplary embodiment, the shaped sealing ring 13 is braced in the radial direction 16 . This requires a first radial sealing surface 11 a on an inner wall, which faces toward the flap shaft 5 , of the bushing 10 . The second radial sealing surface 12 a is correspondingly defined on the lateral surface of the flap shaft 5 . The groove 19 on the face-side end of the bushing 10 thus opens outwardly in the axial direction 15 and inwardly in the radial direction 16 . The shaped sealing ring 13 bears again with the free ends of its legs 17 , 18 against the sealing surfaces 11 a , 12 a.
Even though the invention has been explained above on the basis of the example of a regulating flap arrangement, the sealing arrangement may also be used in an exhaust-gas turbocharger with a variable turbine geometry.
In addition to the above written description of the invention, reference is hereby explicitly made to the diagrammatic illustration of the invention in FIGS. 1 to 4 for additional disclosure thereof.
LIST OF REFERENCE SIGNS
1 Regulating flap arrangement
2 Turbine housing
3 Exhaust-gas turbocharger
4 Flap plate
5 Flap shaft
6 Outer flap lever
7 Regulating rod
8 Drive
9 Inner flap shaft lever
10 Bushing
11 First sealing surface
11 a First radially sealing surface
12 Second sealing surface
12 a Second radially sealing surface
13 Shaped seal
14 Cavity
15 Axial direction
16 Radial direction
17 First leg
18 Second leg
19 Groove
20 Groove depth
100 Regulating flap arrangement according to the prior art
101 Piston rings according to the prior art
104 Flap plate according to the prior art
105 Flap shaft according to the prior art
109 Flap shaft lever according to the prior art
110 Bushing according to the prior art
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A regulating flap arrangement ( 1 ) of an exhaust-gas turbocharger ( 3 ) having a flap shaft ( 5 ), which is guided by means of a bushing ( 10 ) in the turbine housing ( 2 ). A shaped sealing ring ( 13 ), as viewed in cross section, has at least one cavity ( 14 ). The shaped sealing ring ( 13 ) bears simultaneously against the first sealing surface ( 11 ) and against the second sealing surface ( 12 ), and in order to impart its sealing action, is compressed and deformed in the axial direction ( 15 ) of the flap shaft ( 5 ).
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This application is a continuation of U.S. Application Ser. No. 813,242, filed Dec. 24, 1985 now U.S. Pat. No 4,787,183.
BACKGROUND OF THE INVENTION
The present invention relates to forms and components thereof for use in concrete forming and in particular, forms and components thereof which include trusses for forming of concrete floors. The forms preferrably are of the type that are adapted to be lifted by crane between floors of a building during the construction thereof, thereby substantially reducing the time required to set up the form for pouring of the next floor. In particular, the invention is directed to forms which provide additional flexibility and convenient adjustment to define a system for forming of ceilings of different heights or vaulted ceilings.
Flying forms, which are essentially a number of interconnected truss structures adapted to be moved on rollers or the like beyond the building and lifted to the next floor, greatly reduce the required labour necessary for set-up of the forms. Forms of this type include U.S. Pat. Nos. 4,077,172, 3,966,164, and 3,787,020 as but some examples. Recent architectural design to provide additional strength has used concrete ceilings provided with concrete beams which require a stepped ceiling. It is also common to provide a concrete sill at the edge of the floor and a downwardly extending edge portion from the ceiling to reduce the window size. Such structures present additional problems as "packing" is required on the top surface of the truss to accomodate the changing heights of the ceiling. This "packing" is commonly made of wood and beams and as such is very labour intensive and costly. The amount of "packing" can be quite substantial as the top chord of the truss can only be located below the lowest position of the ceiling. When the truss is collapsed for movement between floors, by the lower legs being retracted within the truss, the effective height of the truss is the extent to which the legs may extend below the truss, the height of the truss and the height of any "packing" material secured above the truss. Often this effective height is such that flying forms cannot be used due to the reduced clear area between the concrete sill and downwardly extending ceiling edge.
According to the present invention, a system is provided which uses an intermediate truss which has extendable legs associated therewith. Certain of the legs are associated with the truss to extend below the truss for engaging a support surface and other legs extend above the truss to engage a load collecting beams. Movement of the truss between floors is possible as the lower extension legs collapse or telescope within the truss. The truss is such that the legs each telescope within their own associated tube or recess of the truss whereby the length of the leg can be approximately equal to the height of the truss and, it can be extended further by use of a screw jack. The amount of "packing" and the labour associated therewith is reduced as the extendable legs above the truss are adjusted to accomodate the height of the ceiling and position load collecting beams. As each leg is independently movable within the truss, maximum height of the truss and legs is increased by about the height of the truss as legs extend top and bottom. An upright member for a truss according to an aspect of the invention comprises two paired members disposed in parallel relation and connected to each other by connecting means intermediate the said members. Each of the members includes generally planar opposed parallel bearing surfaces and each bearing surface on one member is colinear with a bearing surface on the other tube member.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings, wherein:
FIG. 1 is a partial perspective view of a truss used in concrete forming;
FIG. 2 is a partial perspective view of a portion of a truss illustrating the co-operation of the upright support members with the top and bottom chords of the truss;
FIG. 3 is a partial perspective view showing additional details of the co-operation between the upright member and the top and bottom chords of the truss;
FIG. 4 is a partial front view of the concrete forming system showing a partial section of a vaulted ceiling;
FIG. 5 is a partial front view of a portion of the truss system adapted for forming of a ledge at the edge of the floor;
FIG. 6 is view similar to FIG. 5 with the truss in its retracted state for removal from between concrete floors.
FIG. 7 is a partial cut-away perspective view of the truss system with a modified construction;
FIG. 8 is a top view of the modified upright; and
FIG. 9 is a partial sideview of the modified upright.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The concrete forming system generally shown as 2 in FIG. 1 has parallel trusses 3 and 4, each having a top chord member 6 and a bottom chord member 8, spaced by upright members 10 and truss diagonal braces 12. The trusses are interconnected by the braces 14. Load collecting beams 22 preferrably run parallel with the top chord 6 of each truss or perpendicular to the top chords 6. The sheeting material 20 is secured atop the beams 18 and at least partially defines the concrete form. A number of trusses 6 can be interconnected for forming larger areas and can be moved as a unit depending upon the construction site and the crane capacity. In the system shown in FIG. 1, 3 different concrete forming levels are shown for accomodating concrete beams and stepped areas formed as part of the floor. Load collecting beams 22 are appropriately positioned by extendable legs 24 or screw jacks as shown, of a size for receipt within an upright member 10. Extendable legs 26 are positioned adjacent the bottom edge of the truss, support the truss at the required height above a support floor. Therefore, the truss, defined between the top chord member 6 and the bottom chord member 8, is positionable at various spacings above a support floor by adjusting the lower extendable legs 26. Extendable legs 24 allow for fast positioning of load collecting beams 22, in accordance with the desired ceiling profile. The legs 24 and 26 are telescopically received within the upright members 10 without interference between leg 24 and 26. This occurs as the legs are adjacent to each other and each upright member 10 has the capacity for receiving two legs. This in effect allows the maximum height of the concrete forming system to be substantially increased relative to the spacing between the top chord 6 and the bottom chord 8 and results in a more efficient and flexible system as the amount of "packing" required has been reduced and the ability to easily define different concrete support levels has been improved. In the system as shown in FIG. 1, "packing" 29, illustrated as 2×4's nailed to the sheeting material 20, is provided at each change in level of the form. The packing for a given level has been replaced by load collecting beams 22 supported by legs 24. Normally it will not be necessary for all uprights 10 to receive extendable legs and some may merely act as a structural member such as upright 10a.
Details of the telescope receipt of extendable leg 24 and extendable leg 26 within one of the upright members 10 can be appreciated from FIG. 2, where upright member 10 has two opposed members 32 and 34, each of a size for receiving an extension leg. Webs 36 and 38 in combination with members 32 and 34, define a closed cavity 40. This cavity is advantageously used to receive bolts 92 for connecting the upright member 10 to the chord members 6 and 8. As the bolts pass through the cavity 40, the hollow portion within each of the tube members 32 and 34 remains clear and allows extendable legs 24 and 26 to collapse or telescope within the full length of each tube member. To the exterior of web members 36 and 38, bolt slots 42 and 44 are provided. Bolt slot 42 has exterior flanges 46 and 48 which define a planar face for engaging the interior surface of the side plate 62 of the bottom chord member 8 and the interior surfaces of the side plate 82 of the top chord member. Bolt slot 44 includes similar flanges and cooperates with side plates 64 and 84. In addition each tube member includes opposed thickened portions 50 and 52 having a planar outer face. The face of portions 50 are co-planar with flanges 48 and 46 which also engage the interior surface of the bottom chord member and the top chord member to provide a more secure fit of the upright member within the chord members. Portion 52 cooperates with the flanges of bolt slot 44 to engage the opposite side plates of the top and bottom chord. The blots 92 pass through the side plates of the chord members and through the bolt slots to apply the pressure adjacent these planar engaging faces to increase the structural integrity of the system. The uprights are preferrably extruded of a magnesium or aluminum alloy although not limited thereto.
To top chord member 6 includes a top plate 80 which extends beyond the side plates 82 and 84 to define downwardly extending lips 86, either side of the longtitudal axis of the top chord member 6. These lips 86 are used for clamping of additional components to the top chord member. The top plate 80, includes a circular opening 81 to allow access to the hollow interior portions of the tube members 32 and 34 whereby the extendable leg 24 can be received in either of the tube members 32 and 34.
The bottom chord member 8, is open on the bottom and as such the hollow interior portions of tube members 34 and 36 are exposed at the bottom of the chord member. However, the bottom chord does include inwardly extending lips 66 and 68, which bearingly engage with the lower surfaces of the thickened portions 50 and 52 and the lower portion of the bolt slots 42 and 44. The top plate 60 of the bottom chord member has an aperture therein for receiving the upright member 10, which is held within the bottom chord member by the bolts 92. The lips 66 and 68 reduce the shear stress that must be carried by the bolts 92. The bottom chord member also includes outwardly extending lips 70 and 72 having the edge thereof flared upwardly. This lip arrangement it used for securing of components to the bottom chord member and increases the stiffness of the bottom chord member.
The top chord member 6, the bottom chord member 8 and the upright members 10, are preferrably extruded of a light weight alloy of aluminum or magnesium although a version of the system made of steel can be used if the increased weight can be accomodated. The extendable legs 24 and 26 can be of many different forms and the form shown for leg 24 includes a support plate 94, having a externally threaded stub tube 100, having a rotatable member 101, thereabout. The leg 24 includes an extension leg rod 95, having a number of holes 102 therein, for receiving the pin member 96. Therefore, the leg is roughly adjusted according to the length required, by proper placement of pin member 96 in one of the holes 102 and member 101 is then adjusted to more accurately position the channel bracket 74 which supports the load collecting beam 22. In this case, the extension leg rod 95, is telescopically received within tube member 34 and the extension rod member 105 of the lower leg is telescopically received within tube member 32. Rod 95 and rod 105 will overlap when the system is arranged in its most compressed or compacted state. A similar type leg arrangement 104, has been shown at the bottom edge of the bottom chord 8, however, these legs are but examples of what can be used and the invention is not limited to these legs. The important point to note, is that the position of the extendable leg rods 95 and 105 intermediate the top chord 6 and the bottom chord 8 can overlap and, therefore, the effective maximum height of the system without considering screw jacks etc. securable to the legs is generally significantly greater than twice the spacing between the bottom chord 8 and the top chord 6. The lower leg can be fully received within the truss when the system is "compacted" independent of the amount of upper leg received within the truss.
FIG. 3 shows a similar type arrangement, however, in this case the tube members 32 and 34 of the upright member 10 have a number of holes 110 through the thickened portions 50 and 52 which are alignable with holes 112 of leg 24a and 104a. A locking U-bar 108 is receivable in adjacent holes 110 of the upright member 10 for passing through holes 112 in the leg 24a or 104a for providing a rough adjustment of the position of the channel bracket 74 above the top chord member 6 or for spacing of the support plate 106, a certain distance below the bottom chord member 8. More accurate adjustment is achieved by turning of the threaded collars 113 of leg 24a or collar 115 of leg 104a. In contrast to the structure of FIG. 2 top plate 80 has a somewhat elongate opening 117 to allow leg 24a to telescope within the hollow interior of tube member 32. This allows the user to position leg 24a to telescope within tube 32 or within tube 34 and appropriately position the bottom leg to telescope within the other tube. Therefore, in the preferred embodiment both tubes 32 and 34 are opened to the upper side of the top chord 6, and are opened to the lower periphery of the bottom chord 8. The elongate opening 117 is not oversized and, therefore, the thickened portions 50 and 52 of each upright member 10 will engage the underside of top plate 80 and similarly the bolt slots 42 and 44 will also engage the top plate. The advantage of two openings rather than one elongate opening 117, is that the portion of the upper chord generally between the tubes remains intact and provides additional bearing surface for upright 10.
FIGS. 4, 5 and 6 illustrate how the concrete forming system of the present application can advantageously be employed. In FIG. 4 a portion of a vaulted ceiling 120 is shown, where load collecting beam 22b supports beam 18b which in turn supports the sheeting material 20b for defining a portion of the form defining the multi-level ceiling. Beams 18c can be directly supported on the top chord member 6 of the truss and support sheeting material 20c for defining the lower surface of the ceiling. Load collecting beam 22a supports beams 18a and sheeting material 20a for defining another step in the ceiling. In addition, sheeting 20d and 20e are shown deleting the vertical surfaces of the vaulted ceiling and nailed to the upper and lower level via a number of 2×4's. When it is desired to remove the system 2 from between the lower floor 200, the lower legs 26 are essentially fully telescoped within the upright members 10 and the legs 24a and 24b preferrably remain at their adjusted position with a certain portion thereof within the upright member 10. Thus the surface 20b, 20c and 20a and any packing will maintain their position relative to the top chord member 6. The system is most effective when the truss is of a height whereby the legs 26 and associated jack screw are close to fully extended whereby the system can pass through a gap slightly larger than the truss and the structure thereabove defining the concrete forming surface. If the height is still too great, packing for surface 20e and 20d may be removed and legs 24a and 24b telescoped within the truss. Normally this is not required but is advantageous in that the ability of the system to move through a narrow space is further increased.
In FIGS. 5 and 6, the system is shown supporting a portion of the concrete floor adjacent the edge of a building. In this case, the floor of the building has a bottom sill 126 projecting upwardly therefrom, and a downwardly projecting portion 124 which extends below the lower surface of the newly poured floor 122. Therefore, the gap between portion 124 and 126 is defined by the spacing "A", and as such the system must compress or collapse to a height less than the spacing "A" to allow the truss to be moved as a unit outwardly through the gap "A" to allow flying of the form to the top surface of the newly poured floor 122.
In FIG. 5, it can be seen that end 27 of leg 26 and end 25 of leg 24, are positioned such that there is an overlap between legs 24 and 26. In this case, the full height capacity of the system was not required. From a consideration of FIG. 6, it can be seen that the end 25 remains at the adjusted position within the upright member 10 and end 27 telescopes to move to be adjacent the top chord 6. Therefore, the ability of the system to compress is independent of legs 24 as each leg 24 and 26 moves independently within the upright member 10. The overall height of the truss can greatly be reduced in its compressed state by telescopic receipt of legs 24 in the truss. This provides a ratio of maximum height of the combined truss and legs independent of jack screws relative to minimum height substantially greater than two and up to about three. This is particularly advantageous in the present design of buildings as it is desirable to have vaulted-type ceilings with downwardly extending ledges where the actual space for moving of the truss exterior of the building has been substantially reduced.
A modified structure is shown in FIGS. 7 through 9, which can be fabricated from commonly available components. The upright 210 has two spaced square tube members 234 and 236 secured and spaced by plates 242 and 244 to define cavity 240 intermediate the tube member 234 and 236 and the top chord 204 defined by opposed channels 205 and 206. Plates 242 and 244 are preferrably welded to tube members 234 and 236. The bottom chord 208 defined by channels 207 and 209, is similiarly attached to the upright 210 secured either side by plates 215 and 217. Bolts 292 pass through the channels and the plates to secure upright 210 to the bottom chord 208 and the top chord 204.
The use of tubes 234 and 236 of square or rectangular section is preferred as welding of plates 242, 244, 215 and 217 thereto is simplified. It is also possible to use tubes of other cross section such as circular and oval although securement to the top and bottom chord is slightly more difficult. The use of welded plates as above will adequately secure the chords to the upright member.
Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.
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A structural member for use in concrete forming structures and the like is disclosed. The member comprises a pair of spaced parallel tubular members interconnected by means of opposed webs. The combination defines an enclosure extending the length of the tubular members. Each of the webs attaches to a side of the tubular member opposite the enclosure. The outer surface of each web includes opposed flanges, which in combination with the web, define an open bolt slot that extends the length of the structural member. This structural member is particularly useful as an upright in concrete shoring.
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GOVERNMENT CONTRACT CLAUSE
The U.S. Government has rights in this invention pursuant to Contract No. F-1067 awarded by the U.S. Air Force.
BACKGROUND OF THE INVENTION
The present invention relates to infrared analyzers which can be used in a variety of industrial and commercial applications. In particular the present invention is a method and an apparatus for enlarging the spectral range of an acousto-optic tunable filter by extending the operation of the transducer structure to its third harmonic.
It has been known to utilize plural acoustic transducers in an acousto-optic tunable filter system in order to increase the spectral range of the system. For example, U.S. Pat. No. 3,759,603 teaches a system with a plurality of transducers, each of which is operable in consecutive frequency ranges to increase the system pass band. U.S. Pat. No. 3,665,204 teaches an acousto-optic device which utilizes a contribution to light output from the second order harmonic. Finally, U.S. Pat. No. 3,807,799 offers a general teaching of utilizing higher order spectra to contribute to total light output through the provision of additional slit openings in an output slit diaphragm for an acousto-optic device.
It is therefore an object of this invention to provide an acousto-optic tunable filter in which the range is extended by utilizing the third harmonic frequency band of the transducer structure.
It is also an object of this invention to provide a transducer structure in which the capacity may be electronically switched so that the electrical impedance match is held approximately constant over the extended frequency range.
It is still another object of this invention to provide a method of operating an acousto-optic tunable filter with an extended spectral range so that the filter efficiency at the third harmonic band is generally equivalent to the filter efficiency at the fundamental band.
SUMMARY OF THE INVENTION
The invention provides a method for enlarging the spectral range of an acousto-optic device by extending the operation of the transducer structure to the third harmonic of the fundamental frequency. A transducer structure is coupled to a crystal employed as a sonic medium. The transducer structure consists of a plurality of individual transducer elements. A switching means is provided for selectively establishing electrical communication among the elements so that the capacitance of the transducer structure can be modified. By modifying the capacitance of the transducer structure, an RF generator can alternately provide both a fundamental frequency and the third harmonic of that frequency to a transducer structure with adequate impedance matching characteristics throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other features and advantages of this invention will become apparent through consideration of the detailed description in connection with the accompanying drawings in which:
FIG. 1 is a somewhat schematical representation of an acousto-optic tunable filter;
FIG. 2 is a graph illustrating a tuning curve for a Tl 3 AsSe 3 crystal, acousto-optic tunable filter;
FIG. 3 is a graph illustrating transducer conversion efficiency at the fundamental frequency and the third harmonic in a transducer of fixed capacity;
FIGS. 4A and 4B schematically illustrate a transducer switching apparatus according to this invention; and
FIG. 5 is a graph illustrating transducer conversion efficiency at the fundamental frequency and the third harmonic in an acousto-optic tunable filter according to the teachings of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An acousto-optic tunable filter operates through the interaction of high frequency acoustic waves with light waves in a suitable crystal. A typical configuration of an acousto-optic tunable filter is schematically illustrated in FIG. 1 and generally indicated by the reference character 11. The acousto-optic tunable filter (AOTF) 11 comprises an input polarizer 13, an acousto-optic crystal 15 and an output polarizer 17. The present material of choice for the AOTF crystal is thallium arsenic selenide, Tl 3 AsSe 3 , which is disclosed in U.S. Pat. No. 3,792,287 which is assigned to the assignee of the present invention. The input optical face 19 of the crystal 15 is cut so as to be normal to the incident infrared beam 21. The filtered output beam 23 is diffracted at an angle of about 6° to the incident beam 21 and the exit optical face 25 of the crystal 15 is cut so as to be normal to this output beam 23. An acoustic transducer according to this invention comprises a plurality of transducer elements 27 mated to one of the opposed side surfaces of the crystal 15. Each element 27 of the transducer can, for example, consist of an X-cut lithium niobate crystal plate which is efficiently coupled to the crystal 15. A conductive electrode pattern is provided on the lithium niobate transducer, and this electrode is driven by a controllable RF signal.
The acoustic energy from the transducer elements 27 is propagated so as to be nearly normal to the optical beam propagation direction. When RF power is applied to the transducer, the polarized input infrared radiation is propagated along a path at a predetermined angle to the optic axis of the crystal and a narrow pass band frequency selectively interacts with the acoustic wave. The polarization is rotated 90 degrees from the polarization of the unfiltered beam. This selected or tuned narrow pass band infrared radiation is also distinguishable from the remaining input radiation because it is shifted or diffracted at a small angle relative to the unaffected input radiation path, such as the 6 degree offset described above. Thus the filtered light can be separated either spatially due to this offset angle without the use of an output polarizer, or by means of an output polarizer.
The frequency of the RF signal driving the transducer elements 27 determines the wavelength of light that is passed by the AOTF crystal 15. For any AOTF material and configuration, there is a relationship that uniquely determines the pass wavelength:
λ=F/f
where λ is the pass wavelength, f is the acoustic frequency and F is a function of the crystal material constants and configuration angles. While it is desirable that acousto-optic tunable filters be capable of operation over a large range of optical wavelength, these filters are limited by the bandwidth of the acoustic transducer structure. Accordingly, the acoustic transducer structure is designed and fabricated with as large a bandwidth as possible, consistent with efficient electro-mechanical transduction. For typical AOTF designs, this bandwidth is generally no larger than about 80% of the center frequency, f o ; that is:
Δf/f.sub.o =0.8
Another important characteristic of the AOTF is the efficiency with which the selected wavelength is passed by the filter. This characteristic is a function of the acoustic power level and the wavelength itself. In order to achieve a given efficiency, the required RF power increases as λ 2 . Thus, the required power over a range of operation will be determined by the product of the transducer response with λ 2 , as follows:
P(RF)˜λ.sup.2 /(transducer response)
The present invention increases the AOTF spectral range by providing a transducer structure to operate over an enlarged bandwidth. The AOTF operates both at its fundamental frequency mode and also at its third harmonic frequency mode. As a result, the AOTF transducer frequency range may extend from the lowest frequency in the fundamental band to the highest frequency in the third harmonic band. Third harmonic operation of transducers results in a much lower electromechanical conversion efficiency than operation at the fundamental frequency, typically about ten times lower. On the other hand, the third harmonic band corresponds to filtered wavelengths three times shorter than the fundamental band. The acoustic power requirement for the third harmonic band is thus only one-ninth that of the fundamental band. As a result, these two effects tend to balance each other, yielding essentially flat optical transmission over the extended range.
A tuning curve for a Tl 3 AsSe 3 crystal, noncollinear AOTF is shown in FIG. 2. In order to employ this AOTF in the spectral range of about 1.5 to 17 micrometers, it is necessary to apply RF power in the range of 10 MHz to 110 MHz. This frequency range corresponds to abou 31/3 octaves. Conventional transducer technology is inadequate for such an application. The optimum bandwidth on a Tl 3 AsSe 3 crystal AOTF is approximately 80% of the center frequency which is selected to be 26 MHz. Plot `a` on the graph of FIG. 3 represents the conversion efficiency obtained with a AOTF crystal having a transducer of predetermined fixed capacitive value driven at 26 MHz according to the conventional practice described above. It is possible to operate acoustic transducers on the third harmonic of their fundamental band under this practice. However, as shown by plot `b` on the graph of FIG. 3, a significantly lower electro-mechanical conversion efficiency is obtained. While the conversion efficiency in the third harmonic band depends upon a number of factors, it will typically be around a factor of 10 lower than the conversion efficiency at the fundamental band. As described above, the AOTF interaction efficiency varies as λ -2 , so that the overall filter efficiency varies as
1/λ.sup.2
transducer response). The transducer response is a function of the electromechanical conversion efficiency of the transducer and also upon the electrical matching of the transducer to the driving circuit.
The transducer is an electrically capacitive load whose value depends upon the physical structure of the transducer, i.e., transducer thickness, transducer area and the dielectric constant of the transducer material. A problem that arises with large area transducers, or even with small area transducers at very high frequencies, is matching the electrical impedance to the impedance of the RF source. This problem is overcome by dividing the transducer into a multielement array of series connected components. The overall capacitance for fixed transducer dimensions can be determined by the number of elements in the array. Accordingly, if there are N elements in the array, the capacity of the transducer is C/N 2 where C is the capacity of the undivided transducer.
A method for forming a series of transducer elements on a crystal is disclosed in U.S. patent application Ser. No. 403,954, which is assigned to the assignee of the present application and is incorporated herein by reference thereto.
While a transducer structure can be formed to provide impedance matching characteristics which optimize matching in the fundamental band, these same characteristics fail to provide acceptable impedance matching characteristics for the operation of the AOTF in the third harmonic of the fundamental band. This invention overcomes this problem by controlling the number of transducer elements driven by the RF source according to which frequency band is operated. A schematical representation of the transducer structure of this invention is illustrated in FIGS. 4A and 4B. Each individual transducer element 27 of the transducer structure is schematically shown as a capacitor and designated C 1 through C 4 (C 1 =C 2 . . . C N ). While only four capacitors are shown, representing a four element transducer structure is to be understood that transducer structure consisting of more than four individual transducer elements can incorporate the features of this invention (FIG. 1, for example, shows an eight element transducer structure). Moreover, while the switching means S1 and S2 of this invention are shown as having mechanical linkage 29, any of a variety of switching devices can be incorporated into the circuitry of this invention. As shown in both FIGS. 4A and 4B, the switches are ganged and operated in unison.
In FIG. 4A, switch means S1 and S2 are placed in a first position in which contacts 31 and 33 are in a first closed position and contacts 35 and 37 are closed. With the switches S1 and S2 in the first position, the pair of elements C 1 and C 2 are in a parallel electrical configuration as are the pair of elements C 3 and C 4 . The pairs of elements, defining parallel groups, are electrically connected in series. This combination of parallel pairs or groups of elements in series permits operation in the fundamental band because the capacity is equal to 4C/N 2 as described above.
In FIG. 4B, the switching means S1 and S2 are shown in a second position in which contacts 31 and 33 are in a second closed position and contacts 35 and 37 are opened. This configuration places the transducer elements C 1 through C 4 in series electrical connection and permits the satisfactory impedance matching of the transducer elements with an RF source operating at the third harmonic band of the fundamental frequency.
Ideally, the capacity of the third harmonic should be one-third the capacity of the fundamental. The present transducer element switching system, however, yields a factor of one-fourth between the elements when switched from the fundamental to the third harmonic. While the impedance match between the transducer elements and the RF driven is not precisely achieved for the third harmonic, the impedance match is such that greatly improved performance over a full range of both the fundamental and the third harmonic is obtained.
The two plots of the graph in FIG. 5 illustrate the conversion efficiency obtained in an AOTF utilizing the switching means of this invention and operating at both the fundamental frequency as at `a` and the third harmonic thereof as at `b`. A reasonably flat efficiency is obtained in the long wavelength region. The present invention greatly extends the operational range with a transducer structure of limited bandwidth.
By utilizing the principles of this invention, the spectral range of an acousto-optic tunable filter system can be extended to include the third harmonic frequency band of the transducer structure. More particularly, the spectral range is extended by designing the transducer structure so that the fundamental plus third harmonic bands correspond to the desired continuous spectral range.
What has been described is an acousto-optic tunable filter with a transducer structure having a capacity which may be electronically switched to match the frequency band of operation. As a result, the electrical impedance is held approximately constant over the extended frequency range.
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The invention relates to a method and an apparatus for enlarging the spectral range of an acousto-optic tunable filter by extending the operation of the transducer structure to its third harmonic. The transducer structure consists of a plurality of individual transducer elements in electrical communication through a switching network which modifies the total capacitance of the transducer structure to provide a satisfactory impedance match at both the fundamental and the third harmonic.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a manual and automatic flusher, particularly to one operable manually and automatically and having a simple structure to be easily made so as to lower its cost.
[0003] 2. Description of Prior Art
[0004] Nowadays a flusher used for a toilet is quite indispensable both in personal houses and public buildings. And a conventional manual flusher was disclosed in a U.S. Pat. No. 4,327,891, which includes a hand rod for forcing a valve to incline to cause a pressure releasing passageway to let water to flow and permitting a film so far pressed down to recover its position and move up to let water to flow in a large volume out of an outlet passageway for flushing a toilet. This manual flusher can operate by gripping directly the hand rod, so the hand rod may become dirty, and should a user forget or not press the hand rod, the toilet may produce bad odor and pollute the environment.
[0005] Further, a conventional automatic flush e r was disclosed in a U.S. Pat. No. 4,793,588, which includes an infrared sensor in an upper portion, and an electric-magnetic valve provided in the infrared sensor having a iron core to be moved out and in so that a pressure releasing passageway may be controlled to open and close so that a pressure-adding room storing water may be reduced in its pressure to let a film to move up for water to flow out of an outlet passageway, obtaining automatic flushing effect.
[0006] However, the conventional automatic flusher has the following disadvantages.
[0007] 1. It depends on the infrared sensor and the electromagnetic valve to operate flushing, and if these electronic components get out of order, the flusher has to be repaired before it can be used to flush water, needing a period of waiting time required in its repair, very embarrassing.
[0008] 2. It needs an electric power of DC or AC, so no matter which is its power, if the AC power happens outage or the DC of a battery is used up, the flusher has to wait until its power is recovered, not convenient.
[0009] 3. It depends on the infrared sensor for flushing water, it cannot continue to let water flushed as the manual flusher for continuously keep water flushed out by keeping pressing the hand rod.
SUMMARY OF THE INVENTION
[0010] The purpose of the invention is to offer a manual and automatic flusher, possible to be used normally by the automatic mode and to be used manually in case of the automatic mode gets out of order, without need of waiting the automatic structure repaired.
BRIEF DESCRIPTION OF DRAWINGS
[0011] This invention will be better understood by referring to the accompanying drawings, wherein:
[0012] [0012]FIG. 1 is a perspective view of a manual and automatic flusher in the present invention;
[0013] [0013]FIG. 2 is a side cross-sectional view of the automatic flusher in the present invention;
[0014] [0014]FIG. 3 is the side cross-sectional view of the manual and automatic flusher in the present invention, showing it filled with water;
[0015] [0015]FIG. 4 is a side cross-sectional view of the manual and automatic flusher in the present invention, showing manual flushing;
[0016] [0016]FIG. 5 is a side cross-sectional view of the manual and automatic flusher in the present invention showing automatic flushing;
[0017] [0017]FIG. 6 is a cross-sectional view of a second embodiment of a communicating tube in the present invention;
[0018] [0018]FIG. 7 is a cross-sectional view of a third embodiment of a communicating tube in the present invention; and,
[0019] [0019]FIG. 8 is a cross-sectional view of a fourth embodiment of a communicating tube in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] The preferred embodiment of a manual and automatic flusher in the present invention, as shown in FIGS. 1, 2 and 3 , includes a cup member 10 , a base tube 20 , a film 30 , a pressure cap 40 , a valve body 50 , a hand rod 60 , an upper cap 70 , a communicating tube 80 and an infrared sensor 90 as main components combined together.
[0021] The cup member 10 is provided with an inlet 11 , a combine hole 12 , an outlet 13 , and a chamber 14 . A tubular base 15 extends upright on the bottom of the chamber 14 ,
[0022] The base tube 20 is firmly fixed inside the tubular base 15 , having a close groove 21 formed in the upper portion for an upper disc member 51 of the valve body 50 to press thereon. The film 30 with a through hole 31 is fixed on the upper end of the base tube 20 , having its circumference pressed by the lower annular edge of the pressure cap 40 . Thus the upper cap 40 , the film 30 , the base tube 20 and the upper disc member 51 define a pressure-adding room (a), which communicates with the inlet 11 via the through hole 31 of the film 30 , the space between the circumference of the base tube 20 and the cup member 10 . The valve body 50 has a pillar member 52 and an upper disc member 51 fixed with the pillar member 52 , and an insert head 53 is inserted in the center of the disc member 51 , and a flow passageway 54 formed in the center of the pillar member 52 under t h e insert head 53 to communicate with the outlet 13 of the cup member 10 . The hand rod 60 is fixed with the opening outlet 12 of the cup member 10 , possible to be pressed down to force its end push against the end of the pillar member 52 so that a gap may formed between the close groove 21 of the base tube 20 and the disc member 51 of the valve body 50 , permitting the pressure-adding room (a) communicate with the outlet 13 of the cup member 10 via the interior of the base tube 20 . The upper cap 70 is closed on the cup member 10 .
[0023] Therefore, when the hand rod 60 is pressed down, the water normally stored in the pressure-adding room (a) can flow through the gap formed in the valve body 50 and the close groove 21 and then through the base tube 20 . Then the water pressure in the pressure-adding room 9 (a) may decrease, and the pressure under the film 30 will increase more than that in the pressure-adding room (a), forcing the film 30 move upward to form a flowing gap (b) between the film 30 and the tubular base 15 and the space between the base tube 20 and the annular base 15 , permitting a large quantity of water flow in through the inlet 11 and then out of the outlet 13 for flushing a toilet. The flushing action may continue until the film 30 moves down to the original position, with the pressure-adding room 9 (a) filled with water. However, this kind of operational function is the same as the conventional flusher. The special feature of the invention is to be described below.
[0024] The valve body 50 has an insert head 53 inserted in the center of the upper disc member 51 and a flow passage way 54 formed in the pillar member 51 to communicate with the outlet 13 of the cup member 13 .
[0025] The pressure cap 40 has an annular wall 41 of a small diameter formed in an upper portion, and a position groove 42 inside the annular wall 41 , a block 43 contained in the position groove 42 , a sealing gasket 44 closing the opening of the position groove 42 to seal the block 43 therein. Further, the pressure cap 40 has a through hole 431 to correspond to a through hole 54 formed in the pressure cap 40 to communicate with the pressure-adding room (a), and a flowing hole 432 in the center to communicate indirectly with the through hole 431 via the sealed space of the position groove 42 .
[0026] The communicating tube 80 is a bellows-shaped flexible tube, having one end connected to the bottom of the flowing hole 432 and the other end fitting firmly around the upper end of the flow passageway 50 of the insert head 53 , letting the pressure-adding room (a) indirectly connected with the outlet 13 via the communicating tube 80 .
[0027] The infrared sensor 90 consists of a fixing frame 91 fixed between the upper cap 70 and the pressure cap 40 , an electronic eye 92 fixed on the fixing frame 91 , an electromagnetic valve 93 fixed in the center of the fixing frame 91 , and a power device 94 fixed on the opposite side of the electronic eye 92 . The iron core of the electro-magnetic valve 93 penetrates through the seal gasket 44 downward, possible to be moved up and down by sensing of the electronic eye 92 to press in due time the block 43 on the flow hole 432 to control the pressure-releasing passageway of the pressure-adding room (a) so as to control flushing action
[0028] Next, it is to be specially mentioned that the communicating tube 80 can be a bellows-shaped flexible tube, but also can be a helical flexible tube as shown in FIG. 6, or a straight flexible tube as shown in FIG. 7. And if the straight flexible tube is used, it is necessary to leave a spare space 433 to correspond to the block 43 for the communicating tube 80 to move up. The communicating tube 80 can also be a rigid tube as shown in FIG. 8, having a spherical member 81 formed in the lower end to fit in a spherical groove 531 formed in an upper portion of the insert head 53 , and a threaded cap 53 to engage with the insert head 53 to keep the spherical member 81 connected with the insert head 53 . Then in conjunction with the spare space 433 of the block 43 , the valve body 50 can incline with the lower end of the rigid communicating tube 80 .
[0029] Next, the manual function and the automatic function of flushing with the invention will be described below.
[0030] AS for the manual function, when a user presses down the hand rod 60 , the hand rod 60 will touch and move the pillar member 52 of the valve body 50 to incline for a preset angle to just form a gap between the disc member 51 of the valve body 50 and the close groove 21 at the upper end of the base tube 20 to produce pressure releasing effect, with the film 30 moving to cause a gap for a large quantity of water flowing through the inlet 11 in the interior of the cup member 10 and out of the outlet 13 into a toilet. So far the flushing action just mentioned is the same as the conventional flusher, and it has to be noticed that the communicating tube 80 has a flexible specialty, not affecting the inclining action and up-and-down movement of the valve body 50 , ensuring manual operation of flushing smoothly carried out.
[0031] As for the automatic function, when a user comes near to the flusher to trigger the infrared sensor 90 , the electro-magnetic valve 93 is started to generate magnetism, with the iron core 931 attracted to move inward. At this moment, the flow hole 432 of the block 43 in the pressure cap 40 becomes open to force the water in the pressure-adding room (a) flow through the through hole 45 of the pressure cap 40 , the through hole 431 of the block 43 , the flow hole 432 of the block 43 , the communicating tube 80 and the passageway 54 of the valve body 50 , producing pressure releasing action, just as the action of the conventional flusher, that is, with the film 30 moved to form a flowing gap (b) for a large quantity of water coming from the inlet 11 flowing out of the outlet 13 for flushing a toilet, as described above.
[0032] Further, it is worthy to say that if the hand rod 60 is released or the source of sense disappears out of the sensing scope of the electric eye 92 of the infrared sensor 90 , the leaking passageway between the valve body 50 and the base tube 20 or that between the iron core 931 and the block 43 will recover at once closing condition, forcing water to flow into the pressure-adding room (a) to be gradually filled with water, with the film 30 moved down to stop flushing immediately, keeping correct function of flushing without fail.
[0033] The invention has the following advantages, as can be seen from the foresaid description.
[0034] 1. The manual mode of flushing can be used, in case the automatic mode cannot function owing to the infrared sensor getting out of order, not necessary to wait until the infrared sensor is repaired.
[0035] 2. The hand rod can be kept under pressed condition to let water continue to flush out into a toilet to use as much water as wanted, for convenience of washing the toilet, removing the inconvenience of impossibility of controlling the conventional flusher.
[0036] 3. It can use many components of the conventional manual flusher and the conventional automatic flusher, with appliance of the communication tube used in the invention, and very profitable in manufacturing.
[0037] While the preferred embodiment of the invention has been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all modifications that may fall within the spirit and scope of the invention.
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A manual and automatic flusher includes an infrared sensor added to a conventional manual flusher, and the infrared sensor consists of an electronic eye and an electromagnetic valve. The electro-magnetic valve has an iron core moved in and out for controlling opening and shutting of a block, and a communicating tube connected between a flow hole of the block and the upper end of a valve body to enable a hand rod and the infrared sensor separately operated by means of the flexibility of the communicating tube, not interfering with each other. Then the flusher can be used by a manual operation or by automatic operation, with a simple structure for manufacturing.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to sintered alloys and a method for the hardening treatment thereof. More particularly, it relates a treatment method which permits iron-based sintered articles to be hardened either wholly or locally and which can be applied especially to synchronizer hubs and like components for use in the transmissions of four-wheeled vehicles.
[0003] 2. Description of the Related Art
[0004] Roughly speaking, the following two methods for improving the wear resistance of an iron-based sintered alloy have been known in the prior art.
[0005] (1) A first method is one for hardening the whole of a sintered alloy or one for hardening a sliding part of a sintered alloy by infiltrating an impregnant into the whole of the sliding part.
[0006] Specific examples thereof include (a) a method for the hardening treatment of a compact in which, in the formation of a compact by compressing an iron-based sinterable powder, the composition of the whole compact is modified by increasing the contents of C, Cr, Mo, V and other elements constituting the sinterable powder, (b) a method for hardening a sintered alloy by a heat treatment such as quenching or tempering, and (c) a method which comprises infiltrating a copper impregnant into a sintered alloy as disclosed in Japanese Patent Provisional Publication No. 61-44152.
[0007] (2) Another method is one for hardening a portion of a sintered alloy or one for hardening a sliding part of a sintered alloy by infiltrating an impregnant into a portion of the sliding part.
[0008] Specific examples thereof include (a) a heat treatment method based on induction hardening, and (b) a method which comprises compacting and sintering a sinterable powder while varying the composition of the sinterable powder locally so that the composition of some parts of the compact will differ from that of other parts.
[0009] However, the above-described conventional methods for the hardening treatment of a sintered alloy have the following problems.
[0010] (1) In the methods based on a heat treatment, a compact is heated again after being sintered, so that the sintered alloy tends to become distorted. Consequently, the sintered ally requires an additional examination of its dimensions and an additional adjustment of its dimensional accuracy, which tends to increase the number of steps.
[0011] (2) In the methods which involve varying the composition of the sinterable powder, the powder control for changing the sinterable powder according to the type of the sintered alloy causes an increase in the number of steps. Moreover, since it is necessary to set particular sintering conditions for each sintered alloy, various types of sintered alloys cannot be produced simultaneously.
[0012] (3) The methods which involves infiltrating a copper impregnant into a sintered alloy within a sintering furnace are efficient from the viewpoint of thermal energy and production control. However, difficulties are encountered in treating a sintered alloy locally. Moreover, its hardness cannot be increased to the fullest extent and, therefore, its wear resistance has a certain limit.
[0013] By way of example, for synchronizer hubs for use in the transmission gears of four-wheeled vehicles, iron-based sintered articles are often used from the viewpoint of uniaxial configuration and strength. However, in the assintered state, these articles have low hardness and hence exhibit insufficient wear resistance. Although they may be subjected to a heat treatment such as induction quenching after sintering, this requires additional thermal energy and causes an increase in manufacturing cost.
[0014] Accordingly, in order to solve the above-described problems, it would be necessary to apply a hardening treatment to only a sliding part of a sintered article instead of the whole of the sintered article, and carry out this hardening treatment at the same time as the sintering.
SUMMARY OF THE INVENTION
[0015] An object of the present invention is to solve the above-described problems by providing sintered alloys in which only a sliding part can be hardened without altering the dimensional accuracy of the article, and a method for the hardening treatment thereof.
[0016] In order to accomplish the above object, the present invention includes the following three embodiments.
Embodiment 1
[0017] First of all, the present invention relates to a method for the hardening treatment of a sintered alloy which comprises the steps of compressing an iron-based sinterable material to form a compact; providing a surface of the compact with a coating material containing aluminum or an aluminum alloy that melts at a temperature lower than the sintering temperature of the compact; and sintering the compact provided with the coating material, so as to form an intermetallic compound of iron and aluminum in a surface layer of the compact.
[0018] According to the above-described method, a hardening treatment for forming an intermetallic compound can be applied to not only the whole of a sintered alloy, but also only a part of a sintered alloy (e.g., a part thereof required for use as a sliding site). Moreover, the present invention can eliminate the necessity for an after-treatment such as quenching, and thereby save labor. Consequently, an enhancement in the efficiency of thermal energy required for sintering and an improvement in the dimensional accuracy of the resulting sintered alloy can be achieved. Furthermore, even when a compact is to be hardened locally, it can be treated under the same conditions as employed commonly for sintering purposes, without adding to an amount of work required for the hardening treatment.
Embodiment 2
[0019] Moreover, the present invention relates to a method for the hardening treatment of a sintered alloy in accordance with the above-described Embodiment 1 wherein the coating material comprises a dispersion of a powder of aluminum or an aluminum alloy in a solvent or a member formed of aluminum or an aluminum alloy.
[0020] According to the above-described method, while the compact is sintered to form a sintered alloy, a portion of the aluminum component present in the coating material penetrates from the surface of the compact into a plurality of pores formed in the compact. On the other hand, the iron component present in the compact also penetrates into the coating material. Consequently, a reaction takes place between the aluminum component of the coating material and the iron component of the compact, so that an intermetallic compound is formed in a surface layer of the sintered alloy. This intermetallic compound has very high hardness and wear resistance, and hence exhibits characteristic suitable for use as a sliding part. Moreover, since the intermetallic compound is a porous body having a multitude of pores or the like, it allows oil and the like to accumulate therein and hence serves to reduce the sliding resistance.
Embodiment 3
[0021] Furthermore, the present invention relates to a sintered alloy having been subjected to a hardening treatment according to the method of the above-described Embodiment 1 or 2.
[0022] The present invention makes it possible to apply a hardening treatment to not only the whole of a sintered alloy, but also only a part of a sintered alloy (e.g., a part thereof required for use as a sliding site). Moreover, the present invention can eliminate the necessity for an after-treatment such as quenching, and thereby save labor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a cross-sectional view of a compact on which a small-sized member formed of an aluminum alloy is placed;
[0024] [0024]FIG. 2 is a cross-sectional view illustrating the state in which the small-sized member placed on the compact begins to melt;
[0025] [0025]FIG. 3 is a cross-sectional view illustrating the state in which the aluminum component present in the small-sized member placed on the compact melts and penetrates into the compact;
[0026] [0026]FIG. 4 is a cross-sectional view illustrating the state in which the iron component present in the compact penetrates into the small-sized member;
[0027] [0027]FIG. 5 is a cross-sectional view illustrating an intermetallic compound formed in the surface region of the compact;
[0028] [0028]FIG. 6 is a cross-sectional view illustrating the intermetallic compound which has undergone a volume shrinkage as a result of cooling;
[0029] [0029]FIG. 7 is photomicrograph (at a magnification of 50 diameters) illustrating a cross section of a surface layer of a sintered alloy formed in the Example;
[0030] [0030]FIG. 8( a ) is a cross-sectional view illustrating a single large-sized intermetallic compound region formed in a surface layer of a compact, and FIG. 8( b ) is a cross-sectional view illustrating the intermetallic compound of FIG. 8( b ) whose top surface has been made flat by grinding;
[0031] [0031]FIG. 9 is a cross-sectional view illustrating a plurality of small-sized intermetallic compound regions formed in a surface layer of a compact; and
[0032] [0032]FIG. 10( a ) is a cross-sectional view of a compact having a powdered aluminum alloy scattered over the top surface thereof, and FIG. 10( b ) is a cross-sectional view of a sintered alloy having an intermetallic alloy layer formed on the surface of the compact of FIG. 10( a ).
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] Sintered alloys in accordance with the present invention and the method for the hardening treatment thereof are more specifically described hereinbelow with reference to the accompanying drawings.
[0034] According to the present invention, an iron-based sintered alloy is made by compressing a sinterable powder to form a compact, placing a coating material comprising an appropriate amount of aluminum or an aluminum alloy on a part of the compact (i.e., a part thereof to be hardened), and sintering this assembly by the application of heat so as to produce an iron-based sintered article. Thus, an intermetallic compound of aluminum and iron can be formed in a surface layer of the sintered alloy.
Steps of Hardening Treatment
[0035] (1) Formation of a compact
[0036] First of all, an iron-based sinterable powder is compressed to form a compact. This sinterable powder contains not less than 90% by weight of the Fe component, and preferably has a particle diameter of 20 to 200 μm. No particular limitation is placed on the type of the aforesaid sinterable powder, and there may be used any of various sinterable powders as specified in JIS. For example, iron-based sinterable powders specified in the SMF Types 3, 4 and 5 of JIS may preferably be used.
[0037] (2) Application of a coating material
[0038] Then, a coating material comprising aluminum or an aluminum alloy is applied to the compact. This can be accomplished, for example, by applying a coating material comprising a dispersion of a powder of aluminum or an aluminum alloy in a solvent to the compact (e.g., with a brush), or by placing a coating material comprising a small-sized member 1 formed of aluminum or an aluminum alloy on a surface of the compact 2 as illustrated in FIG. 1, and heating the compact 2 to melt the small-sized member 1 .
[0039] (3) Sintering
[0040] The compact 2 having the coating material applied thereto is sintered by means of a conventional sintering furnace. The sintering temperature is generally in the range of 1,000 to 1,300° C., and the melting point of aluminum or the aluminum alloy in the coating material is lower than the aforesaid sintering temperature.
[0041] (3-1) Penetration of the aluminum component of the coating material into the compact 2
[0042] As illustrated in FIG. 2, the small-sized member 1 constituting the coating material begins to melt at the aforesaid sintering temperature. Then, as illustrated in FIG. 3, a portion of the aluminum component 5 present in the molten small-sized member 1 penetrates from surface of the compact 2 into fine pores (or voids) formed in the compact 2 . Thus, a reaction takes place between the aluminum component 5 of the small-sized member 1 and the iron component of the compact 2 . Consequently, as illustrated in FIG. 5, an intermetallic compound 10 is formed in a surface layer 7 having a certain depth from the surface of the compact 2 .
[0043] (3-2) Penetration of the iron component of the compact 2 into the coating material
[0044] On the other hand, as illustrated in FIG. 4, the iron component 11 present in the compact 2 also penetrates into the small-sized member 1 . Thus, a reaction also takes place between the aluminum component 5 present in the small-sized member 1 and the iron component 11 having migrated from the compact 2 . Consequently, as illustrated in FIG. 5, an intermetallic compound 13 is also formed in the small-sized member 1 placed on the surface 6 of the compact 2 . Accordingly, as illustrated in FIG. 5, while the compact 2 is sintered to form a sintered alloy 15 , intermetallic compounds 13 and 10 precipitate simultaneously in both the small-sized member 1 placed on the surface 6 of the sintered alloy 15 and the surface layer 7 thereof, and these intermetallic compounds 13 and 10 are combined together.
[0045] (4) Cooling
[0046] Finally, the aforesaid sintered alloy 15 is cooled. As illustrated in FIG. 6, this cooling causes the combined intermetallic compound 20 to undergoes a volume shrinkage, so that the intermetallic compound 20 forms a porous body having cracks 21 and pores 22 therein.
Coating Material
[0047] The coating material used in the present invention contains aluminum or an aluminum alloy. Specifically, there may be used, for example, a dispersion of a powder of aluminum or an aluminum alloy in a solvent, or a small-sized member formed of aluminum or an aluminum alloy. When a powder of aluminum or an aluminum alloy is used, its particle diameter is preferably in the range of 10 to 100 μm. As to the alloy composition, useful alloys include, for example, Al—Cu, Al—Mg, Al—Si and Al—Zn alloys. Moreover, ternary and higher multicomponent alloys obtained by combining the foregoing alloys are also useful. Furthermore, there may also be used pure aluminum and other aluminum alloys.
[0048] The metallic aluminum present in the coating material needs to melt at the sintering temperature of the compact 2 without fail. Accordingly, it is preferable to use a coating material in which the aluminum or aluminum alloy melts at a temperature that is about 100° C. lower than the sintering temperature of the compact 2 . Since the sintering temperature for common iron-based sintered alloys is in the range of 1,000 to 1,300° C., the melting temperature of the aluminum or aluminum alloy present in the aforesaid coating material should be lower than the sintering temperature and preferably about 200° C. lower than the sintering temperature.
Compact
[0049] The compact 2 used in the present invention is a porous body having a plurality of interconnected fine pores (or voids) formed therein. As described above, no particular limitation is placed on the type of the sinterable powder used to form this compact 2 , and there may be used any of various iron-based as specified in JIS.
[0050] The present invention is further illustrated by the following example.
EXAMPLE 1
[0051] First of all, a powder mixture (corresponding to JIS SMF5030) was prepared by mixing 0.7% of powdered carbon, 1% of powdered Cu, 1% of powdered Ni, and the balance comprising powdered iron. Then, this iron-based powder mixture was compressed so as to give a sintered density of 6.9 g/cm 3 .
[0052] A small-sized member (coating material) 1 formed of an aluminum alloy (i.e., Al-40% Cu) was placed on the aforesaid compact 2 . This assembly was inserted into a sintering furnace having a temperature of 1,150° C. and held at the maximum temperature for 15 minutes.
[0053] A photomicrograph of a section in the neighborhood of the surface of the sintered alloy 15 thus obtained is shown in FIG. 7. The rhombic black marks 23 seen in this photomicrograph are impressions left after the measurement of Vickers hardness.
[0054] When the Vickers hardness of this sintered alloy 15 was measured, it was HV180 for the base metal and HV700 for the intermetallic compound 20 of aluminum and iron, indicating that the intermetallic compound was much harder than the base metal. Moreover, the aforesaid intermetallic compound 20 was a porous body having a multitude of pores 22 formed therein. Since the penetration of oil into these pores 22 creates an oil reservoir, the surface of the intermetallic compound 20 functions as a sliding member.
[0055] It is to be understood that the present invention is not limited to the above-described embodiments, but various changes and modifications may be made on the basis of the technical idea of the present invention.
[0056] For example, FIG. 8( a ) illustrates an embodiment in which a sintered alloy 15 in accordance with the present invention is used as a sliding member and a mating member 24 coming into contact with the sintered alloy 15 has a flat surface 25 . In this embodiment, after an intermetallic compound 20 is formed in a surface layer 7 , the upper part of the intermetallic compound 20 may be ground to form a flat top surface 27 as illustrated in FIG. 8( b ). Moreover, as illustrated in FIG. 9, a plurality of small-sized intermetallic compound regions 30 may be formed in a surface layer 7 of a sintered alloy 15 . In this case, it is not always necessary to grind the upper parts of the intermetallic compound regions 30 and thereby form a flat surface. Furthermore, as illustrated in FIG. 10( a ), it is also possible to place a powder 35 of aluminum or an aluminum alloy on a surface 6 of a compact 2 , spray an aqueous solution of PVA (polyvinyl alcohol) onto the compact 2 so as to prepare a paste, and then sinter the compact 2 having the surface 6 coated with this paste. Thus, as illustrated in FIG. 10( b ), an intermetallic compound layer 40 having a uniform thickness can be formed in a surface layer 7 of a sintered alloy 15 .
[0057] In addition, the hardening treatment in accordance with the present invention may preferably be applied to sintered articles such as crank pulleys and timing belt gears, and cast iron articles such as locker arm chips and cam shaft lobes.
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The present invention provides sintered alloys in which only a sliding part can be hardened without altering the dimensional accuracy of the article, and a method for the hardening treatment thereof. Specifically, the present invention relates to a method for the hardening treatment of a sintered alloy which comprises the steps of compressing an iron-based sinterable material to form a compact 2; placing a small-sized member 1 containing aluminum or an aluminum alloy that melts at a temperature lower than the sintering temperature of the compact, on a surface of the compact; and sintering the compact 2 so as to form an intermetallic compound 20 of iron and aluminum in a surface layer 7 of the compact 2, and to a sintered alloy having been treated according to this method.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to controlling of pixels of display devices.
[0003] 2. Description of Related Art
[0004] FIG. 1 is a schematic view of a conventional liquid crystal display (LCD). As shown in FIG. 1 , a conventional LCD panel 100 generally includes a gate driver 102 , a source driver 104 and a display area 106 . The display area 106 includes a pixel array constructed by a plurality of pixels. For example, a conventional display area with 1024×768 resolution has 1024 columns and 768 rows of pixels, such as the pixels 112 , 114 , 126 , 122 , 124 , 126 and so on shown in FIG. 1 . In addition, each pixel has a red sub-pixel, a green sub-pixel and a blue sub-pixel. For example, the pixel 112 in the first row and first column of the display area 106 has a red sub-pixel 112 r, a green sub-pixel 112 g, and a blue sub-pixel 112 b. Therefore, the display area 106 has 3072 columns and 768 rows of sub-pixels.
[0005] In FIG. 1 , each sub-pixel has a thin film transistor (TFT) and a capacitor, wherein the capacitor is connected between the drain of the TFT and the common electrode. The gate of each TFT is connected to and controlled by the gate driver 102 via a corresponding scan line. In addition, the source of the TFT is connected to and controlled by the source driver 104 via a corresponding data line. Conventionally, the gate driver 102 generates a plurality of scan signals that are provided to the scan lines. Therefore, when one of the scan lines (e.g., the first scan line) receives the scan signal, all the TFTs connected to the first scan line (e.g., the TFTs of the sub-pixels 112 r , 112 g , 112 b , 114 r , 114 g , 114 b and so on) will be turned on, and the data signals may be stored in the capacitors connected to the TFTs.
[0006] Conventionally, the number of the source lines of the display area is three times the number of the pixels in each column of the display area since each pixel of the display area has three sub-pixels (e.g., as described above, the 1024×768 resolution display area has 3072 scan lines). In addition, the total pin number of the integrated circuit (IC) of the source driver has to be equal to or greater than the number of the source lines. Therefore, the bonding between the scan lines of the conventional display area and the pins of the source driver is complex and time consuming. Accordingly, it is important to reduce the number of the source lines of the display area and the pin number of the source driver.
[0007] FIG. 2 is a schematic view of another conventional LCD device. As shown in FIG. 2 , LCD device 200 comprises a gate driver device 202 , a source driver device 204 and a display area 206 . The display area 206 comprises a multiplexer device 208 and a plurality of pixels such as 212 , 214 , 216 , 218 , 220 , 222 , 232 , 234 , 236 , 238 , 240 , 242 , and so on. Moreover, each pixel of the display area comprises a red sub-pixel, a green sub-pixel and a blue sub-pixel. For example, the pixel 216 comprises a red sub-pixel 216 r , a green sub-pixel 216 g and a blue sub-pixel 216 b.
[0008] The multiplexer device 208 is disposed in the display area and connected between the data lines of the sub-pixels and the pins of the source driver device 204 . The multiplexer device 208 comprises a plurality of multiplexers such as multiplexers 222 , 224 , 226 and so on. Each multiplexer comprise 6 switches. For example, the multiplexer 224 comprises transistors 224 a , 224 b , 224 c , 224 d , 224 e and 224 f , wherein the source (or drain) of the transistors 224 a , 224 b , 224 c , 224 d , 224 e and 224 f may be connected to the drain of TFTs of the sub-pixels 216 r , 216 g , 216 b , 218 r , 218 g and 218 b via the corresponding data lines
[0009] However, for any two adjacent sub-pixels, the one that is turned on later in time may be electrically coupled to the other. Therefore, the charges stored in the capacitor of the sub-pixel that is turned on later in time may be influenced by the other sub-pixel. Accordingly, because a typical turn on sequence controlled by the control device 210 of the prior art is RGBRGB, i.e., the turn on sequence is started from transistor 224 a , sequentially followed by transistors 224 b , 224 c , 224 d , 224 e and 224 f , the coupled charge on the capacitor of sub-pixel 216 r may be twice as much as those on the capacitor of sub-pixels 216 g , 216 b , 218 r and 218 g , and the coupled charge on the capacitor of sub-pixel 218 b is zero. Unfortunately, the different coupled charges between the same colored sub-pixels (for example, 216 r and 218 r ) can make the display non-uniform even when displaying a pure color.
SUMMARY OF THE INVENTION
[0010] Methods for controlling display panels, in which the display panel comprises a plurality of pixels and wherein each of the plurality of pixels comprises a plurality of sub-pixels, are provided. An exemplary embodiment of such a method comprises: controlling a timing sequence for turning on the pixels such that at least one of: an average influence of coupling of each of the sub-pixels in two sequential time frames is the same; and an average influence of coupling of two of the sub-pixels on two adjacent rows of the sub-pixels is the same.
[0011] Devices also are provided. In this regard, an exemplary embodiment of such a device comprises: a display device comprising a plurality of pixels, each of the plurality of pixels having sub-pixels, the display device being operative to illuminate the sub-pixels in accordance with a timing sequence, the timing sequence being configured such that at least one of: an average influence of coupling of each of the sub-pixels in two sequential time frames is the same; and an average influence of coupling of two of the sub-pixels on two adjacent rows of the sub-pixels is the same.
[0012] It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0014] FIG. 1 is a schematic view of a conventional liquid crystal display device.
[0015] FIG. 2 is a schematic view of another conventional liquid crystal display device.
[0016] FIG. 3A is a schematic view of a liquid crystal display device according to one embodiment of the present invention.
[0017] FIG. 3B and FIG. 3C are timing diagrams of a driving method of the sub-pixels according to one embodiment of the present invention.
[0018] FIG. 4A and FIG. 4B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention.
[0019] FIG. 5A and FIG. 5B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention.
[0020] FIG. 6A and FIG. 6B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention.
[0021] FIG. 7A and FIG. 7B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention.
[0022] FIG. 8A and FIG. 8B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention.
[0023] FIG. 9 is a block diagram of an electronic device according to one embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0024] The present invention will be described more fully hereinafter with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout.
[0025] Refer to FIG. 3 , which is a schematic view of a liquid crystal display device according to one embodiment of the present invention. In the embodiment, the liquid crystal display device 300 includes a control device 310 operated in a driving method different from the control device 200 , a corresponding gate driver device 302 , a source driver device 304 and a display area 206 that includes the same pixel architecture as the display area 206 shown in the FIG.2 . With the driving method described below, the liquid crystal display device 300 could provide improvements in image uniformity.
[0026] FIG. 3B and FIG. 3C are timing diagrams of a driving method of the sub-pixels according to one embodiment of the present invention. For example, in any one of the scan lines (e.g., the first scan line), the timing sequence for turning on the TFTs in an N th frame is shown as FIG. 3B , and in an N+1 th frame is shown as FIG. 3C . Referring to FIG. 3B , it is noted that the 6 sub-pixels of two adjacent pixels that are connected to the same multiplexer may be turned on for storing the corresponding data signals as a sequence of sub-pixels R 1 , G 1 , B 1 , R 2 , G 2 and B 2 . For example, the sub-pixels R 1 , G 1 , B 1 may represent the red, green and blue sub-pixels of the left side pixel (e.g., the pixel 212 / 216 / 220 ), and the sub-pixels R 2 , G 2 , B 2 may represent the red, green and blue sub-pixels of the right side pixel (e.g., the pixel 214 / 218 / 222 ).
[0027] In FIG. 3B , the sub-pixels in the N th frame may turned on as a sequence of R 1 , G 1 , B 1 , R 2 , G 2 , B 2 . It should be noted that, for any two adjacent sub-pixels, the one that is turned on later may be electrically coupled to the other. Therefore, the charges stored in the capacitor of the sub-pixel that is turned on later may be influenced by the other sub-pixel, wherein the amount of the influence is denoted as D. For example, sub-pixel 216 r is electrically coupled to sub-pixels 214 b and 216 g . Sub-pixels 214 b and 214 g are turned on after sub-pixel 216 r (indicated by the arrow from sub-pixels 214 b to 216 r and the arrow from sub-pixels 216 g to 216 r ). Thus, the amount of the influence of the coupling of the sub-pixel 216 r is represented as 2 D. In addition, the sub-pixels 216 g / 216 b / 218 r / 218 g are electrically coupled to the sub-pixels 216 b / 218 r / 218 g / 218 b . The amount of the influence of the coupling of the sub-pixels 216 g / 216 b / 218 r / 218 g is represented as D. Moreover, the sub-pixel 218 b is turned on latest, and thus is not electrically coupled to any other sub-pixel. Thus, the amount of the influence of the coupling of the sub-pixel 218 b is 0.
[0028] As described above, the amounts of the influence of the coupling of the red sub-pixels 212 r , 214 r , 216 r , 218 r , 220 r and 222 r in the N th frame are 2 D, D, 2 D, D, 2 D, D, respectively. Therefore, the brightness of the red sub-pixels in the whole LCD panel is not uniform. In addition, the amounts of the influence of the coupling of the blue sub-pixels 212 b , 214 b , 216 b , 218 b , 220 b and 222 b in the N th frame are D, 0 , D, 0 , D, 0 , respectively. Thus, the brightness of the blue sub-pixels in the whole LCD panel is also not uniform.
[0029] Referring to FIG. 3C , in the N+1 th frame, the timing sequence of the sub-pixels R 1 , G 1 , B 1 , R 2 , G 2 and B 2 is changed to be different from the N th frame. In particular, in this embodiment, the sequence for turning on the TFTs is B 2 , G 2 , R 2 , B 1 , G 1 and R 1 . Accordingly, the amounts of the influence of the coupling of the sub-pixels 216 r , 216 g , 216 b , 218 r , 218 g and 218 b in the N th frame as shown in FIG. 3B are 2 D, D, D, D, D, 0 , respectively and in the N+1 th frame as shown in FIG. 3C are 0 , D, D, D, D, 2 D, respectively. Therefore, the average influences of the coupling of any two red sub-pixels, for example, the sub-pixels 216 r and 218 r in two adjacent frames, are the same. In addition, the average influences of the coupling of any two blue sub-pixels, for example, the sub-pixels 216 b and 218 b in two adjacent frames, are the same. Thus, the average brightness of any red/green/blue sub-pixels of the LCD panel in two adjacent frames is uniform.
[0030] In one embodiment of the present invention, the timing sequence for turning on the TFTs of the sub-pixels 212 b , 214 b , 216 b , 218 b , 220 b and 222 b , for example, the sequence R 1 , G 1 , B 1 , R 2 , G 2 and B 2 shown in FIG. 3B , and the sequence B 2 , G 2 , R 2 , B 1 , G 1 and R 1 shown in FIG. 3C is controlled by the control device 310 shown in FIG. 3A .
[0031] FIG. 4A and FIG. 4B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention. For example, in any frame, the timing sequence for turning on the TFTs connected to the M th scan line is shown as FIG. 4A , and the timing sequence for turning on the TFTs connected to the M+1 th scan line is shown as FIG. 4B . Accordingly, the amounts of the influence of the coupling of the sub-pixels, for example, the sub-pixels 216 r , 216 g , 216 b , 218 r , 218 g and 218 b of the first scan line as shown in FIG. 4A are 2 D, D, D, D, D, 0 , respectively and that of the sub-pixels 236 r , 236 g , 236 b , 238 r , 238 g and 238 b of the second scan line that is adjacent to the first scan line as shown in FIG. 4B are 0 , D, D, D, D, 2 D, respectively. Therefore, in any frame, the average influences of the coupling of any two adjacent red sub-pixels, for example, the sub-pixel 216 r on the M th scan line and the sub-pixels 236 r on the M+1 th scan line, are the same. In addition, the average influences of the coupling of any two adjacent blue sub-pixels, for example, the sub-pixel 216 b on the M th scan line and the sub-pixel 236 b on the M+1 th scan line, are the same. Thus, the average brightness of two red/green/blue sub-pixels of the LCD panel on two adjacent scan lines is uniform.
[0032] FIG. 5A and FIG. 5B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention. For example, the timing sequence for turning on the TFTs connected to the M th and M+1 th scan lines in the N th frame is shown as FIG. 5A , and the timing sequence for turning on the TFTs connected to the M th and M+1 th scan lines in the N+1 th frame is shown as FIG. 5B . Accordingly, in the N th and N+1 th frames, the average influences of the coupling of two red, green or blue sub-pixels on any two scan lines (i.e., the M th and M+1 th scan lines) are the same. In addition, the average influences of the coupling of any red, green or blue sub-pixels in any two adjacent frames are the same. Thus, the average brightness of two red/green/blue sub-pixels of the LCD panel on two adjacent scan lines is uniform, and the average brightness of any red/green/blue sub-pixels of the LCD panel in two adjacent frames is also uniform.
[0033] FIG. 6A and FIG. 6B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention. For example, in any one of the scan lines (e.g., the first scan line), the timing sequence for turning on the TFTs connected to the first scan line in an N th frame is shown as FIG. 6A , and in a next N+1 th frame is shown as FIG. 6B . The sequence for turning on the TFTs of the sub-pixels shown in FIG. 6A may comprise R 1 , G 1 , B 1 , R 2 , G 2 and B 2 , and that of the sub-pixels shown in FIG. 6B may comprise R 2 , G 2 , B 2 , R 1 , G and B 1 . Accordingly, the amounts of the influence of the coupling of the sub-pixels 216 r , 216 g , 216 b , 218 r , 218 g and 218 b in the N th frame as shown in FIG. 6A are 2 D, D, D, D, D, 0 , respectively and in the N+1 th frame as shown in FIG. 6B are D, D, 0 , 2 D, D, D, respectively. Therefore, the average influences of the coupling of any two red sub-pixels, for example, the sub-pixels 216 r and 218 r in two adjacent frames, are the same. In addition, the average influences of the coupling of any two blue sub-pixels, for example, the sub-pixels 216 b and 218 b in two adjacent frames, are the same. Thus, the average brightness of any red/green/blue sub-pixels of the LCD panel in two adjacent frames is uniform.
[0034] FIG. 7A and FIG. 7B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention. For example, in any frame, the timing sequence for turning on the TFTs connected to the M th scan line is shown as FIG. 7A , and the timing sequence for turning on the TFTs connected to the M+1 th scan line is shown as FIG. 7B . Accordingly, the amounts of the influence of the coupling of the sub-pixels, for example, the sub-pixels 216 r , 216 g , 216 b , 218 r , 218 g and 218 b of the first scan line as shown in FIG. 7A are 2 D, D, D, D, D, 0 , respectively and that of the sub-pixels 236 r , 236 g , 236 b , 238 r , 238 g and 238 b of the second scan line that adjacent to the first scan line as shown in FIG. 7B are D, D, 0 , 2 D, D, D, respectively. Therefore, in any frame, the average influences of the coupling of any two adjacent red sub-pixels, for example, the sub-pixel 216 r on the M th scan line and the sub-pixels 236 r on the M+1 th scan line, are the same. In addition, the average influences of the coupling of any two adjacent blue sub-pixels, for example, the sub-pixel 216 b on the M th scan line and the sub-pixel 236 b on the M+1 th scan line are, the same. Thus, the average brightness of two red/green/blue sub-pixels of the LCD panel on two adjacent scan lines is uniform.
[0035] FIG. 8A and FIG. 8B are timing diagrams of a driving method of the sub-pixels according to another embodiment of the present invention. For example, the timing sequence for turning on the TFTs connected to the M th and M+1 th scan lines in the N th frame is shown as FIG. 8A , and the timing sequence for turning on the TFTs connected to the M th and M+1 th scan lines in the N+1 th frame is shown as FIG. 8B . A Accordingly, in the N th and N+1 th frames, the average influences of the coupling of two red, green or blue sub-pixels on any two scan lines (i.e., the M th and M+1 th scan lines) are the same. In addition, the average influences of the coupling of any red, green or blue sub-pixels in any two adjacent frames are the same. Thus, the average brightness of two red/green/blue sub-pixels of the LCD panel on two adjacent scan lines is uniform, and the average brightness of any red/green/blue sub-pixels of the LCD panel in two adjacent frames is also uniform.
[0036] Referring to FIG. 9 , a block diagram of an embodiment of an electronic device 90 is depicted. The electronic device 90 comprises a display device 92 and an input device 94 . The input device 94 generates display data to the data driver 920 . Accordingly, data driver 920 can send the display data to the display area 900 with proper operation of scan driver 910 . Notably, the display device 92 uses a driving method such as provided in one of the embodiments described above.
[0037] Accordingly, an average influence of coupling of each of the sub-pixels in two adjacent frames is the same, and/or an average influence of coupling of two of the sub-pixels on two adjacent scan lines is the same by controlling the timing sequence. Thus, the average brightness of any red/green/blue sub-pixels of the LCD panel in two adjacent frames is uniform.
[0038] It will be apparent to those skilled in the art that various modifications and variations can be made to the above described embodiments without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
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Methods for controlling display panels, in which the display panel comprises a plurality of pixels and wherein each of the plurality of pixels comprises a plurality of sub-pixels, are provided. A representative the method comprises: controlling a timing sequence for turning on the pixels such that at least one of: an average influence of coupling of each of the sub-pixels in two sequential time frames is the same; and an average influence of coupling of two of the sub-pixels on two adjacent rows of the sub-pixels is the same.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to electric motors, and particularly to reciprocating electric motors having permanent magnets with a reciprocating electromagnet cooperating with the permanent magnets.
2. Description of the Prior Art
Reciprocating electric motors have been known in the past. The Cobe U.S. Pat. No. 1,804,375 describes a reciprocating hermetically sealed compressor for use with a refrigerator or an air conditioner. One feature of this compressor is that it is hermetically sealed to prevent leakage of the refrigerant. Hence, the are no moving parts extending to the outside of the compressor housing, and this vastly simplifies the bearing packing problems. In this Cobe compressor, there is a central reciprocating piston having a pair of aligned piston rods projecting in opposite directions from each end thereof. A fixed electromagnet is positioned at each end of the compressor so as to cause the central piston to reciprocate. In order that the electromagnets may be alternately energized and de-energized to reciprocate the central piston within the cylinder, there is an automatically operated switch that is adapted to alternately make and break the circuit leading from the battery.
The Reutter U.S. Pat. No. 3,103,603 describes an AC synchronous reciprocating motor comprising an axially movable armature inside a field magnet fed with alternating current and subjected to the action of elastic drawback forces. The motor has a field magnet that includes two annular magnets made of ferrite having axial magnetization and between which is coaxially disposed the energizing coil that is fed with alternating current. The polarity of the magnets is symmetrical with respect to the transverse median plane, so that the flux reverses in the above-mentioned armature when it moves from one side to the other of the transverse median plane. There is a permanent magnet positioned at each end of the field magnet. Moreover, there is a coil formed as part of the field magnet between the two permanent magnets. One use described for this Reutter motor is that it actuates a fuel oil pump and an air-pump, both serving to feed a fuel oil burner.
The Olson et al U.S. Pat. No. 3,135,880 describes a linear motion electromagnetic motor wherein the armature may be positioned at any selected point within the limits of its stroke by means of an external control. This motor allows the armature to be positioned at a continuous infinite number of null points along the length of its stroke by means of a remote setting. This Olson et al motor may employ either direct or alternating current. This motor has a U-shaped core made of ferromagnetic material having two parallel legs joined at one end by a central segment to form two parallel deflection coils. Slideably mounted between the two deflection coils is an armature comprising a permanent magnet oriented so that the flux lines emerging from its ends cut the conductors of each coil at right angles. The armature is attached to one end of a connecting rod, and the free end of this connecting rod is provided with a coupling to which the motor is connected, such as a pump or the like.
The Lovell U.S. Pat. No.3,162,134 describes an electromagnetic pump having a central reciprocating piston that is controlled by a pair of electromagnets which surround the piston. It is noted that the energizing circuit can be powered from either an AC or a DC source, and that this piston pump or compressor is hermetically sealed.
The Drye U.S. Pat. No. 3,681,629 describes a reciprocating electric motor that has an armature shaft that is acted upon lengthwise by a moving magnetic field produced by a field device having stationary field part comprising windings interposed between sheet metal discs that are disposed around the armature shaft. A tubular member is rigidly secured over the field device. Means are associated with the armature shaft to enclose therein two liquid-filled hermetic enclosures through which the shaft extends, and which are connected by a limited-delivery duct so that the volumes of the enclosures vary in inverse proportion and by the same amount for a movement of the shaft in either direction.
OBJECTS OF THE PRESENT INVENTION
The principal object of the present invention is to provide an electric motor with a reciprocating electromagnet that is positioned between a pair of spaced permanent magnets, where the permanent magnets are adjustably mounted so that they serve to control the strength of the magnetic field on the electromagnet and thereby the speed of reciprocation.
A further object of the present invention is to provide a reciprocating drive motor of the class described where the permanent magnets are piston shaped and operate within hydraulic cylinders, whereby hydraulic fluid under pressure is present in each cylinder in varying amounts so as to force the permanent magnets into variable positions, thereby controlling the speed of reciprocation of the electromagnet.
A further object of the present invention is to provide a reciprocating drive motor whereby a double-acting pump is associated with the reciprocating electromagnet for producing work.
A further object of the present invention is to provide a reciprocating drive motor with electrical switching means that is operated by the position of the electromagnet at each end of its stroke for reversing the flow of current within the electromagnet so as to reverse the direction of sliding movement of the electromagnet.
A further object of the present invention is to provide a reciprocating drive motor having a sliding electromagnet that is joined to a connecting rod between a pair of double-acting pistons in a pump mechanism.
A still further object of the present invention is to provide a reciprocating drive motor of the class described wherein a double-acting piston pump is integrated within the motor housing, with a piston mounted on each end of the electromagnet and fitted within an operating cylinder having inlet and discharge valve means associated with the cylinders for controlling the flow of a working fluid therein.
SUMMARY OF THE INVENTION
The present invention provides a reciprocating drive motor having a housing with guide means for supporting a movable electromagnet for reciprocating motion. A pair of spaced permanent magnets are aligned with the electromagnet for applying an alternate attraction and repulsion force to the electromagnet dependent upon the direction of electrical current flow through the coil of the electromagnet, where the electrical current flow is reversed as the electromagnet reaches the end of its stroke so as to reverse the polarity of the electromagnet and thereby reverse the magnetic field forces between the electromagnet and the pair of permanent magnets so as to reverse the direction of movement of the electromagnet and produce the reciprocating motion of the electromagnet.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will be better understood from the following description taken in conjunction with the accompanying drawings and its scope will be pointed out in the appended claims.
FIG. 1 is a front elevational view, partly in cross section, of the preferred embodiment of a reciprocating drive motor of the present invention, showing a double-acting piston pump positioned beneath the motor.
FIG. 2 is a transverse, cross-sectional, elevational view of the invention of FIG. 1 taken on the line 2--2 thereof.
FIG. 3 is a front elevational view, partly in cross section, of a second modification of the present invention wherein a double-acting piston pump is integrated within the housing of the reciprocating drive motor, there being a piston mounted on each end of the sliding electromagnet and fitted within an operating fluid cylinder that is interposed between the electromagnet and the permanent magnets, where the pistons also serve as the guide means for supporting the movable electromagnet for reciprocating motion.
FIG. 4 is a transverse, cross-sectional, elevational view of the second modificatiion of this invention, taken on the line 4--4 of FIG. 3.
FIG. 5 is a schematic circuit diagram for the reciprocating electromagnet of both FIGS. 1 and 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to a consideration of the drawings, and in particular to the front, cross-sectional, elevational view of FIG. 1, there is shown a reciprocating drive motor 10 in combination with a double-acting piston pump 11. The motor has a motor housing 12 with guide means associated with the pump for supporting a movable electromagnet 16 for reciprocating motion. The electromagnet 16 has a soft iron core 18 extending through the longitudinal center thereof, and it is fitted with a soft iron contact plate 20 on each end of the iron core. These two contact plates 20, 20 serve as the opposite ends of the electromagnet 16. A coil of insulated wire 22 is wound around the core 18 so that when an electric current is passed through the wire it will magnetize the core, with the two contact plates 20 being of opposite polarities, N and S. One end of the coil or wire 22 terminates at a copper slide conductor 24, while the other end of the coil of wire terminates at a second copper slide conductor 26. Associated with each slide conductor 24 and 26 is a spring-biased contact brush 28 which is mounted through the wall of the motor housing 12 and is pressed into sliding contact with the slide conductor, as is best seen in FIG. 2.
Associated with each contact plate 20 at the end of the electromagnet 16 is a strong permanent magnet 34 and 34' respectively that are adjustably mounted. Notice that the facing poles of the two permanent magnets 34 and 34' are of the same polarity; namely, N and N. Each magnet 34 and 34' is formed as a cylindrical piston that is mounted in a mating hydraulic cylinder 36 and 36' respectively. The rear portion of each magnet 34 is fitted with a rod 38 which extends out through an opening 40 in the cylinder head 42 of the cylinder 36. The outer end of the magnet rod 38 is supplied with a helical compression spring 44, which is held in place by a nut 46 that is threaded onto the free end of the rod 38. Thus, the natural tendency of the compression springs 44 is to force the magnets 34 and 34' away from the electromagnet 16. This force of the compression spring 44 is resisted by a hydraulic fluid 48 under pressure, which is introduced into the cylinders 36 and 36' through a hydraulic fitting 50 to control the speed of reciprocating of the electromagnet 16.
A very important use of the present invention is for this reciprocating drive motor 10 and piston pump 11 to be used as the propulsion system for an electric automobile, truck, or other vehicle. In order to control the speed of the vehicle, the hydraulic fluid 48 under pressure would be introduced into or withdrawn from the cylinder 36 and 36' so as to shift the position of the permanent magnets 34 and 34' respectively, and thereby control the strength of the magnetic field acting on the electromagnet 16. In order to reduce the speed of reciprocation, it is necessary to reduce the strength of the magnetic field acting on the electromagnet 16. This can be accomplished by bleeding the hydraulic fluid 48 from the cylinders 36 and 36' so that the force of the springs 44 would shift each permanent magnet 34 and 34' away from the electromagnet 16. In a similar manner, the speed of reciprocation can be increased by increasing the strength of the magnetic field by forcing more hydraulic fluid 48 into the cylinder 36 to force the magnets 34 and 34' toward the electromagnet 16, as is best shown in FIG. 1.
It should be understood by those skilled in this art that the permanent magnets 34 and 34' may be fixed in place, so as to render the motor a constant speed motor or air compressor.
Electrical switching means 56 is located in proximity to the reciprocating electromagnet 16 for automatically reversing the flow of current within the coil 22 of the electromagnet near the end of each stroke of the electromagnet, so as to reverse the direction of sliding movement of the electromagnet. Looking at FIG. 1, the electromagnet 16 is at the left end of its stroke. A transfer slide member 58 is mounted within the side wall of the motor housing 12 so as to be able to reciprocate back and forth to a limited amount due to a lost-motion connection with the electromagnet 16 by means of a slide shifter member 60 that is formed as an integral part of the electromagnet 16. The shifter member 60 is not in engagement with the slide member 58 at all times. The slide member 58 has an elongated recess 62 on its underside in which the shifter member 60 operates. This elongated recess 62 has two opposite end walls, 64 and 66, which are adapted to be engaged by the shifter member 60 near the end of each stroke of the electromagnet for carrying the slide member 58, along with the electromagnet for a limited amount measured in a fraction of an inch. This transfer slide member 58 is fitted with a conductive strip 68, which extends along the top side of the slide member as well as down across each end of the slide member, as at 70 and 72 respectively. Associated with this conductive strip 68 is a spring-biased contact brush 74, which extends out through the wall of the motor housing 12 and is capable of delivering electrical current to the conductive strip 68. This contact brush 74 is fitted with a stem 76 which is supplied with a compression spring 78. This stem 76 has a sliding fit in an opening 80 of a removable cap 82 which serves to hold the brush and spring within the brush housing 84. The free end of the brush stem 76 is threaded, as at 86, to receive a nut 87 and serve as a terminal so that an electrical lead wire 88 may be joined thereto to bring in a supply of direct current.
FIG. 5 is a schematic circuit diagram for the reciprocating electromagnet 16 of FIGS. 1 and 3, where the same reference numerals are used throughout.
One limit switch 92 is positioned at the left side of the transfer slide member 58, and a second limit switch 94 is positioned at the right side of the slide member. Each limit switch 92 and 94 includes a movable contact 96 that is mounted for limited sliding movement through the wall of the motor housing 12. Each movable contact 96 has a shoulder 98 which serves as a seat for a compression spring 100. The other end of the spring 100 is confined by a removable plug 102 that also serves as a support bearing for the sliding action of the movable contact 96. The outer end of this plug 102 includes a ground washer 104, which is electrically connected to ground 106 by lead wire 108. The outer end of the movable contact 96 includes a contact pad 110 for engagement with the ground washer 104 when the transfer slide member 58 is out of contact with the movable contact 96, as is seen with the right-hand limit switch 94 in FIG. 1. A flexible spring contact member 112 is mounted to the motor housing 12, as at 114, so as to be in constant engagement with the outer end of each movable contact 96. An electrical lead wire (not shown) would connect the mounting terminal 114 for the spring contact member 112 of the left-hand limit switch 92 to a spring-biased contact brush 28 for making wiping electrical contact with the copper slide conductor 24 of the electromagnet 16. In a similar manner, the mounting terminal 114 of the right-hand limit switch 94 would be connected by an insulated lead wire (not shown) to a spring-biased contact brush 28' for making electrical contact with the copper slide conductor 26 of the electromagnet. It should be noted that these two contact brushes, 28 and 28', function in a manner similar to the contact brush 74 that has a wiping engagement with the conductive strip 68 of the transfer slide member 58.
The movable electromagnet 16 of FIG. 1 is shown at the left end of its stroke. The transfer slide member 58 has also been forced to the left by the slide shifter member 60; thus, closing a circuit from the contact brush 74 between the conductive strip 68 and the movable contact 96 of the left-hand limit switch 92, while at the same time breaking the ground connection on that left side between the contact pad 110 and the ground washer 104. This transfer slide member action creates the opposite action in the right-hand limit switch 94 where the contact pad 110 closes a circuit with the ground washer 104 while the circuit is broken between the movable contact 96 of the right-hand limit switch 94 and the conductive strip 68. Thus, the flow of current in the electromagnet 16 is reversed, thus creating a north pole N on the left side of the electromagnet, and a south pole S on the right side. This north pole N on the left side of the electromagnet will repel the north pole N of the permanent magnet 34 at the left side. Moreover, the south pole S on the right side of the electromagnet will be attracted to the north pole N of the permanent magnet 34' at the right end of the motor. These forces will cause the electromagnet 16 to shift to the right side of its stroke, and the slide shifter member 60 will pick up the transfer slide member 58 near the end of its stroke, thereby closing a circuit between the conductive strip 68 and the movable contact 96 of the right-hand limit switch 94. At the same time, this will break the circuit to ground of the right-hand limit switch 94 between the contact pad 110 and the ground washer 104. Moreover, the spring 100 of the left-hand limit switch 92 will force the movable contact 96 to move to the right until the contact pad 110 closes a circuit with the ground washer 104. These actions will reverse the flow of current in the coil of the electromagnet 16; thus, changing poles from south to north on the right side of the electromagnet, and from north to south on the left side of the electromagnet; thus, forcing the electromagnet 16 to shift back to the left end of its stroke and starting a new cycle.
Behind each soft iron contact plate 20 is an insulating support plate 122. These two support plates 122, 122 are joined at the top of the motor by an insulating connecting plate 124. It is this connecting plate 124 that supports the slide shifter member 60, which is likewise of insulating material. Looking at FIG. 2, it will be seen that the insulating support plate 122 is generally circular in nature so as to fit within the cylindrical cavity of the motor housing 12 that encompasses the electromagnet 16. Notice, also in FIG. 2, that the combined motor 10 and pump 11 have a FIG. 8 configuration in transverse cross section. The upper cylindrical half consists of the motor housing 12, while the lower cylindrical half is a pump housing 126. These two housings, 12 and 126, are joined together by a pair of horizontally spaced vertical walls, 128 and 130.
As is seen in FIG. 1, the pump housing 126 includes a left-hand cylinder 132, a right-hand cylinder 134, and opposing pistons 132' and 134' respectively that are supported on the opposite ends of a common connecting rod 136.
Looking back at FIG. 2, the insulating support plate 122 is shown with a lower vertical column 138, which extends down between the two vertical walls 128 and 130 and is supported on the connecting rod 136 by means of bearings 140. Thus, it will be understood that the weight of the movable electromagnet 16 is carried by means of the two insulating support plates 122 through the vertical columns 138 to the connecting rod 136 and then through the two pistons, 132' and 134', to the opposing cylinders 132 and 134 of the pump housing 126.
Some means must be provided for centering the electromagnet 16 within the motor housing 12. This is accomplished, as is best seen in FIG. 2, by providing roller bearings 142 on each side of the vertical column 138 to operate within a horizontal track 144 on the inner surface of each vertical wall 128 and 130. Each roller bearing 142 has a vertical shaft 146 that is supported in a pair of vertically spaced bearings 148.
Each pump cylinder 132 and 134 has an intake ball valve 152 and a discharge ball valve 154. Hence, when the electromagnet 16 is moving from right to left, it carries with it the two pistons, 132' and 134'. The compression stroke of the piston 132' causes the discharge ball valve 154 of the cylinder 132 to open, as is shown in FIG. 1. At the same time, the suction stroke of the piston 134' causes the intake ball valve 152 to open for the cylinder 134. This pump 11, which is associated with the reciprocating electrical motor 10, may be either an air compressor or a fluid pump for driving a turbine (not shown) that may serve as the propulsion system for an electric operated vehicle, such as a passenger automobile, a light-duty delivery truck, a golf cart, or fork truck, or the like.
FIG. 3 shows a second modification of the present invention wherein a double-acting piston pump 158 is integrated within the housing of a reciprocating drive motor 160. In order to simplify the description of this second modification, the same reference numerals for the same elements will be used for the second modification as in the first modification if the parts or elements in both modifications are identical or generally similar. This reciprocating drive motor 160 has a motor housing 162 which supports adjacent its center a movable electromagnet 16 for reciprocating motion. This electromagnet 16 has a soft iron core 18 extending through the center thereof, but it is extended at each end to form a piston rod that carries a piston 164 on the left end of the electromagnet and a piston 166 on the right end. These two pistons 164 and 166 take the place of the two pistons 132' and 134' respectively of the first modification of FIG. 1. Moreover, these two pistons 164 and 166 are of magnetic material to serve the same purpose as the soft iron contact plates 20 of the first modification. These two pistons, 164 and 166, fit snugly within the cylindrical bore 170 of the motor housing 162 so that no fluid passes between the periphery of the pistons and the interior surface of the motor cylinder so as to protect the electromagnet 16 from any danger of electrical failure. Piston rings 168 are shown mounted on each piston 164 and 166 to obtain a proper sealing action between the piston and its cylinder 170. Moreover, it should be understood that these two pistons 164 and 166 serve as the supporting means for the electromagnet 16 within the motor housing in place of the superstructure of elements 122, 138, and the connecting rod 136, and the pistons, 132' and 134', of the first modification.
Located beyond each end of the cylindrical bore 170 for the reciprocating electromagnet 16 is a cylinder 172 at the left side and cylinder 174 at the right side. Associated with each cylinder 172 and 174 is a strong permanent magnet 176 and 178 respectively. These two permanent magnets 176 and 178 function in a similar manner to the permanent magnets 34 and 34' of the first modification of FIG. 1, as will be understood by those skilled in this art.
In order to reduce the amount of hydraulic fluid 48 needed to control the position of the permanent magnets 176 and 178, the cylinder head or end wall 182 is enlarged with a crown or a central cylindrical enlargement 184 for receiving a piston-like extension that is mounted on the outer side of each permanent magnet 176 and 178. A hydraulic fitting 50 is mounted in the end of the central cylindrical enlargement 184 so as to allow the amount of hydraulic fluid 48 in this miniature cylinder to be adjusted in order to adjust the position of the permanent magnets 176 and 178. Notice that each permanent magnet 176 and 178 is provided with a pair of rods 38 which extend through suitable openings 40 within the cylinder head 182 so that a compression spring 44 may be fitted over the outer end of the rod 38 and held in place by a nut 46.
The electrical circuitry and switching means for the movable electromagnet 16 of this second modification of FIG. 3 is substantially the same as that for the first modification of FIG. 1, therefore, no further explanation is deemed necessary.
Interposed between the left-hand piston 164 and the left-hand permanent magnet 176 is a fluid cylinder 192. This fluid cylinder 192 is furnished with an intake ball valve 152 and a discharge ball valve 154 to function in the same manner as the intake and discharge valves 152 and 154 of the first modification of FIG. 1.
Similarly, there is a fluid cylinder 194 interposed between the right-hand piston 166 and the right-hand permanent magnet 178. This fluid cylinder 194 is also furnished with an intake ball valve 152 and a discharge ball valve 154.
Modifications of this invention will occur to those skilled in this art. Therefore, it is to be understood that this invention is not limited to the particular embodiments disclosed, but that it is intended to cover all modifications which are within the true spirit and scope of this invention as claimed.
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A reciprocating electric motor is shown having a sliding electromagnet aligned between a pair of spaced permanent magnets, where the facing poles of the permanent magnets are of the same polarity, and electrical circuit means is provided for energizing the electromagnet with alternate current flows to create alternate polarities of the electromagnetic field surrounding the electromagnet, whereby at any time there is a strong magnetic field attraction force between the electromagnet and one of the permanent magnets, while there is a strong magnetic field repulsion force between the electromagnet and the other permanent magnet. An electrical switching means is operated by the position of the electromagnet at each end of its reciprocating stroke for reversing the flow of current within the electromagnet and the polarity of the opposite ends of the electromagnet so as to reverse the direction of sliding movement of the electromagnet once it arrives at each end of its stroke. A driven means, such as a pump, is joined to the electromagnet for producing an energy force for driving a turbine, as in an electrically operated vehicle.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the processing of digital signals to render modular multiplication.
2. Description of Related Art
Modular multiplication, which is the computation of A-B modulo M where A, B, and M are integer values, is a fundamental mathematical operation in applications based on number-theoretic arithmetic. A central application area is cryptography, where techniques such as the popular RSA and DSS methods utilize modular multiplication as the elemental computation. Since large word lengths on the order of thousands of bits are typically processed, hardware approaches to modular multiplication are typically very slow. Existing art attempts to address this deficiency through a handful of approaches.
Linear systolic array approaches dominate the art, with the article C. Walter, “Systolic modular multiplication,” IEEE Transactions on Computers, v. 42, no. 3, pp. 376-378, 1993, being representative. In such an approach, a linear array of processing elements is connected so that all signal paths are formed between adjoining elements only. Thus, signal path lengths are minimized. Accordingly, all signal paths only connect two adjoining elements, guaranteeing unit fan out. The forgoing properties of systolic arrays ensure that the clock rate is determined solely by the processing element delay. However, efforts to scale the performance beyond the level offered by a single linear array have encountered very limited success. Cell optimization is the commonly applied technique to gain performance. However, performance scales only logarithmically with respect to consumed integrated circuit area.
Another method which attempts to provide a performance-area tradeoff is the digit-serial array. In the paper, J. Guo and C. Wang, “A novel digit-serial systolic array for modular multiplication,” in Proc. of the 1998 IEEE International Symposium on Circuits and Systems, v. 2, pp. 177-180, 1998, a digit-serial modular multiplier methodology was presented. However, the arrays were not pipelined, and thus the clock period of the digit-serial cells grows proportionally with digit size. Therefore, performance scaling occurs in a sub-linear fashion for small digit sizes and quickly saturates to yield negligible performance gains for large digit sizes.
A non-systolic array was presented in the article H. Orup, “Simplifying quotient digit determination in high-radix modular multiplication,” in Proc. of the 12th Symposium on Computer Arithmetic, pp. 193-199, 1995. A roughly linear performance-area tradeoff was achieved through retiming of the modular correction loop within the modular multiplication algorithm. However, the clock rate is severely limited by the required fill-word-length signal broadcasts of the modular correction selection bit. Thus, the fan out of the aforementioned signal is the complete word length. Implementational efforts to increase the signal drive through transistor sizing destroys the linear performance-area trade off and only provide minor mitigation of the slow-clock-rate obstacle plaguing this methodology.
SUMMARY OF THE INVENTION
The present invention describes a method for parallel modular multiplication capable of processing multiple independent data streams simultaneously.
An implementation realizing this method consists of a multi-row array of processing elements having a column count equivalent to the modular multiplication word length. Each processing element accepts and generates bit-level data and performs partial product formation, modular correction formation, and summation of these generated bits with the right-single-bit-shifted result of the previous algorithmic iteration. The number of rows of the array is determined in accordance with the available integrated circuit implementation area and the desired throughput performance, which scales linearly with row count.
The data stream capacity and operational throughput are directly scalable with the available integrated circuit implementation area. This performance scalability is accomplished while maintaining a systolic paradigm, such that all interconnection paths are locally connected to neighboring processing elements and entail minimal fan out. Thus, the achievable clock rate is maximized and is dictated by the processing element delay rather than by long interconnect paths or loading due to multiple-gate fan out. Moreover, in contrast to isolated parallel modular multiplication arrays, the unified array structure of the present invention incorporates single input and output data buses, thereby reducing global integrated circuit wiring overhead. Additionally, the unified array permits a single controller to be utilized when the modular multiplier is utilized as a component in a higher-level functional unit such as a modular exponentiator.
Objects and Advantages of the Invention
The primary object of this invention is fast parallel processing of modular multiplication.
It is an advantage of this invention that multiple independent data streams may be simultaneously processed. The number of data streams is arbitrary, limited only by implementation area.
It is a primary advantage of this method that throughput performance scales linearly with the area of the integrated circuit implementation while maintaining the optimal systolic clock rate. The latter is attained through guaranteeing properties of purely nearest neighbor interconnections between processing elements and unit signal fan out.
It is an advantage of this invention that input and output data share signal lines such that the number of internal signal buses in an integrated circuit implementation are reduced.
It is an advantage of this invention that a unified control unit may be utilized when the modular multiplier unit is used in a modular exponentiator.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the modular multiplier with its connections
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The preferred embodiment is an array consisting of K rows and N+1 columns of bit-wise processing cells, where N represents the word length of the modulus value in bits and K is an integer parameter with value greater than one chosen according to the amount of integrated circuit area available for the implementation. The value of K directly relates to the amount of parallelism implemented in the array.
Each cell possesses a set of bit-wise inputs corresponding to the multiplicand, multiplier, modular correction, modular selection, partial sum, and two previous carry signals. Each cell also possesses a set of bit-wise outputs corresponding to the multiplicand, multiplier, modular correction, modular selection, generated partial sum, and two generated carry signals. Each inner cell 1 , excluding the leftmost, rightmost, and bottommost peripheral cells, is interconnected within the structure in the following manner: the multiplicand output delayed by two cycles is connected to the multiplicand input of the below-adjacent cell. The multiplier output delayed by one cycle is connected to the left-adjacent cell's multiplier input. The modular correction output delayed by two cycles connects to the modular correction input of the below-adjacent cell. The modular selection output delayed by one cycle is connected to the left-adjacent cell's modular selection input. The generated partial sum output delayed by one cycle is connected to the below-right-adjacent cell's partial sum input. Finally, each of the two carry outputs delayed by one cycle is connected to the corresponding carry inputs of the left-adjacent cell.
Rightmost, least-significant cell 2 connections for the multiplicand and modular correction outputs are identical to the above description for the inner cells. However, the partial sum output connections differ. The partial sum output is connected to the modular selection input of the below-adjacent cell. The multiplier input of each rightmost cell is supplied externally in the form of a serial, lesser-significance-to-greater-significance stream. Both carry inputs are connected to ground.
Leftmost, most-significant cell 3 connections for the multiplicand, modular correction, and partial sum outputs are identical to the inner cell description. The single carry output is connected to the partial sum input of the below-adjacent cell.
In the bottommost row 4 , modular selection and multiplier outputs are connected identically to the aforementioned inner cell description. The modular correction output is delayed by H+2 clock cycles and is recirculated to the PRI input of the multiplexed delay element in the topmost row, whose output is connected to the modular correction input of the topmost cell residing in the same column. The SEC input of the same multiplexed delay input is connected externally for provision of initial modular correction data. H is a fixed parameter for the entire array structure and is chosen to be an integer value such that 1≦H≦K−2 The multiplicand output is delayed by H+2 clock cycles and is recirculated to the PRI input of the multiplexed delay element in the topmost row, whose output is connected to the multiplicand input of the topmost cell residing in the same column. The SEC input of the same multiplexed delay input is connected externally for provision of initial multiplicand data. The partial sum output delayed by H+1 delays is recirculated to the multiplexed delay element associated with the right-adjacent cell in the topmost array, whose output is connected to the partial sum input of the same cell. The partial sum output is also provided externally at the bottommost row as the overall array output. Note that the recirculated modular correction, multiplicand, and partial sum signals may be physically routed through the intervening cells of the array, with the H or H−1 delays being distributed as evenly as possible among the cell interconnections involved. While this description is operationally equivalent to the former description in terms of processing behavior, it assists in increasing the achievable clock rate in the physical integrated circuit. For instance, when H=K−2 is chosen, the partial sum output of a cell in the bottom row is delayed by one cycle and routed to a pass-through input in the above-right-adjacent cell. The signal is then output and delayed by one clock cycle and is connected to the above-adjacent cell. The latter process is repeated until the topmost cell is reached. Therefore, one delay element exists prior to each inter-cell excursion within the array, thus guaranteeing minimal interconnect lengths and maximum clock rate. In the same way, the modular correction and multiplicand signal outputs of the cell in the bottommost row are recirculated such that at least one delay element exists prior to each inter-cell excursion.
Each cell performs a computation which, for the purposes of illustration, may be decomposed into the following sequence of bit-wise operations. The multiplicand input bit is ANDed with the multiplier input bit. Similarly, the modular correction input bit is ANDed with the modular selection input bit. The outputs of the two aforementioned computations are added with the partial sum input and the two carry inputs. The least significant bit of the latter sum is connected to the cell's partial sum output, while the two bits generated in the most significant position are connected to the two carry outputs. The multiplicand, modular correction, multiplier, and modular selection inputs are also passed to the multiplicand, modular correction, multiplier, and modular selection outputs, respectively. Within each rightmost cell, all aspects of the above description remain valid except that only a single bit in the most significant position is generated. Thus, each rightmost cell possesses a single carry output.
Delay elements 6 , have one input, and delay the input signal by a specified number of clock cycles before presenting the resultant signal at the single output.
The multiplexed delay element 5 takes in two data inputs, labeled PRI and SEC. An additional input SEL is used to multiplex data at the PRI and SEC inputs to the input of a delay register. De-assertion of the SEL input selects the PRI input, while assertion selects the SEC input. The output of the delay register constitutes the output of the multiplexed delay element.
A counter 7 asserts the signal PASS_DATA 8 for 2K+H clock cycles every (2K+H)*[(N+2)/K] clock cycles, where [ARGUMENT] denotes the next highest integer when the ARGUMENT is not an integer, otherwise [ARGUMENT]=ARGUMENT. The signal PASS_DATA is connected to the SEL input of the multiplexed delay element associated with the rightmost cell in the topmost row. De-assertion of the PASS_DATA signal selects the PRI input to the multiplexed delay element, whereas assertion selects the SEC input. The PASS_DATA signal is delayed by one clock cycle and passed to the left-adjacent cell where it is input to the SEL input of the associated multiplexed delay element. Once again, the signal is also again delayed by one clock cycle and passed to the left-adjacent cell. This procedure is repeated until the leftmost cell is reached.
Initial data is supplied externally to the unit such that 2K+H new independent data sets commence processing in sequence every (2K+H)*[(N+2)/K] clock cycles. Multiplicand and modular correction data bits are entered into the cells of the topmost row in the following manner. The rightmost cell receives the least significant modular correction, multiplicand and multiplier bits associated with the first of the 2K+H data streams upon the first clock cycle wherein PASS_DATA is asserted. Upon the next clock cycle, the least significant modular correction, multiplicand and multiplier bits associated with the second of 2K+H currently entering data streams are received. In each of the subsequent 2K+H−2 cycles, the rightmost cell successively receives the remaining 2K+H−2 least significant bits of each input type. An identical process commences for the next-to-least significant modular correction and multiplicand inputs in the left-adjacent cell in the second clock cycle wherein PASS_DATA is asserted. Similarly, the delivery of the first of 2K+H bits corresponding to column J significance is provided J cycles after the initial assertion of PASS_DATA. After 2K+H bits have been successively received by the first cell of each column, no more modular correction or multiplicand initial data is taken in until the next assertion of PASS_DATA renew the above procedure. As mentioned above, the rightmost cell of the topmost row begins successively accepting the least significant bits of the multiplier input data upon the assertion of PASS_DATA. After 2K+H clock cycles. the bit position K of the multiplier input data begins to arrive and is received for the remaining data streams for the next 2K+H cycles. In general, for a rightmost cell in row R where 0≦R≦K−1, clock cycle C*(2K+H)+2R marks the beginning of the multiplier input bit position C*K+R where C is an arbitrary integer such that 0≦C≦[(N+1)/K].
An illustration of the modular multiplier array for the K=3, H=1, N=3 case is shown in FIG. 1 . Arrays for other parameterizations should be evident to an individual in the field with a grasp of the above description.
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A fast, scalable, systolic modular multiplier is presented. Linear throughput scalability with respect to consumed hardware resources is achieved through simultaneous parallel processing of multiple independent data streams. Optimal clock rates are attained by virtue of systolic properties of limited fan-out of all signal paths and nearest neighbor interconnections. Signal sharing among input and output busses and a common control interface for all independent data streams is made possible, thus benefiting integrated circuit implementations.
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TECHNICAL FIELD
This invention relates to electrode packages for defibrillators.
BACKGROUND
There is a growing trend toward the replacement of multiple use defibrillator paddles with single-use disposable therapeutic electrodes for defibrillation, external transthoracic pacing, or the combination of both. This trend is driven by numerous factors including, but not limited to: (1) convenience related to not having to apply a conductive media (e.g., gel), (2) speed of care when switching from delivering a defibrillation shock to a pacing current, (3) caregiver safety in that contact with the patient can be avoided as the therapy can be delivered remotely from the host device, and (4) increased use of defibrillators incorporating algorithms that analyze the presented ECG rhythm for appropriateness of therapeutic (shock) delivery. These applications typically work only with single-use, disposable therapeutic electrodes.
Defibrillation of cardiac arrest is a time sensitive matter. It is well documented that for every minute delivery is delayed, the chance of survival falls 7 to 10 percent. One way manufacturers have addressed the time to shock issue, has been to create electrodes that can be pre-connected to a defibrillator. If electrodes are not pre-connected or present, valuable time will be lost, and chance of survival diminished as responders must address this matter.
Owing to many factors both chemical and environmental in nature, single-use therapeutic electrodes have a finite shelf life. Manufacturers typically label individual electrodes with specific dates of expiration beyond which therapeutic delivery cannot be insured. It is incumbent on the operator to read the electrode labeling prior to use to insure a non-expired electrode is deployed for therapy.
Electrode packaging is designed to be both airtight and watertight. This is to minimize environmental fluctuations that might shorten the useful life of an electrode. Should an electrode package be breached, chemical reactions will be accelerated and shelf life shortened.
SUMMARY
In a first aspect, the invention features an electrode package for use with a defibrillator, the electrode package comprising an outer shell providing a vapor barrier between an interior space inside the outer shell and an exterior environment, a breakaway connection element positioned at the perimeter of the outer shell, one or more defibrillation electrodes positioned in the interior space inside the outer shell, a further electrical element positioned in the interior space inside the outer shell, electrical paths extending from the further electrical element through the breakaway element to the exterior environment, wherein the breakaway element and electrical paths are configured so that, when the outer shell is opened and the defibrillation electrodes are removed, the electrical paths are disconnected within the breakaway element.
Preferred implementations of the invention may incorporate one or more of the following. The breakaway element and electrical paths may be so configured as to also include defibrillation current electrical paths, and on removal of the defibrillation electrodes the breakaway elements may be removed with the electrodes and the electrical paths connected to the further electrical element may be disconnected upon its removal. The breakaway element may be a gasket element.
In a second aspect, the invention features an electrode package for use with a defibrillator, the electrode package comprising an outer shell providing a vapor barrier between an interior space inside the outer shell and an exterior environment, a gasket element positioned at the perimeter of the outer shell, wherein the gasket element is shaped and positioned so that one surface of the gasket element is exposed to the interior space within the outer shell and the other surface of the gasket element is exposed to the exterior environment, and wherein the gasket element comprises a plurality of internal electrical paths extending from the one surface to the other surface, including at least a first, second, and third internal electrical path, one or more defibrillation electrodes positioned in the interior space inside the outer shell, a defibrillation current path extending from each defibrillation electrode to one of the first and second internal electrical paths within the gasket element, a further electrical element positioned in the interior space inside the outer shell, a further electrical path extending from the further electrical element to the third internal electrical paths within the gasket element, wherein the gasket element, defibrillation current paths, further electrical path, and first, second, and third internal electrical paths are configured so that, when the outer shell is opened and the defibrillation electrodes are removed for application on the patient, the gasket element and the first and second internal electrical paths remain connected to the defibrillation current paths and the gasket element and the third internal electrical path is disconnected from the further electrical path within the gasket element.
Preferred implementations of the invention may incorporate one or more of the following. The further electrical paths may comprise a metallic post and the third internal electrical path may comprise a metallic receptacle into which the metallic post extends and with which the post make electrical contact prior to opening of the electrode package, and wherein upon opening the electrode package the post may break away from contact with the receptacle. The further electrical path and the metallic post may be portions of the same insulated conductive wire, and the insulation may have been removed to provide the post. The receptacle may comprise a generally conical element conductor making a friction fit with the post.
Among the many advantages of the invention (some of which may be achieved only in some of its various aspects and implementations) are the following: The invention provides a simple and inexpensive technique for breaking electrical connections when electrodes are removed from an electrode package. This makes it possible, for example, to leave an electrical component inside the package when the electrodes are removed (e.g., a condition sensor that is only used during storage of the package).
Other features and advantages of the invention will be found in the detailed description, drawings, and claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a defibrillator implementation of the invention.
FIG. 2 is a perspective view of the defibrillator of FIG. 1 with an electrode package shown removed.
FIG. 3 is a side elevation view of the defibrillator of FIG. 1 looking toward the side with the electrode package.
FIG. 4 is a cross-sectional view taken along section 4 - 4 in FIG. 3 .
FIG. 5 is a plan view of the electrode package after being opened to expose its contents.
FIG. 6 is a plan view of the two defibrillation electrodes stored inside the electrode package.
FIG. 7 is an exploded, cross-sectional view taken along 7 - 7 in FIG. 6 .
FIG. 8 is an exploded, cross-sectional view taken along 8 - 8 in FIG. 6 .
FIG. 9 is a plan view of the condition sensor (electrochemical cell) secured inside the electrode package.
FIG. 10 is an exploded, cross-sectional view taken along section 10 - 10 in FIG. 9 .
FIG. 11 is a schematic view of the electrical connections between the contents of the electrode package (electrodes, condition sensor, CPR puck) and the electrode package connector.
FIG. 12 is a plan view showing the rigid shell of the electrode package with its removable lid removed and its contents removed.
FIG. 13 is a partial cross-sectional view taken along section B-B in FIG. 12 showing a cross section through an inner end of the gasket element of the electrode package.
FIG. 14 is a partial cross-sectional view taken along section A-A in FIG. 12 showing a cross section through an outer end of the gasket element of the electrode package.
FIG. 15 is a plan view of the gasket element.
FIG. 16 is an end view of the gasket element.
FIG. 17 is a cross-sectional view taken along section 17 - 17 in FIG. 15 .
FIG. 18 is a perspective view of the gasket element.
FIG. 19 is another perspective view of the gasket element.
FIG. 20 is a block diagram of the electronics and components of the defibrillator of FIG. 1 .
FIG. 21 is a plan view showing the triangular electrode of FIGS. 6-7 applied to a the chest of a patient.
FIG. 22 is a plan view showing an alternative, crescent shaped electrode that could be used in place of the triangular electrode.
DETAILED DESCRIPTION
There are a great many possible implementations of the invention, too many to describe herein. Some possible implementations that are presently preferred are described below. It cannot be emphasized too strongly, however, that these are descriptions of implementations of the invention, and not descriptions of the invention, which is not limited to the detailed implementations described in this section but is described in broader terms in the claims.
FIGS. 1-4 show an external defibrillator 10 (e.g., a hospital crash cart defibrillator, such as the R Series manufactured by ZOLL Medical of Chelmsford, Mass.). User interface elements (graphical display, speaker, microphone, input buttons and dials) are provided on the front face of the defibrillator. Attached to the right side of the defibrillator is an electrode package 12 , which is removable from the defibrillator, as shown in FIG. 2 , and normally electrically connected to the defibrillator by cable 14 even when the defibrillator is not in use. The multi-conductor cable 14 emerging from the electrode package passes through a connector (not shown in FIG. 1-4 , but shown in the schematic of FIG. 11 ) and divides into two cables 11 , 13 which attach to the back of the defibrillator. A removable lid 16 is removed (by grasping tab 18 ) to open the defibrillator package.
The electrode package 12 includes a rigid base (or tray) 20 (polypropylene), which with the removable lid 16 (foil lined paper) constitutes the outer shell of the package. The base and lid provide a moisture barrier to prevent the gel layers of the electrodes from drying out during the shelf life of the package. The lid is heat sealed to the perimeter of the base (tray). The rigid base (a molded polymer part) is removable snapped into the receptacle 22 on the side of the defibrillator also used to secure a defibrillator paddle. Upper and lower flexible clips 24 , 26 snap into engagement with mating elements of the receptacle 22 . Engagement of the flexible clips 24 , 26 is shown in the cross section of FIG. 4 , which shows the electrode package snapped into place on the side of the defibrillator.
FIG. 5 shows the electrode package with lid 16 peeled back to expose the contents of the package. A first defibrillation electrode 28 (generally square in this plan view) for the back (posterior) of the patient's chest is adhered to a release liner (not shown) secured to the inside face of lid 16 . Electrode 28 is peeled off of the release liner and adhered to the back of the chest.
A second defibrillation electrode 30 (generally triangular in this plan view) for the front (anterior) of the patient's chest is adhered to another release liner (not shown) secured to the rigid based of the electrode package. Electrode 30 is an assembly of a defibrillation electrode and three ECG monitoring electrodes, and is described in co-pending U.S. patent application Ser. No. 11/055,572, filed on Feb. 11, 2005, hereby incorporated by reference.
A device for assisting CPR, known as a CPR puck or pad 32 , is also stored within the electrode package. A similar CPR pad is described in U.S. Pat. No. 6,782,293, hereby incorporated by reference. It includes an accelerometer for measuring movement of the chest during CPR.
The fourth element within the electrode package is a condition sensor 34 that assists the defibrillator in determining whether the liquid-containing (gel) layers of the defibrillation electrodes are still sufficiently moist to function properly. The condition sensor 34 is not intended to be removed from the package, as it is not used during defibrillation.
Various electrical conductors pass into the electrode package to connect the contents with the defibrillator. These conductors pass through a gasket element 36 that is sealed between the rigid base 20 and removable lid 16 of the package. When the electrodes and CPR puck are removed from the package, the gasket element is also removed, as the electrical conductors for the electrodes and CPR puck extend through the gasket element.
FIGS. 6-8 show the two defibrillation electrodes 28 , 30 in greater detail. The triangular front electrode 30 is shown in FIGS. 6-7 . The construction of the electrode is shown in exploded, cross-sectional view in FIG. 7 . A conductive liquid-containing layer 40 (solid gel) contacts the patient's skin, and conveys electrical current from the metallic layer 42 (tin plate or other metallic material such as silver chloride) to the patient. The gel and tin layer are supported on foam layer 44 , which carries adhesive to secure the electrode to the patient. The metallic layer is connected to wire 46 through which the defibrillation pulse is delivered from the defibrillator. A foam insulator layer 48 covers the area where the metallic layer and wire emerge from the electrode. A label 50 is applied over the foam layer 44 .
FIG. 21 shows the triangular electrode in place on the chest of the patient. The triangular shape greatly facilitates application of the electrode to the chest in the vicinity of a breast. The front electrode is adhered at the edge of the patient's breast, and the triangular shape has an advantage over circular or square electrodes in this location. These other shapes tend to fold or roll back on themselves. E.g., with a square electrode in this location, one corner of the electrode rides up on the breast, and will tend to roll back off the breast. This also tends to occur with circular electrodes. But with the triangular shape the problem is usually avoided. Another shape that will work well is a crescent shape, as shown in FIG. 22 , with the smaller radius of the crescent closest to the breast. It is the lateral perimeter of the electrode that has the triangular or crescent shape.
Three ECG monitoring electrodes are built into the three corners of the electrode. Each monitoring electrode includes a solid gel layer 52 for contacting the patient, a conductive stud 54 (Ag/Cl) in contact with the gel layer, and conveying electrical potentials from the gel layer to the snap conductor 56 (Ni/Brass) to which a monitoring wire is connected. Alternatively, the snap conductor can be eliminated, and the ECG monitoring wires connected directly to the conductive studs 54 .
The square defibrillation electrode 28 is shown in exploded, cross-sectional view in FIG. 8 . It includes most of the same layers as the other defibrillation electrode (identified in the figure by using the same reference numeral for corresponding parts).
FIGS. 9-10 show the condition sensor 32 , which functions as an electrochemical cell producing an electrical potential that is measured by the defibrillator to determine whether the moisture in the aqueous layer of the sensor has dried out. As the aqueous layer dries out (because moisture has escaped from the electrode package, e.g., because the package has been damaged), the potential of the electrochemical cell will fall off in magnitude. Once it falls below a threshold, indicating that the aqueous layer of the sensor has dried out, the defibrillator concludes that there is a high probability that the liquid-containing layers of the defibrillation electrodes have also dried out, and a warning prompt is delivered and the defibrillator may not deliver a defibrillation pulse to the electrodes.
Various other alternative tests could be applied to decide that the electrode is no longer suited for its intended use. E.g., the potential could be sampled frequently enough to establish a rate of change, and too high a rate of change could be a basis for deciding that something is wrong with the electrode. Depending on the circuitry used to measure the potential, a problem with the electrode could be detected by a voltage exceeding a threshold, and there could be multiple limits that the measured voltage is tested against.
FIG. 10 shows an exploded, cross-sectional view of the condition sensor. At the top of the stack of layers is a styrene release liner 60 , which is removed when the sensor is installed in the electrode package, to expose adhesive on the vinyl mask layer 62 , which is adhered to an interior surface of the electrode package to secure the condition sensor within the package. A aqueous layer 64 (gel) is positioned below the vinyl mask. A first metallic layer (metallic element) 66 (tin) is in contact with the gel. That is followed by an insulator layer 68 that is larger in area than the tin layer. Following the insulator layer is a second metallic layer (metallic element) 70 (aluminum) that is also in contact with the gel along its periphery outside of the extent of the insulator layer 68 . A foam backing layer 72 and foam cover 74 complete the sandwich of layers. A wire 76 (electrical conductor) is connected to each of the metallic layers (both shown in FIG. 9 ; one shown in FIG. 10 ). A bridging resistor 78 (approximately 100K ohms) is connected across the two metallic layers to control the rate of the electrochemical reaction (the size of this resistor will vary with the metals and gels used in the electrochemical cell and with other factors well known to those skilled in the art). The wires 76 are connected to the metallic layers with rings 80 and sockets 82 . A foam insulator layer 84 and length of tape 86 are positioned between the aqueous layer 64 and the first metallic layer 66 .
FIG. 11 is an electrical schematic of the electrode package 12 . Defibrillator electrodes 28 , 30 , condition sensor 32 , and CPR puck 34 are shown within the electrode package. Cables connecting these elements tot the defibrillator pass out of the package through gasket element 36 (shown diagrammatically as a dashed rectangle in the schematic). Each defibrillation electrode has a single electrical conductor 90 configured to carry a high voltage signal. Three shielded wires 92 connect to the three ECG monitoring electrodes (designated by the snap conductors 56 at the locations of the monitoring electrodes. Two wires 94 connect to the condition sensor 32 (although in a preferred embodiment the electrical conductors connecting to the condition sensor are shared with other wires (e.g., one or more of the CPR puck wires). Eight wires 96 connect to the CPR puck.
All of wires 90 , 92 , 94 , and 96 pass through the gasket element 36 , and extend to an electrode package connector 102 (electrodes end connector), which is plugged into the patient end connector 104 of a cable that runs back to the defibrillator. The two connectors 102 , 104 are shown mated in FIG. 11 .
An electronic memory device 100 (e.g., a Dallas Maxim semiconductor chip, Part No. DS2431) is built into connector 102 . A variety of information is stored on the chip, including: an authentication code, a configuration code (e.g., whether the package contains ECG monitoring electrodes, a CPR puck, or only defibrillation electrodes), the type of electrodes (adult or pediatric), the expiration date of the electrode package, the serial number, and the date of manufacturing and manufacturing line. Other information (or less information) could be stored on the chip.
FIGS. 12-19 show the gasket element through which the electrical conductors extend. The gasket element is shown in perspective view in FIGS. 18 and 19 . It has gradually tapered extensions 108 extending in the direction in which it is adhered to the perimeter of the seal between the rigid base 20 and removable lid 16 of the package 12 . A bead 110 of silicone adhesive seals one surface of the gasket element to the rigid base 20 of the package. This material is chosen so that the gasket will part from the rigid base when the electrodes are removed from the base. Between the tapered extensions 108 is a central portion 112 .
The gasket element has at least one surface exposed to the interior of the electrode package and at least one surface exposed to the exterior of the package. Holes pass through the gasket element from a surface exposed to the interior to a surface exposed to the exterior. Three electrical paths for the monitoring electrodes pass through three holes 120 . Eight smaller holes 122 (or one narrow opening) provide access for the electrical paths connecting the CPR puck.
When the gasket releases from the rigid base of the electrode package, certain electrical connections can be broken. For example, a conductive shorting element 130 that shorts across the two high-voltage defibrillation wires 90 (to allow testing of the integrity of these electrical pathways outside of the electrical package) is broken away. A second electrical connection that is broken is the connection to the condition sensor. Wires 94 (or their equivalent) that provide electrical pathways to the metallic layers of the condition sensor are disconnected from the condition sensor. This is necessary because the condition sensor in this implementation remains in the electrode package, as its usefulness as a package condition sensor has ended with the opening of the package.
Various techniques could be used to accomplish the disconnection of these electrical connections when the gasket element is removed. In the implementation shown herein, conductive posts 150 , extending upward from the rigid base of the package, and normally received in conductive apertures 152 (conically shaped to receive the posts) in the gasket element, withdraw from the apertures when the gasket is removed. the conductive posts shown are simply the ends of wires, bent 90 degrees to point upwardly, and stripped of insulation (the wider portion of the posts in the drawing is the wire with insulation; the narrower portion of the posts is the wire stripped of insulation). The conductive apertures (into which the posts extend) can be made from plated brass alloy with multiple fingers to engage the posts.
A general block diagram of the defibrillator is shown in FIG. 20 . Processing circuitry and associated software (processing 160 ) is at the heart of the defibrillator. Inputs from sensors 162 such as the accelerometer in the CPR puck and the ECG monitoring electrodes on one of the electrode assemblies are received through signal conditioning and detection circuitry 164 , 166 . A user interface 168 provides outputs to a display 170 (and possibly to lights that direct the user to graphical images 172 ) and to an audio system 174 with speaker 176 and microphone 178 .
Many other implementations other than those described above are within the invention, which is defined by the following claims. As mentioned earlier, it is not possible to describe here all possible implementations of the invention, but a few possibilities not mentioned above include the following: Not all of the features described above and appearing in some of the claims below are necessary to practicing the invention. Only the features recited in a particular claim are required for practicing the invention described in that claim. Features have been intentionally left out of claims in order to describe the invention at a breadth consistent with the inventors' contribution.
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An electrode package for use with a defibrillator, the electrode package comprising an outer shell providing a vapor barrier between an interior space inside the outer shell and an exterior environment, a breakaway connection element positioned at the perimeter of the outer shell, one or more defibrillation electrodes positioned in the interior space inside the outer shell, a further electrical element positioned in the interior space inside the outer shell, electrical paths extending from the further electrical element through the breakaway element to the exterior environment, wherein the breakaway element and electrical paths are configured so that, when the outer shell is opened and the defibrillation electrodes are removed, the electrical paths are disconnected within the breakaway element.
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BACKGROUND OF THE INVENTION
The present invention relates to a liquid dispensing and fuel vapor recovery system and more particularly to a hose and adapter assembly which will dispense liquid volatile fuel while recovering the fuel vapors without admixing the two particularly in the recovery system.
It is conventional practice to store volatile hydrocarbon fuel such as gasoline at a service station in underground reservoirs from which the gasoline is pumped into the fuel tank of a customer's vehicle. As these fuel tanks are filled with gasoline, the vaporized fuel in the vehicle tank is displaced therefrom and escapes into the surrounding atmosphere. In certain areas of the United States, anti-pollution legislation has required the recovery and return of the volatile vapors of the gasoline during such filling operations. Newly designed pollution recovery apparatus for use in service station pumps including newly designed nozzles have failed to effectively and efficiently dispense fuel while recovering vapors. Such newly designed vapor recovery apparatus have recommended custom made fuel nozzles, which required a considerable capital investment while rendering others obsolete. The present invention provides an adapter means which can be used with all types of modified pollution control nozzles and accessories minimizing parts replacement while additionally providing a means for increasing their reliability in the recovery of vapor and eliminating the admixing of the fuel with the vapor in the vapor recovery system.
SUMMARY OF THE INVENTION
According to the present invention, a fuel hose assembly has a pair of concentric flexible hoses that are secured to tubular coupling members which are separately rotatable and spaced apart by a spider. The tubular coupling members are held in longitudinally aligned positions and connected to a swivel nut that permits the connection of the hose assembly to an adapter fitting that allows dispensing of liquid fuel via the inner hose and recovery of hydrocarbon fuel vapors via the outer hose. Sensing means are provided to prevent the liquid fuel from being conveyed via the fuel vapor recovery lines or passages.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a service station installation having a gasoline storage tank, pedestal, hose dispensing assembly with nozzle, vapor recovery system, and vehicle receptacle.
FIG. 2 partly in section is a side elevational view of the end portion of a gasoline dispensing nozzle and intake pipe of a vehicle receptacle.
FIG. 3 is a fragmentary side elevational view of one end of a hose assembly with an adapter to which it is connected.
FIG. 4 is a side elevational view in cross section of an adapter fitting.
FIG. 5 is an isometric view of a fuel dispensing nozzle.
FIG. 6 is an isometric view of a modified form of a fuel dispensing nozzle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings wherein like reference characters designate like or corresponding parts throughout the several views, there is shown in FIG. 1 an underground tank or storage means 10 for storing liquid fuel such as gasoline for delivery to pedestals 12 (only one shown) above ground in reasonable proximity to the tank 10.
Suitable pump means 13 is disposed in the tank 10 and is operative to pump gasoline through a conduit 14 and its associated accessories to the pedestal 12 for delivery to an adapter fitting 15 mounted thereon.
A delivery hose assembly 16 has one end connected to the adapter fitting 15 and the other end connected to a dispensing unit or gasoline pump fuel nozzle 17. The pedestal 12, pump means 13, and fuel pump nozzle 17 are described in detail in U.S. Pat. Nos. 3,907,010, 3,651,837 and 3,952,781 the disclosure of which is hereby incorporated by reference. Therefore, for the convenience of presentation the structural details of these units are not shown in detail and will only be described generally. The pump means 13 is of an electrically operated centrifugal type submersible pump which upon actuation pumps the gasoline up conduit 14, through adapter 15 in a manner to be described, through hose assembly 16 for dispensing through fuel pump nozzle 17 into receptacle 18. In lieu of pump means 13, other pump means may be used, such as a suction type pump located in pedestal 12.
The adapter fitting 15 has a body portion 20 with laterally spaced threaded opening 21 and 22. Opening 21 is adapted to be connected to the hose assembly 16 to the described, while threaded opening 22 is connected to a vapor recovery conduit 23 that extends downwardly in pedestal 12 into the tank 10, terminating in the upper portion thereof. Located closely adjacent to vapor recovery opening 22 is threaded sensor opening 24 with a liquid sensor 25 positioned therein. Sensor 25 has a probe 26 extending through opening 24 into the chamber 28 that interconnects opening 21 and opening 22. Located coaxially in alignment with opening 21 is a cylindrical tubular hub 29 whose external and internal surfaces are smooth. The external diameter of cylindrical hub 29 is substantially less than the internal diameter of threaded opening 21. Located diametrically opposite threaded opening 21 is an outwardly extending cylindrical hub 30. The outer external end portion of hub 30 has a circumferentially extending groove that receives a snag ring 31. A threaded coupling 32 is closely received by the hub 30 and retained thereon by the snap ring 31. The external surface of hub 30 is grooved closely adjacent to body portion 20 to receive an o-ring 9 to sealingly engage the threaded coupling 32. The threaded coupling 32 is connected to gasoline conduit 14 that supplies gasoline from the storage means or underground tank 10.
The fuel delivery hose assembly 16 has an outer flexible conduit 40 and an inner flexible conduit 41 which conduits or hoses form a pair of concentric passages. The inner flexible conduit defines a passage or passageway 42 and cooperates with the outer flexible conduit 40 to define an annular passageway or passage 43 since the outer conduit 40 has an inside diameter that is greater than the outside diameter of inner flexible conduit 41. A coupling designated 45 connects the hose assembly to the adapter fitting 15. Coupling 45 includes an outer tubular member 46, an inner tubular member, a spider 61 and a swivel nut 62. Outer tubular member 46 has a tubular member 11 suitably press fitted to the one end portion thereof to provide a groove 47, which groove 47 receives the one end portion of outer flexible conduit 40. The inner periphery of groove 47, which includes the inner periphery of outer tubular member 46 and the outer end portion of tubular member 11, is serrated to insure a secure connection to conduit 40. The other end portion of outer member 46 has one circumferentially extending groove around the outer periphery for receiving a snap ring 48 and a pair of circumferentially extending grooves on the inner diameter thereof to receive a pair of snap rings 50 and 51. The inner tubular member of coupling 45 has a stepped outer configuration defining a large end portion 55, a small end portion 56, an intermediate portion 57 located therebetween, which intermediate portion 57 is larger in diameter than the end portion 56 but smaller in diameter than the large end portion 55. The inner periphery of the large end portion 55 of the inner tubular member is recessed to receive a tubular member 19 that is suitably press fitted therein. Such tubular member 19 cooperates with inner periphery of large end portion 55 to define a groove 53 to receive the one end of the inner flexible conduit or hose 41. Such groove 53 which includes the inner periphery of the large end portion 55 and the outer periphery of the one end portion of tubular member 19 may be serrated to insure the connection to inner flexible conduit or hose 41. The outer end surface of the small end portion 56 is grooved to receive a pair of o-rings 58-59 and a groove adjacent to the intermediate portion 57 to receive a snap ring 60 that retains a spider 61 on the intermediate portion of the one piece inner tubular member. Spider 61 has a passage 52 to communicate the annular passageway 43 with the chamber 28 and the vapor recovery conduit 23. The snap rings 50 and 51 retain outer tubular member 46 relative to the inner tubular member and permits the relative rotation of the inner flexible conduit 41 relative to the outer flexible conduit 40 and vice versa. Slidably mounted on the outer periphery of outer tubular member 46 is a swivel nut 62, which has a pair of spaced low friction bearings 63 and 64 mounted on the respective inner peripheral ends thereof. In addition, the intermediate inner periphery of the swivel nut 62 is grooved to receive an o-ring 49 to sealingly engage the outer periphery of the outer tubular member 46. Snap ring 48 retains the swivel nut 62 on the coupling 45 but permits the relative rotation of the swivel nut 62 relative thereto so that the coupling 45 may be connected to the adapter fitting 15 yet permitting the hoses or conduits 40 and 41 to be rotated relative thereto without kinking of any of the conduits. A similar coupling 45 is connected to the other end of the pair of conduits or hoses 40 and 41 so as to facilitate their connection to the fuel pump nozzle 17 as depicted by FIG. 6 and FIG. 1.
The fuel dispensing or pump nozzle is indicated generally as reference 17 and includes a discharge nozzle 70 connected to a valve housing 71. Valve housing 71 includes a tubular portion 72 which contains an inner tubular member shown generally as 73 which communicates with the discharge nozzle 70, and outer annular passageway 74 that communicates with the passageway 75 formed by a resilient flexible boot or shroud 76 with the discharge nozzle 70 (as best seen in FIG. 6). The flexible boot 76 is attached at its rear portion to the nozzle 17 by suitable clamp means 78 while allowing its other end to be free. As shown more clearly in FIG. 2, the fuel dispensing or pump nozzle 17 has its nozzle positioned into an inlet pipe 80 of an automobile gasoline tank to be filled while the free extremity of boot 76 abuttingly engages the rim 81 of the inlet pipe 80. The nozzle is positioned off center in the inlet pipe 80 such that a projection 82 on the nozzle 70 engages the underside of rim 81 of inlet pipe 80 to retain such dispensing nozzle 17 in position for fueling the tank 18. Tube 83 extending within discharge nozzle 70 is operative to shut off the flow of gasoline from the discharge nozzle 70 as is old and well known in the art. Note U.S. Pat. No. 3,651,837. Operating lever 84 is suitably held in its operating position by latch means or recesses and is moved into inoperative position by actuation of the flow of gasoline through tube 83. The end portion of the gasoline hoses or conduits are connected to the fuel dispensing pump nozzle 17 by threading swivel nut 62 (FIG. 3) into threaded opening 85 of the pump nozzle 17 while the o-rings 58 and 59 of the inner tubular member of the coupling 45 slidably engage the inner wall periphery of inner tubular member 73.
To connect the coupling 45 to the adapter fitting 15, a conical compression spring 65 is positioned within the hub 29 such that the end portion of the inner tubular member of coupling 45 compresses spring 65 to insure the grounding of the inner tubular conduit or hose 41, which hose 41 has a suitable spiral wound wire 66 along its entire length.
A fuel dispensing pump nozzle is shown in FIG. 5 that is substantially identical to that described above except that nozzle 70 is connected to a separate threaded opening 86 on the other end of the pump nozzle while the annular vapor recovery space between the boot 76 and the nozzle 70 communicates via a separate passageway to threaded outlet opening 87. This type of constructed fuel pump nozzle utilized separate parallel hoses from the pumping tank and the vapor recovery system. There are many of these pump nozzles in use and the present invention is adaptable to these pump nozzles through the use of adapter 89 shown generally in FIG. 4. Adapter 89 has a body portion 90 with a large threaded opening 91 for use in connection with the coupling 45 of hose assembly 16. Located coaxially within opening 91 is a cylindrical tubular hub 92 whose internal and external surfaces are smooth. The external diameter of cylindrical hub 92 is substantially less than the internal diameter of threaded opening 91. Communicating directly with cylindrical tubular hub 92 is an outwardly extending cylindrical hub 93 that is grooved around the outer peripheral end portion to receive a snap ring 94 that retains a threaded swivel nut 95 thereon. Extending outwardly from body portion 90 substantially parallel to cylindrical hub 93 is a cylindrical tubular hub 96 slidably receiving a threaded swivel nut 97, which nut 97 has journaled on its inner periphery on o-ring 98 that frictionally engages the outer wall surface of tubular 96. Extending into body portion 90 adjacent to tubular hub 96 is a threaded opening 99 which threadedly receives a screw cap 100.
A liquid sensor 25 is shown as suitably threaded into threaded opening 24. Such liquid sensor 25 through its probe 26 which projects into the passageway 28 where the vapors are conducted will detect or sense any liquid such as gasoline to provide an output signal that is operative to de-energize the pump B while simultaneously energizing an auditory signal such as bell 102 (depicted in FIG. 1).
In the operation of the described apparatus, the operator inserts the nozzle 70 of the pump fuel nozzle 17 into the inlet pipe 80 of the receptacle 18 such that the top of the projection 82 comes into abutting contact with the inner bottom circumferential portion of rim 81. This action compresses the boot 76 such that its free end portion abuttingly contacts the rim 81 and sealingly engages it. Energization of pump 13 pumps liquid fuel via conduit 14 and the inner tubular hose 41 of hose assembly 16 to nozzle 70 into the inlet pipe 80 of tank 18. The vaporized hydrocarbon fuel in the tank 18 is displaced from the tank and forced up out of the inlet pipe 80 into the annular passageway defined by the boot 76 and the nozzle 70 into the outer passageway 43 of hose assembly 16 defined by the outer conduit 40 and the inner conduit 41, for passage through the passageway 52 of spider 61 into chamber 28 of adapter fitting 15 for passage into vapor return conduit 23. Any overflow of gasoline or liquid fuel into the vapor recovery line or passageways is sensed by sensor probe 26 which is located in adapter fitting 15 at the pump end as described above to de-energize the pump 13 when liquid is detected and prevents the return of the fuel to the tank via the vapor recovery system. With the respective ends of the inner and outer hoses 41 and 42 journaled in their coupling 45, hoses 41 and 42 are able to rotate relative to each other and prevent crimping of the fuel dispensing hose 16. In addition, swivel nut 62 permits the rotation of the hose assembly line 16 relative to its connection to adapter 15 to ensure the ease of manipulation of the fuel pump nozzle 17 and its boot relative to the inlet pipe 80 of the vehicle receiving tank or receptacle 18 to assure a good seal on such inlet pipe 80.
Various modifications are contemplated and may obviously be resorted to by those skilled in the art without departing from the described invention, as hereafter defined by the appended claims, as only a preferred embodiment thereof has been disclosed.
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A fuel hose assembly having an inner and outer hose that have their respective ends secured to a coupling member that retains their ends in spaced apart positions thereby defining separate passageway while permitting the hoses to rotate relative to each other. The coupling member has means for rotating the fuel hose assembly relative to their connection to a fuel dispensing pump and vapor recovery system such that the one hose will convey the liquid fuel while the other hose will convey the fuel vapors that are displaced from the tank being filled with the liquid fuel. Sensing means are provided to prevent the flow of the liquid fuel via the vapor recovery passageways.
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BACKGROUND OF THE INVENTION
The present invention is described in terms of an igniter assembly and method for igniting a pyrotechnic propellant and more particularly to an air bag inflator system for releasing gas at impact moment to timely inflate a personnel protective air bag, but its utilitity is not limited to that application.
A large number of air bag igniter devices of various types have been employed in the automobile industry to be capable in a matte of milliseconds to convert electrical energy into chemical energy rapidly to inflate protective air bags. These past devises for the most part have included comparatively complex, but not always satisfactory mechanisms to avoid premature and undesirable ignition. An early igniter assembly device, concerned with inadvertent energy releases is disclosed in U.S. Pat. No. 3,971,320, to J. T. M. Lee issued on Jul. 27, 1976, which employs a grounding shunt form a coaxial lead to the housing of an igniter to avoid against accidental firing. Such accidental firings, which can be brought about by changes in outside factors such as an electrostatic charge or radiant or electromagnetic energy or radio frequencies, could result in great harm to persons during the manufacturing process of ignitors or those otherwise meant to be protected by air bag equipment. To further insure against accidental firing, other comparatively complex, expensive and not always satisfactory arrangements have been employed. In this regard attention is directed to the two European patent publications: No. 0658739A2, inventor J. H. Evans, published on Jun. 21, 1995, which teaches an electrostatic spark gap discharge arrangement for two spaced electrodes outside a pyrotechnic cup on one side of a glass-to-metal seal with a bridge wire on the other side of the seal in intimate communication with a secondary pyrotechnic, and No. 745519A1, inventor, D. D. Hansen, published Dec. 9, 1996, which teaches a metal oxide varistor made of pressed powder for protecting the igniter from premature ignitions.
For the most part, past protective devices for preventing premature ignition of igniter assemblies have been comparatively complex in manufacture and assembly, expensive and not always efficient in operation, requiring comparatively complex manufacturing steps and additional parts in assembly.
The present invention provides a new and useful arrangement which is straightforward, and economical in manufacture and assembly, requiring a comparative minimum of parts and space and which optimizes the use of several parts which are also required for normal ignition performance, at the same time, avoiding inadvertent energy discharges often brought about in the past by electrostatic charges created by outside factors.
Various other features of the present invention will become obvious to one skilled in the art upon reading the disclosure set forth herein.
BRIEF SUMMARY OF THE INVENTION
More particularly, the present invention provides an electrically conductive assembly comprising: a housing shell of preselected material defining at least two internal chambers, upstream and downstream, each chamber including a defining peripheral wall with a preselected electrically insulatively sealing material extending transversely thereacross in sealed relation with the chamber-defining peripheral wall and with the insulative sealing material of one chamber being preselectively spaced from the insulative sealing material of the other chamber to provide an insulatively sealed void or partial vacuum chamber therebetween, and electrical conductors having a portion thereof extending in sealed relation through the electrically insulative sealing material of each chamber and the sealed void chamber therebetween with projecting upstream and downstream ends respectively. The insulatively sealed void chamber is made to serve to prevent possible undesirable preignition sparking. In addition, the present invention provides for a method of charging and discharging electrical energy through an electrically conductive conduit assembly extending in sealed relation through spaced first and second electrically insulatively sealed zones into an electric discharge zone with the space between the first and second insulatively sealed zones serving as a sealed void chamber accommodating isolated bleeding of high voltage electrostatic charges to prevent possible undesirable preignition sparking.
It is to be understood that various changes can be made by one skilled in the art in one or more of the several parts and in one or more of the several steps of the novel invention disclosed herein without departing from the scope or spirit of the present invention. For example, although the present invention as disclosed herein is usefuil with an igniter structure, particularly that used to inflate an air bag, the novel features of the present invention can be employed in a number of other electrical current carrying applications such as electrical switches, other explosive igniters and electric motors.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Referring to the drawings which disclose one advantageous embodiment of the present invention and a modification thereof:
FIG. 1 is a cross-sectional view of an igniter header or collar incorporating one advantageous embodiment of the present invention, the arrows indicating a conductive flow path in accordance with a feature of the invention; and
FIG. 2 is a cross-sectional view similar to that of FIG. 1, of an igniter header or collar incorporating modification in the positioning of an insulation layer to the header disclosed in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, and particularly FIG. 1 thereof, an igniter assembly 2 is disclosed which incorporates the novel features of the present invention and which can be particularly useful for igniting an explosive charge which, in turn, serves to inflate a protective air bag like those presently used as a safety device in the automobile industry.
It is to be understood that the inventive features of the novel system as described herein, which are principally useful to dissipate unwanted high voltage electrical charges which might be brought about by ambient or surrounding factors, are not to be considered as limited to use with air bags igniters but can be used in any one of a number of electricity conveying situations where it is desirable to dissipate stray electrical charges in a conductive system.
In FIG. 1, the disclosed igniter assembly 2, includes a housing shell or collar 3 4 which can be formed from any one of a number of suitable materials. It is here shown as being formed from a preselected, cold rolled steel to include three, internal, contiguous, cylindrical chambers which are axially aligned about the longitudinally extending central axis of housing 3. The first two chambers, namely an upstream chamber 4 and downstream chamber 6, each includes a defining peripheral wall 7 and 8, respectively, and each contains a preselected electrically insulating sealing material 9 and 1 1, respectively, extending transversely thereacross substantially normal to the longitudinal central axis of housing shell 2 in sealed relation with the chamber-defining peripheral walls 7 and 8, respectively. The sealing material 9 in the illustration embodiment shown, is a T seal, preformed in the shape shown and fused within a complimentarily shaped carbon cup. The seal 9, has an upper surface 18 and a lower surface 19, and passages transversely through it to accommodate terminal pins to which the sealing material 9 is fused. The sealing material 11 in the illustrative embodiment is also preformed as a cylindrical pellet, with an upper surface 21 and a lower surface 22 and transverse passages to accommodate the terminal pins to which the sealing material 11 is fused. In one advantageous embodiment of the present invention, the upstream sealing material 9 for upstream chamber 4 can be of a ceramic loaded fused sealing glass containing cobalt oxide, for example, and the sealing material 11 of the contiguous downstream chamber 6 can be of a preselected fused glass material which can be substantially similar in chemical composition to known glasses commonly used in the glass-to-metal sealing of hermetic terminal assemblies associated with refrigeration compressors, loaded with aluminum oxide, for example. In the illustration shown, the downstream face 19 of the upstream electrically insulated sealing material 9 of chamber 4 is spaced from the upstream face 21 of downstream electrically insulative sealing material 11 of down stream chamber 6 to provide a novel insulatively sealed void chamber 12 therebetween of preselected volume. It is to be noted that the volume of sealed void chamber 12 and the volume and chemistry of upstream and downstream insulative sealing materials 9 and 11 can be selectively varied by one skilled in the art in accordance with the requirement of a particular application and the results desired from the novel spacing arrangement forming the sealed void chamber 12. When the present invention is employed as an air bag igniter, advantageously the sealed void chamber has a volume of approximately zero point zero zero two six five cubic inches (0.00265 cu.in.) with a diameter of approximately zero point two six zero inches (0.260") and a thickness of approximately zero point zero five zero inches (0.050"). In accordance with the present invention, it is important that sealed void chamber 12 serve as an insulator at imposed established normal voltages and that chamber 12 be surface conductive at inadvertently imposed higher voltages which might be brought about by undesirable surrounding voltage creating factors, such as static electric charges, changing radiant energy, changing electromagnetic energy or changing radio frequencies. In the event of such occurrences and as can be seen in FIG. 1 of the drawings, the conductive currents move along the surfaces 19 and 21 of both upstream and downstream sealing materials 9 and 11 through sealed void chamber 12 to the steel shell 3, to be dissipated with insignificant consequence. Sealed void chamber 12 is in a partial vacuum condition to enhance dissipation of any unsolicited surrounding unwanted high voltages. This desired vacuum or partial pressure of sealed void chamber 12 is brought about when the upstream and downstream sealing materials 9 and 11 are first heated to fusing temperature and then cooled, gas trapped between them contracting to form a partial vacuum. The gas is that of the atmosphere of the furnace or oven in which the fusing takes place, preferably nitrogen, although a reducing gas may be used, particularly if the surface reduction transition metal oxides in the sealing glass is desired to produce a thin conductive film on the surfaces 18 and 19. In the latter case, arcing may take place outside the void space 12, but nevertheless at a place isolated from the explosive chamber. Traces of carbon monoxide from residual binder of the pelletized sealing materials along with methane, hydrogen and carbon dioxide may also be present if natural gas is used as the atmosphere in the furnace.
As can be seen in FIG. 1 of the drawings, the electrical conducting assembly as disclosed includes at least two electrically conductive terminal pins 13 which are disposed in preselectively spaced relation about the longitudinally extending central axis of the upstream and downstream contiguous insulated chambers 4 and 6. These electrically conductive pins 13 advantageously can be of fifty-two (52) alloy, nickel plated steel. It is to be understood, however, that the spacing, chemistry and number of such pins can vary in accordance with the usage and results desired. Spaced pins 13, which are substantially parallel to each other, are each in spaced relation from the chamber-defining peripheral walls 7 and 8 respectively with a central portion of each pin member 13 extending in glass sealed relation through the glass insulative sealing material 9 and 11 respectively of each upstream and downstream chamber 4 and 6 respectively and the sealed partial pressure or vacuum chamber 12 therebetween. The projecting ends of electrically conductive pins 13 serve as charging and discharging areas respectively and the insulatively sealed partial pressure chamber 12, as above described, permits arcing between the pins 13 and the steel shell 3 isolated from the explosive chamber 16 to prevent undesirable preignition sparking between pins 13.
As can be seen in FIG. 1 of the drawings, advantageously a preselected ceramic electrically insulating sealing material 14 can be provided, facing the downstream face 22 of insulating sealing material 11 with the spaced, electrically conductive pins 13 extending therethrough. As also can be seen in FIG. 1 of the drawings the downstream extremities of pins 13 terminate in a third internal contiguous axially aligned chamber 16, which, in the disclosed embodiment, can serve as an explosive charge air bag ignition chamber. The downstream pin extremities can have a suitable bridge wire or igniter circuit 17 (schematically shown) electrically connected thereto so as to be capable of igniting an explosive charge to be inserted in explosive chamber 16. If the chamber 16 is provided with a radially inwardly extending lip at its upper end, the axial thickness of the lip can help define the axial height of the void 12, the position of the pelletized seal 11 being determined by moving it into contact with the lip.
Referring to FIG. 2 of the drawings, which discloses an igniter assembly, with most of the parts similar to those of the structure of FIG. 1, it can be seen that the preselected ceramic insulating material 14, alternatively, can be positioned downstream of the downstream face 19 of upstream insulative sealing material 9 in upstream chamber 4 rather than in downstream chamber 6 as shown in FIG. 1 of the drawings.
In accordance with the novel method of charging and discharging electric current as disclosed hereinabove, the electric current is passed from an electric charging zone from a source of current not here shown through an electrically conductive conduit assembly extending in sealed relation through spaced first and second sealed insulated zones with the space therebetween serving as a sealed void chamber to accommodate for possible undesirable preigniting sparking in the electrically conductive conduit assembly.
The normal ignition voltage is of the magnitude of 9-12 volts DC, with a firing current of typically one point two (1.2) amps.
Transient static electric voltages are high, in the neighborhood of 1,000 to 25,000 volts with current greater than the one point two (1.2) amps for three (3) milliseconds required for ignition.
By loading the sealing material 11 with alumina, the sealing material retains its integrity sufficiently to enable the dimensions of the void chamber 12 to be held closely enough. Those dimensions are relatively flexible, the important thing is to provide a definite, partially evacuated space.
The chemistry of the seals and the entrapped gas is such as to make the breakdown voltage around 2000 volts. At 3,000-4,000 volt s, the spaced seals 9 and 11 will arc across their spaced surfaces. To insulate the ignition wire from these voltages it is desirable, in addition to the incorporation of void 12, to ensure that such arcing occurs across surfaces 19 or 21, and not at surface 22, and to that end, transition metal oxides in sealing material 9 can be utilized to produce a controlled surface conductive condition advantageously cobalt can be employed as the metal oxide.
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An electrically conductive system including an apparatus and method wherein an electric current is sealingly passed through at least two spaced insulatively sealed zones with an insulatively sealed void space provided therebetween under a vacuum and serving as a discharge zone for possible inadvertent preignition brought about accidentally by outside external factors.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Application No. 2002-46778, filed Aug. 8, 2002, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a washing machine, and more particularly, to a disinfecting washing machine equipped with a disinfecting liquid dispenser.
[0004] 2. Description of the Related Art
[0005] Colloidal silver can be produced by forming silver ions (Ag + ) and dissolving them in water. The colloidal silver is used as an antibacterial agent or a bactericide. It is reported that the colloidal silver eliminates about 650 different kinds of bacteria. In particular, the colloidal silver is characterized as not inducing resistance, which is different from general antibiotics, and is safe because the colloidal silver has no toxic effects. Methods of manufacturing the colloidal silver are an electrolysis method, a chemical resolution method and a pulverization method.
[0006] A disinfecting washing machine is a washing machine that is equipped with a disinfecting liquid dispenser that produces and supplies a colloidal silver to disinfect laundry through antibacterial and bactericidal actions of the colloidal silver.
[0007] A conventional disinfecting washing machine is described below with reference to FIGS. 1 and 2.
[0008] [0008]FIG. 1 is a cross section of a conventional disinfecting washing machine. As shown in FIG. 1, a water tub 104 is disposed in a body casing 102 to contain washing water. A washing tub 106 is disposed in the water tub 104 . A pulsator 108 is mounted in a lower portion of an interior of the washing tub 106 to be rotated in forward and reverse directions so as to form currents of the washing water. A drive unit 110 is positioned under the water tub 104 to rotate the washing tub 106 and the pulsator 108 . The drive unit 110 comprises a drive motor 112 and a power transmission unit 114 . The drive motor 112 is rotated by power supplied thereto, and the power transmission device 114 serves to selectively transmit power generated by the drive motor to the pulsator 108 and the washing tub 106 . A belt 116 is wound around the drive motor 112 and the power transmission device 114 to mediate transmission of the power. A drain assembly 118 comprises a pipe 118 a to drain the washing water from the washing tub 106 and a drain pipe valve 118 b , which selectively opens and closes the drain pipe 118 a to allow draining of the washing water from the washing tub 106 .
[0009] [0009]FIG. 2 is a partially sectional view of a conventional disinfecting liquid dispenser. As depicted in FIG. 2, when power is supplied to the washing machine and a washing course is selected while laundry is contained in a disinfecting washing machine, washing water is fed into an interior of a water tub 104 . The washing water fed into the water tub 104 dissolves a detergent while passing through a detergent dispenser (not shown), and is supplied to the water tub 104 along with the dissolved detergent.
[0010] If a user selects a disinfection washing course, an inlet valve 204 of a disinfecting liquid dispenser 120 , connected to external source of water through an inlet pipe 212 , is opened and the water is supplied to an interior of a storage container 122 , whereas the washing water is fed to the water tub 104 . When power is applied to two silver plates 220 and 222 of the disinfecting liquid dispenser 120 , a silver disinfecting liquid is produced. The silver disinfecting liquid is supplied to the interior of the washing tub 106 and disinfects the laundry.
[0011] The water supplied though an inlet 202 of the storage container 122 is halted to stabilize a speed and a current of the water while filling a first space 210 of the storage container 122 . The water contained in the first space 210 overflows a first partition 206 and flows into a second space 214 . The water having passed through the first space 210 and flowing into the second space 214 fills the second space 214 to a water level corresponding to the height of a second partition 208 . After the second space 214 is filled with the water, the water overflows the second partition 208 and flows into a third space 224 and then is supplied to the interior of the washing tub 106 through an outlet pipe 124 from an outlet 216 of the storage container 122 . The water flows into the third space 224 while a certain amount of the water is contained in the second space 214 . In a process, the silver disinfecting liquid is produced through electrolysis in the water, and the produced disinfecting liquid is supplied to the washing tub 106 through the outlet 216 . The process of producing a disinfecting liquid is continuously carried out while the water is supplied to the storage container 122 . A top 218 of the storage container 122 fixedly holds the sliver plates 220 and 222 in the water contained in the second space 214 . The storage container 122 , the top 218 , the inlet 202 , the outlet 216 and the bypass pipe 128 may be of a nonconductive material.
[0012] Further, in the process of producing the disinfecting liquid, if the amount of the water supplied through the inlet 202 is large, the water contained in the interior of the storage container 122 flows into a drain pipe 118 a through a bypass pipe 128 from a bypass outlet 126 at an upper portion of the storage container 122 , so the water can be maintained at an appropriate water level in the storage container 122 , thereby enabling a disinfecting liquid of a certain concentration to be produced. When the process of producing a disinfecting liquid is stopped, the water supply to the storage container 122 is stopped by closing of the inlet value 204 and the power to the silver plates 220 and 222 is stopped. At that time, the water remaining in the interior of the storage container 122 flows into the outlet 216 through remaining water discharging holes 206 a and 208 a and is completely discharged from the storage container 122 .
[0013] After the washing water including the disinfecting liquid fills the washing tub 106 , washing of the laundry is performed by a rotation of the pulsator 108 and bacteria are killed by the disinfecting liquid in a process of the washing of the laundry.
[0014] The disinfecting liquid dispenser 120 carries out the electrolysis in the water by alternately applying a positive voltage and a negative voltage to the two silver plates 220 and 222 , respectively, thus generating the silver ions. The amount of the silver ions, which is a concentration of the colloidal silver, is proportional to an amount of current flowing through the two silver plates 220 and 222 or an amount of voltage applied to the two silver plates 220 and 222 .
[0015] The disinfecting performance obtained by the colloidal silver is determined by the concentration of the colloidal silver. If the concentration of the colloidal silver is excessively low, a disinfecting performance of the colloidal silver decreases; but if the concentration of the colloidal silver is excessively high, the colloidal silver discolors the laundry. Accordingly, the concentration of the colloidal silver has to be appropriately adjusted so as not to damage the laundry while disinfecting the laundry. To produce the appropriate concentration of the colloidal silver, the amount of voltage applied to the two silver plates 220 and 222 or the amount of current flowing through the two silver plates 220 and 222 has to be appropriately adjusted.
[0016] Since the concentration of the colloidal silver is varied according to a pressure and temperature of the water, the voltage applied to the two silver plates 220 and 222 or the current flowing through the two silver plates 220 and 222 must not be limited to a fixed value but must be varied in a certain range so as to maintain the concentration of colloidal silver in an appropriate range.
SUMMARY OF THE INVENTION
[0017] Accordingly, an aspect of the present invention is to provide a disinfecting washing machine, which is capable of controlling an amount of voltage applied to silver plates using a pulse width modulation signal, so a colloidal silver can have a concentration in an appropriate range that sufficiently disinfects laundry but does not damage the laundry.
[0018] Additional aspects 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.
[0019] To accomplish the above and/or other aspects, a disinfecting washing machine comprises a disinfecting liquid dispenser supplying a disinfecting liquid to disinfect laundry; a drive unit outputting first and second voltages to determine a concentration of the disinfecting liquid; and a control unit detecting the concentration of the disinfecting liquid and controlling the drive unit so that the concentration of the disinfecting liquid is within a preset range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] These and other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which:
[0021] [0021]FIG. 1 is a cross section of a conventional disinfecting washing machine;
[0022] [0022]FIG. 2 is a partially sectional view showing a disinfecting liquid dispenser of FIG. 1;
[0023] [0023]FIG. 3 is a block diagram showing a device for controlling a concentration of colloidal silver used in a washing machine of an embodiment of the present invention;
[0024] [0024]FIG. 4 is a circuit diagram of a drive unit of the colloidal silver concentration control device of the embodiment of the present invention; and
[0025] FIGS. 5 A- 5 E are charts showing waveforms of signals applied to the drive unit of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Reference will now be made in detail to the present preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0027] A disinfecting washing machine and method of controlling the disinfecting washing machine are described with reference to FIGS. 3, 4 and 5 A- 5 E. FIG. 3 is a block diagram showing a device for controlling the concentration of colloidal silver used in a washing machine of an embodiment of the present invention. As shown in FIG. 3, a drive unit 302 alternately applies positive and negative voltages to a disinfecting liquid dispenser 304 to produce colloidal silver. Levels and polarities of the voltages applied to the disinfecting liquid dispenser 304 from the drive unit 302 are controlled by a duty ratio of a pulse width modulation signal 314 , a first switching signal 316 and a second switching signal 318 outputted from a control unit 306 to the drive unit 302 .
[0028] An amount of current supplied to the disinfecting liquid dispenser 304 is proportional to amounts of voltages applied to the disinfecting liquid dispenser 304 . The amount of current, supplied to the disinfecting liquid dispenser 304 , is detected by a current detection unit 308 and a current/voltage conversion unit 310 . The control unit 306 determines the duty ratio of the pulse width modulation signal 314 in consideration of the amount of the current being currently supplied to the disinfecting liquid dispenser 304 . If the amount of current being currently supplied to the disinfecting liquid dispenser 304 deviates from an appropriate range that can produce the colloidal silver of an appropriate concentration necessary for a disinfection of laundry, the amount of current supplied to the disinfecting liquid dispenser 304 is controlled to be in the appropriate range by increasing or decreasing a pulse width of the pulse width modulation signal 314 .
[0029] If excessive amounts of voltages are supplied to the disinfecting liquid dispenser 304 , a concentration of the colloidal silver is increased, thus damaging the laundry. A current limiter 312 generates an excessive current signal 320 and inputs the excessive current signal 320 to the control unit 306 when the amount of current detected by the current detection unit 308 exceeds a preset reference value. When the excessive current signal 320 is generated, the control unit 306 decreases the concentration of the colloidal silver by lowering a level of voltage applied to the disinfecting liquid dispenser 304 by decreasing the duty ratio of the pulse width modulation signal 314 to the drive unit 302 , or by completely shutting off a power supply to the disinfecting liquid dispenser 304 .
[0030] A construction of the drive unit 304 controlling the concentration of the colloidal silver is described in detail below with reference to FIGS. 4 and 5A- 5 E. FIG. 4 is a circuit diagram showing the drive unit of the colloidal silver concentration control unit. As shown in FIG. 4, a PNP bipolar transistor 402 and an NPN bipolar transistor 404 form a first series circuit between a voltage VCC and a second voltage GND. A PNP bipolar transistor 406 and a NPN bipolar transistor 408 form a second series circuit in parallel with the first series circuit.
[0031] First and second NPN bipolar transistors 410 and 412 are connected in series to each other between a base of the PNP bipolar transistor 402 of the first series circuit and the second voltage GND. The first NPN bipolar transistor 410 is controlled by the pulse width modulation signal 314 , while the second NPN bipolar transistor 412 is controlled by the first switching signal 316 . Accordingly, when the pulse width modulation signal 314 and the first switching signal 316 are both at a high level, the first and second NPN bipolar transistors 410 and 412 are both turned on. When the first and second NPN bipolar transistors 410 and 412 are both turned on, the PNP bipolar transistor 402 of the first series circuit is turned on. As a result, while the second NPN bipolar transistor 412 is turned on, the duty ratio of the pulse width modulation signal 314 determines a turned-on range of the PNP bipolar transistor 402 of the first series circuit. The NPN bipolar transistor 404 of the first series circuit is controlled by the second switching signal 318 . A first control voltage 326 outputted from between the PNP bipolar transistor 402 and the NPN bipolar transistor 404 of the first series circuit is applied to one of the two silver plates 220 or 222 of the disinfecting liquid dispenser 304 .
[0032] Third and fourth NPN bipolar transistors 414 and 416 are connected in series to each other between a base of the PNP bipolar transistor 406 of the second series circuit and the second voltage GND. The third NPN bipolar transistor 414 is controlled by the pulse width modulation signal 314 , while the fourth NPN bipolar transistor 416 is controlled by the second switching signal 318 . Accordingly, when the pulse width modulation signal 314 and the second switching signal 318 are both at a high voltage level, the third and fourth NPN bipolar transistors 414 and 416 are both turned on. When the third and fourth NPN bipolar transistors 414 and 416 are both turned on, the PNP bipolar transistor 406 of the second series circuit is turned on. As a result, while the fourth NPN bipolar transistor 416 is turned on, the duty ratio of the pulse width modulation signal 314 determines a turned-on range of the PNP bipolar transistor 406 of the second series circuit. The NPN bipolar transistor 408 of the second series circuit is controlled by the first switching signal 316 . A second control voltage 328 outputted from between the PNP bipolar transistor 406 and the NPN bipolar transistor 408 of the second series circuit is applied to a remaining one of the two silver plates 220 or 222 of the disinfecting liquid dispenser 304 . In FIG. 4, an emitter current of the NPN bipolar transistors 404 and 416 is detected by the current detection unit 308 , as shown in FIG. 3, and converted into a voltage signal in the current/voltage conversion unit 310 . The control unit 306 determines an amount of current being currently supplied to the disinfecting liquid dispenser 304 based on a magnitude of the converted voltage signal.
[0033] FIGS. 5 A- 5 E are charts showing waveforms of signals applied to the drive unit of FIG. 4.
[0034] As shown in FIGS. 5 A- 5 B, the first and second switching signals 316 and 318 , which are input signals, have opposite phases, respectively. A slight dead time t d exists between transition points of the first and second switching signals 316 and 318 . If the first and second switching signals 316 and 318 transition at a same time, an overlapped range is formed. In this case, the two silver plates 220 and 222 of the disinfecting liquid dispenser 304 are short-circuited. When the dead time t d is provided between the first and second signals 316 and 318 , the two silver plates 220 and 222 of the disinfecting liquid dispenser 304 can be prevented from short-circuiting. As shown in FIG. 5C, the pulse width modulation signal 314 , which is another input signal, is a signal whose duty ratio is variable by the control unit 306 . The duty ratio of the pulse width modulation signal 314 , as shown in FIG. 5C, is 100%.
[0035] As shown in FIGS. 5 D- 5 E, the first and second control voltages 326 and 328 , which are output signals, have opposite phases. A phase of the first control voltage 326 is a same phase as that of the first switching signal 316 , while a phase of the second control voltage 328 is a same phase as that of the second switching signal 318 . Levels of the first and second control voltages 326 and 328 are proportional to the duty ratio of the pulse width modulation signal 318 . In FIG. 5D- 5 E, the levels “A” of the first and second control voltages 326 and 328 are for the case where the duty ratio of the pulse width modulation signal 314 is 100%, the levels “B” of the first and second control voltages 326 and 328 are for the case where the duty ratio of the pulse width modulation signal 314 is about 90 %, and the levels “C” of the first and second control voltages 326 and 328 are for the case where the duty ratio of the pulse width modulation signal 314 is about 50%.
[0036] An operation of the drive unit 302 , which controls the colloidal silver concentration, of the disinfecting liquid dispenser 304 is described with reference to FIGS. 4 and 5A- 5 E. If the first switching signal 316 of the input signals 314 , 316 and 318 , as shown in FIGS. 5 A- 5 C, respectively, is at a high voltage level and the second switching signal 318 is at a low voltage level, the first switching signal 316 is a high voltage level, so the second NPN bipolar transistor 412 is turned on. In this state, since the first NPN bipolar transistor 410 is only turned on when the pulse width modulation signal 314 is in a high voltage level range, the PNP bipolar transistor 402 of the first series circuit has a turned-on range which is equal to the high voltage level range of the pulse width modulation signal 314 . At this time, the second switching signal 318 is at the low voltage level, so the NPN bipolar transistor 404 of the first series circuit is turned off.
[0037] In contrast, the fourth NPN bipolar transistor 416 is turned off by the second switching signal 318 of the low voltage level. Accordingly, turned-on and turned-off operations of the third NPN bipolar transistor 414 in response to the pulse width modulation signal 314 do not affect operation of the PNP bipolar transistor 406 of the second series circuit. At this time, the first switching signal 316 is at the high voltage level, so the NPN bipolar transistor 408 of the second series circuit is turned on.
[0038] As described above, in a range where the first switching signal 316 is at the high voltage level and the second switching signal 318 is at the low voltage level, only the PNP bipolar transistor 402 of the first series circuit and the NPN bipolar transistor 408 of the second series circuit are turned on, so that a source voltage VCC, the PNP bipolar transistor 402 of the first series circuit, the disinfecting liquid dispenser 304 , the NPN bipolar transistor 408 of the second series circuit and the second voltage GND provide a closed circuit to enable current to flow through the two silver plates 220 and 222 . In this case, the first control voltage 326 has a positive polarity, while the second control voltage 328 has a negative polarity. Since a turned-on range of the PNP bipolar transistor 402 of the first series circuit is proportional to the duty ratio of the pulse width modulation signal 314 , the levels of the first and second control voltages 326 and 328 are proportional to the duty ratio of the pulse width modulation signal 314 .
[0039] If the first switching signal 316 is at the low voltage level and the second switching signal 318 is at the high voltage level as a result of alternating the voltage levels of the first and second switching signals 316 and 318 , the second switching signal is at the high voltage level, so the fourth NPN bipolar transistor 416 is turned on. In this state, the third NPN bipolar transistor 414 is only turned on when the pulse width modulation signal 314 is in the high voltage level range, so that the PNP bipolar transistor 406 of the second series circuit has a turned-on range which is equal to the high voltage level range of the pulse width modulation signal 314 . At this time, the first switching signal 316 is at the low voltage level, so that the NPN bipolar transistor 408 of the second series circuit is turned off.
[0040] In contrast, the second NPN bipolar transistor 412 is turned off by the first switching signal 316 of the low voltage level. Accordingly, turned-on and turned-off operations of the first NPN bipolar transistor 410 in response to the pulse width modulation signal 314 do not affect operation of the PNP bipolar transistor 402 of the first series circuit. At this time, the second switching signal 316 is at the high voltage level, so that the NPN bipolar transistor 404 of the first series circuit is turned on.
[0041] As described above, in a range where the second switching signal 318 is at the high voltage level and the first switching signal 316 is at the low voltage level, only the PNP bipolar transistor 406 of the second series circuit and the NPN bipolar transistor 404 of the first series circuit are turned on, so the source voltage VCC, the PNP bipolar transistor 406 of the second series circuit, the disinfecting liquid dispenser 304 , the NPN bipolar transistor 404 of the first series circuit and the second voltage GND provide a closed circuit and enable current to flow through the two silver plates 220 and 222 . In this case, the first control voltage 326 has the negative polarity, while the second control voltage 328 has the positive polarity. Since the turned-on range of the PNP bipolar transistor 406 of the second series circuit is proportional to the duty ratio of the pulse width modulation signal 314 , the levels of the first and second control voltages 326 and 328 are proportional to the duty ratio of the pulse width modulation signal 314 .
[0042] As described above, the polarities of the first and second control voltages 326 and 328 outputted from the drive unit 302 to the disinfecting liquid dispenser 304 are repeatedly alternated by the first and second switching signals 316 and 318 . The amounts of the first and second control voltages 326 and 328 are controlled to be proportional to the duty ratio of the pulse width modulation signal 314 . Since the first and second control voltages 316 and 318 are voltages applied to the two silver plates 220 and 222 , the colloidal silver of a concentration proportional to the levels of the first and second control voltages 326 and 328 is produced. The control unit 306 determines whether the concentration of a currently produced colloidal silver is within an appropriate range by monitoring an amount of current flowing through the two silver plates 220 and 222 . If the concentration of the colloidal silver deviates from the appropriate range, the control unit 306 adjusts the amounts of the first and second control voltages 326 and 328 applied to the disinfecting liquid dispenser 304 by varying the duty ratio of the pulse width modulation signal 314 . Since the polarities of the first and second control voltages 326 and 328 are repeatedly alternated, an oxidation and a reduction of silver ions are uniformly carried out on the two silver plates 220 and 222 , thus preventing only one of the two silver plates 220 and 222 from being consumed.
[0043] As described above, a disinfecting washing machine is provided, which is capable of maintaining a concentration of a colloidal silver within an appropriate range, which does not damage laundry while sufficiently disinfecting the laundry, by controlling amounts of voltages applied to silver plates based on a preset concentration of the colloidal silver using a duty ratio of a pulse width modulation signal. Further, the disinfecting washing machine prevents only one of the two silver plates from being consumed by repeatedly alternating polarities of first and second control voltages 326 and 328 .
[0044] Although a few preferred embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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A disinfecting washing machine includes a disinfecting liquid dispenser, a drive unit and a control unit. The disinfecting liquid dispenser supplies a disinfecting liquid to disinfect laundry. The drive unit outputs first and second voltages to determine a concentration of the disinfecting liquid. The control unit detects the concentration of the disinfecting liquid and controlling the drive unit so that the disinfecting liquid has a concentration within a preset range.
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