description
stringlengths
2.98k
3.35M
abstract
stringlengths
94
10.6k
cpc
int64
0
8
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation-in-part of U.S. application Ser. No. 11/609,237, filed Dec. 11, 2006, now pending, the disclosure of which is incorporated by reference in their entirety herein. TECHNICAL FIELD [0002] The present invention relates to disposable absorbent articles formed from biodegradable aliphatic polyester polymers including antimicrobial compositions. These disposable absorbent articles are intended for absorbing body fluids, such as disposable infant diapers, feminine hygiene products including sanitary napkins, panty liners and tampons, products for adult incontinence, personal care wipes, and household wipes that include a microbial control material. BACKGROUND [0003] A large variety of disposable absorbent articles are known in the art. These include personal absorbent articles used to absorb bodily fluids such as perspiration, urine, blood, and menses. Such articles also include disposable household wipes used to clean up similar fluids or typical household spills. These disposable absorbent articles are formed from thermoplastic polymers in the form of extruded films, foams, nonwovens or sometimes woven material. An issue with these articles is that they are designed for short term use but may not be disposed of immediately so that there is an opportunity for microorganisms to grow prior to disposal creating issues with formation of toxins, irritants or odor. However these absorbent articles are eventually disposed of so that the ability to form these absorbent articles of degradable thermoplastic materials is highly desirable. [0004] One type of disposable absorbent articles is disposable absorbent garments such as infant diapers or training pants, products for adult incontinence, feminine hygiene products such as sanitary napkins and panty liners and other such products as are well known in the art. The typical disposable absorbent garment of this type is formed as a composite structure including an absorbent assembly disposed between a liquid permeable bodyside liner and a liquid impermeable outer cover. These components can be combined with other materials and features such as elastic materials and containment structures to form a product that is specifically suited to its intended purposes. Feminine hygiene tampons are also well known and generally are constructed of an absorbent assembly and sometimes an outer wrap of a fluid pervious material. Personal care wipes and household wipes are well known and generally include a substrate material, which may be a woven, knitted, or nonwoven material, and often contain functional agents such as cleansing solutions and the like. [0005] An issue with these articles is that once body fluids, or household spills, are absorbed into the articles various microbes can grow in these articles. A well known problem with such articles is the generation of malodors associated with microbial growth and metabolites. For disposable absorbent articles such as infant diapers, products for adult incontinence, and feminine hygiene products the generation of such malodors can be a source of embarrassment for the user of these products. This can be particularly true for users of adult incontinence and feminine hygiene products. The issue of generation of malodor can include odors that are potentially detectable while the article is being worn and additionally after the article is disposed. In the case of household wipes the microbe associated generation of malodor is undesirable and can be embarrassing. Additionally the growth of bacteria and other microbes in such household wipes may lead to the undesired spreading of such microbes if the wipe is used subsequent to such microbial growth. [0006] Various odor control solutions include masking, i.e., covering the odor with a perfume, absorbing the odor already present in the bodily fluids and those generated after degradation, or preventing the formation of odors that are associated with microbial growth. Examples of approaches to controlling the generation of malodor by controlling microbial growth include U.S. Pat. No. 6,767,508, which teaches the use of nonwoven fabrics that have been treated with an alkyl polyglycoside surfactant solution to result in a heterogeneous system having antibacterial activity when in contact with an aqueous source of bacteria. As discussed in U.S. Pat. No. 6,855,134 the dominant offensive malodors arising from urine biotransformation and urine decomposition are sulfurous compounds and ammonia. [0007] An additional problem that is known to be associated with the use of some disposable absorbent articles, such as tampons, is that of specific bacteria producing harmful toxins. For example, toxic shock syndrome toxin (TSST) produced by Stapylococcus aureus can cause toxic shock syndrome (TSS) in non-immune humans. An increased incidence of TSS is associated with growth of S. aureus in the presence of tampons, such as those used in nasal packing or as catamenial devices. There is a need to provide a product that is effective at reducing these toxins that is also easily manufactured and preferably degradable following use. [0008] The use of biodegradable polymers has been described to reduce the amount of waste materials land-filled and the number of disposal sites. Biodegradable materials have adequate properties to permit them to break down when exposed to conditions which lead to composting. Examples of materials thought to be biodegradable include aliphatic polyesters such as poly(lactic acid), poly(glycolic acid), poly(caprolactone), copolymers of lactide and glycolide, poly(ethylene succinate), and combinations thereof. [0009] Degradation of aliphatic polyesters can occur through multiple mechanisms including hydrolysis, transesterification, chain scission, and the like. Instability of such polymers during processing can occur at elevated temperatures as described in WO 94/07941 (Gruber et. al.). [0010] The processing of aliphatic polyesters as microfibers has been described in U.S. Pat. No. 6,645,618. U.S. Pat. No. 6,111,160 (Gruber et. al.) discloses the use of melt stable polylactides to form nonwoven articles via melt blown and spunbound processes. [0011] Antimicrobial polymer compositions are known, as exemplified by U.S. Pat. Nos. 5,639,466 (Ford et. al.) and 6,756,428 (Denesuk). The addition of antimicrobial agents to hydrophilic polypropylene fibers having antimicrobial activity has been described in U.S. Patent Application Publication No. 2004/0241216 (Klun et. al.). These fibrous materials include nonwovens, wovens, knit webs, and knit batts. [0012] The synergistic effect of antimicrobial agents, such as fatty acid monoesters, and enhancers have been described in WO 00/71183 (Andrews et. al.) and U.S. Patent Application Publication 2005/0089539 (Scholz et. al.) both herein incorporated by reference. BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 illustrates a line graph of antimicrobial activity of Examples 10, 11 and 13 against S. aureus. [0014] FIG. 2 illustrates a bar graph of antimicrobial activity of Examples 9-13 against high numbers of Proteus mirabilis in the presence of artificial urine. [0015] FIG. 3 illustrates a bar graph of antimicrobial activity of Examples 11 and 13 against low numbers of P. mirabilis in the presence of artificial urine. [0016] FIG. 4 illustrates a bar graph of viable P. mirabilis recovered after odor testing of Examples 11-13 in the presence of artificial urine. [0017] FIG. 5 illustrates a bar graph of TSST production by S. aureus in the presence of extracts from Examples 9, 11 and 12. [0018] FIG. 6 illustrates a bar graph of TSST production by S. aureus in Example 12 compared to that in a standard tampon. DISCLOSURE OF INVENTION [0019] The present disclosure is directed to disposable absorbent articles formed with a degradable thermoplastic aliphatic polyester including an antimicrobial (preferably biocompatible) composition, which are preferably dry prior to use. The antimicrobial compositions, or components thereof, are used as melt additives in the melt-processable degradable thermoplastic aliphatic polyester polymer and includes an antimicrobial component and an enhancer. The melt-processable degradable aliphatic polyester with the included antimicrobial component and enhancer can be easily and directly formed into disposable absorbent articles without additional coating or loading steps greatly simplifying the manufacture of these disposable absorbent articles. The melt processed antimicrobial component and enhancer are stable prior to both the manufacture of the final disposable absorbent article and the ultimate end use providing extended antimicrobial activity. Further, when exposed to moisture when ultimately used the degradable aliphatic polyester at least partially degrades or hydrolyzes assisting in releasing the antimicrobial composition or component into the surrounding environment. [0020] For disposable absorbent articles of the present invention, that are disposable absorbent garments of the type that are composite structures including an absorbent assembly disposed between a liquid permeable bodyside liner and a liquid impermeable outer cover, the degradable thermoplastic aliphatic polyester polymer including an antimicrobial composition can preferably be in the form of a nonwoven material or loose fibers that are positioned within the absorbent assembly (e.g. distributed within the bulk of the absorbent), on the body facing side of the absorbent, or on the opposite side of the absorbent assembly. Alternately the degradable thermoplastic aliphatic polyester polymer including an antimicrobial composition can be formed into the liquid permeable bodyside liner. Alternately the degradable thermoplastic aliphatic polyester polymer including an antimicrobial composition can be formed into a film that can be positioned on the liquid impermeable outer cover side of the absorbent assembly, or the film can serve as the liquid impermeable outer cover of the disposable absorbent garment. [0021] When the disposable absorbent article of the present invention is a tampon the degradable thermoplastic aliphatic polyester polymer including an antimicrobial composition can be in the form of a nonwoven material or loose fibers that are positioned within the absorbent assembly or, when a nonwoven, it can serve as the fluid pervious outer wrap of the tampon. [0022] When the disposable absorbent articles of the present invention are a personal care or household wipe the substrate of the wipe can be made with, or incorporate, the aliphatic polyester with the included antimicrobial component and enhancer. For example the woven, knitted or nonwoven substrate can be made with a blend of fibers, one of which comprises the aliphatic polyester with the included antimicrobial component and enhancer. Generally the wipe would be formed from a nonwoven such as by carding or entanglement for one time or limited use applications. Alternatively aliphatic polyester fibers could be woven or knitted in whole or in part into a wipe product which could be used for longer periods. The inclusion of the antimicrobial component or composition into the degradable aliphatic polyester fibers gives the wipe extended antimicrobial activity over time. Additional fibers that could be blended in with the aliphatic polyesters include fibers to increase absorbency or other properties include fibers based on polyolefins, polyesters, acrylates, superabsorbent fibers, and natural fibers such as bamboo, soy bean, agave, coco, rayon, cellulosics, wood pulp or cotton. [0023] Nonwoven webs of the aliphatic polyester with the included antimicrobial component and enhancer can be prepared via any standard process for directly making nonwoven webs, including spunbond, blown microfiber and nanofiber processes. Additionally fibers or filaments can be prepared with the aliphatic polyester with the included antimicrobial component and enhancer and such fibers or filaments can be cut to desired lengths and further processed into nonwoven webs using various known web forming processes, such as carding. In such cases the chopped fibers may be blended with other fibers in the web forming process. Alternatively fibers or filaments prepared with the aliphatic polyester with the included antimicrobial component and enhancer could be woven or knitted alone or in combination with other fibers. [0024] In one aspect, the disposable absorbent article includes a melt formed aliphatic polyester composition comprising a thermoplastic aliphatic polyester; an antimicrobial component incorporated within the aliphatic polyester, in which the antimicrobial component is present at greater than 1 percent by weight of the aliphatic polyester; and an enhancer. The aliphatic polyester is in sufficient proportion to the antimicrobial component(s) with enhancers to yield an effective antimicrobial composition. The antimicrobial component(s) are selected from fatty acid esters of polyhydric alcohols, fatty ethers of polyhydric alcohols, hydroxy acid esters of fatty alcohols, alkoxylated derivatives thereof (having less than 5 moles of alkoxide group per mole of polyhydric alcohol) and combinations thereof. The enhancer provides for enhanced antimicrobial activity of the antimicrobial component(s) in the degradable aliphatic polyester composition. [0025] Exemplary preferred aliphatic polyesters are poly(lactic acid), poly(glycolic acid), poly(lactic-co-glycolic acid), blends, and copolymers thereof. The antimicrobial component may be selected from (C 7 -C 14 ) saturated fatty acid esters of a polyhydric alcohol or (C 8 -C 22 ) unsaturated fatty acid esters of a polyhydric alcohol such as propylene glycol monoesters and glycerol monoesters. Examples are propylene glycol monolaurate, propylene glycol monocaprylate, glycerol monolaurate, and combinations thereof. [0026] Inventive disposable absorbent articles include disposable diapers, adult incontinent articles or pads, feminine pads, sanitary napkins, catamenial tampons, dental tampons, medical tampons, surgical tampons, nasal tampons or wipes (such as personal cleansing or household wipes) that are preferably dry prior to use but are moist or wet in their end use environment. These disposable absorbent articles are formed using polymeric sheets, polymeric fibers, woven webs, knitted webs, nonwoven webs, porous membranes, polymeric foams, thermal or adhesive laminates, layered compositions, and combinations thereof made of the degradable aliphatic polyester polymer including an antimicrobial composition as described above. [0027] Desirably, antimicrobial components of the antimicrobial composition when wet are released into the surrounding medium in which microbes are to be controlled. The antimicrobial components are released as the aliphatic polyester degrades and/or swells when wet, giving the aliphatic polyester, in some measure, a self-disinfecting property. The degradation of the aliphatic polyester may be controlled to some extent to adjust the release characteristics of the antimicrobial component when exposed to moisture. The antimicrobial properties of the degradable aliphatic polyester polymer with the antimicrobial component(s) and enhancer also potentially delays the degradation of the degradable aliphatic polyester polymer or the disposable absorbent article until after use. Prior to use the degradable aliphatic polyester polymer composition is generally dry and the antimicrobial composition or component is in a generally stable form within the degradable aliphatic polyester polymer matrix. DETAILED DESCRIPTION OF INVENTION [0028] For the following defined terms, these definitions shall be applied, unless a different definition is given in the claims or elsewhere in the specification. [0029] The term “antimicrobial” or “antimicrobial activity” means having sufficient antimicrobial activity to kill pathogenic and non-pathogenic microorganisms including bacteria, fungi, algae and virus, prevent the growth/reproduction of pathogenic and non-pathogenic microorganisms or control the production of exoproteins, such as toxic shock syndrome toxin (TSST). [0030] The term “biodegradable” or “degradable” means degradable by the action of naturally occurring microorganisms such as bacteria, fungi and algae and/or natural environmental factors such as hydrolysis, transesterification, exposure to ultraviolet or visible light (photodegradable) and enzymatic mechanisms or combinations thereof. [0031] The term “biocompatible” means biologically compatible by not producing toxic, injurious or immunological responses in living tissue. Biocompatible materials may also be broken down by biochemical and/or hydrolytic processes and absorbed by living tissue. [0032] The term “sufficient amount” or “effective amount” means the amount of the antimicrobial component and/or enhancer when in a composition, as a whole, provides an antimicrobial (including, for example, antiviral, antibacterial, or antifungal) activity that reduces, prevents growth of, or eliminates colony forming units for one or more species of microorganisms such that an acceptable level of the organism results. [0033] The term “enhancer” means a component that enhances the effectiveness of the antimicrobial component such that when the composition without the enhancer is used separately, it does not provide the same level of antimicrobial activity as the composition including enhancer. The enhancement may be in speed of antimicrobial activity, extent of antimicrobial activity, greater spectrum of activity or combinations thereof. An enhancer in the absence of the antimicrobial component may not provide any appreciable antimicrobial activity. The enhancing effect may also not be seen for all microorganisms. [0034] The term “fatty” means a straight or branched chain alkyl or alkylene moiety having 6 to 22 (odd or even number) carbon atoms, unless otherwise specified. [0035] The recitation of numerical ranges by endpoints includes all numbers subsumed within that range. [0036] As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. [0037] Aliphatic polyesters useful in the present invention include homo- and copolymers of poly(hydroxyalkanoates) and homo- and copolymers of those aliphatic polyesters derived from the reaction product of one or more polyols with one or more polycarboxylic acids and is typically formed from the reaction product of one or more alkanediols with one or more alkanedicarboxylic acids (or acyl derivatives). Aliphatic polyesters may further be derived from multifunctional polyols, e.g. glycerin, sorbitol, pentaerythritol, and combinations thereof, to form branched, star, and graft homo- and copolymers. Miscible and immiscible blends of aliphatic polyesters with one or more additional semicrystalline or amorphous polymers may also be used. [0038] One useful class of aliphatic polyesters are poly(hydroxyalkanoates), derived by condensation or ring-opening polymerization of hydroxy acids, or derivatives thereof. Suitable poly(hydroxyalkanoates) may be represented by the formula: [0000] H(O—R—C(O)—) n OH, [0000] where R is an alkylene moiety that may be linear or branched having 1 to 20 carbon atoms, preferably 1 to 12 carbon atoms optionally substituted by catenary (bonded to carbon atoms in a carbon chain) oxygen atoms; n is a number such that the ester is polymeric, and is preferably a number such that the molecular weight of the aliphatic polyester is at least 10,000, preferably at least 30,000, and most preferably at least 50,000 daltons. Although higher molecular weight aliphatic polyester polymers generally yield films with better mechanical properties. It is a significant advantage of the present invention that the antimicrobial component in many embodiments plasticizes the aliphatic polyester component allowing for melt processing of higher molecular weight aliphatic polyester polymers. Thus, the molecular weight of the aliphatic polyester is typically less than 1,000,000, preferably less than 500,000, and most preferably less than 300,000 daltons. R may further comprise one or more caternary (i.e. in chain) ether oxygen atoms. Generally, the R group of the hydroxy acid is such that the pendant hydroxyl group is a primary or secondary hydroxyl group. [0039] Useful poly(hydroxyalkanoates) include, for example, homo- and copolymers of poly(3-hydroxybutyrate), poly(4-hydroxybutyrate), poly(3-hydroxyvalerate), poly(lactic acid) (also known as polylactide), poly(3-hydroxypropanoate), poly(4-hydropentanoate), poly(3-hydroxypentanoate), poly(3-hydroxyhexanoate), poly(3-hydroxyheptanoate), poly(3-hydroxyoctanoate), polydioxanone, polycaprolactone, and polyglycolic acid (i.e. polyglycolide). Copolymers of two or more of the above hydroxy acids may also be used, for example, poly(3-hydroxybutyrate-co-3-hydroxyvalerate), poly(lactate-co-3-hydroxypropanoate), poly(glycolide-co-p-dioxanone), and poly(lactic acid-co-glycolic acid). Blends of two or more of the poly(hydroxyalkanoates) may also be used, as well as blends with one or more semicrystalline or amorphous polymers and/or copolymers. [0040] The aliphatic polyester may be a block copolymer of poly(lactic acid-co-glycolic acid). Aliphatic polyesters useful in the degradable aliphatic polyester polymer compositions may include homopolymers, random copolymers, block copolymers, star-branched random copolymers, star-branched block copolymers, dendritic copolymers, hyperbranched copolymers, graft copolymers, and combinations thereof. [0041] Another useful class of aliphatic polyesters includes those aliphatic polyesters derived from the reaction product of one or more alkane diols with one or more alkanedicarboxylic acids (or acyl derivatives). Such aliphatic polyesters have the general formula: [0000] [0000] where R′ and R″ each represent an alkylene moiety that may be linear or branched having from 1 to 20 carbon atoms, preferably 1 to 12 carbon atoms, and m is a number such that the ester is polymeric, and is preferably a number such that the molecular weight of the aliphatic polyester is at least 10,000, preferably at least 30,000, and most preferably at least 50,000 daltons, but less than 1,000,000, preferably less than 500,000 and most preferably less than 300,000 daltons. Each n is independently 0 or 1, R′ and R″ may further comprise one or more caternary (i.e. in chain) ether oxygen atoms. [0042] Examples of aliphatic polyesters include those homo- and copolymers derived from (a) one or more of the following diacids (or derivative thereof): succinic acid, adipic acid, 1,12 dicarboxydodecane, fumaric acid, glutartic acid, diglycolic acid, and maleic acid; and (b) one of more of the following diols: ethylene glycol, polyethylene glycol, propanediols, butanediols, hexanediol, alkane diols having 5 to 12 carbon atoms, diethylene glycol, polyethylene glycols having a molecular weight of 300 to 10,000 daltons, preferably 400 to 8,000 daltons, propylene glycols having a molecular weight of 300 to 4000 daltons, block or random copolymers derived from ethylene oxide, propylene oxide, or butylene oxide, dipropylene glycol and polypropylene glycol, and (c) optionally a small amount, i.e. 0.5-7.0 mole % of a polyol with a functionality greater than two such as glycerol, neopentyl glycol, and pentaerythritol. [0043] Such polymers may include polybutylenesuccinate homopolymer, polybutylene adipate homopolymer, polybutyleneadipate-succinate copolymer, polyethylenesuccinate-adipate copolymer, polyethylene glycol succinate and polyethylene adipate homopolymer. [0044] Commercially available aliphatic polyesters include poly(lactide), poly(glycolide), poly(lactide-co-glycolide), poly(L-lactide-co-trimethylene carbonate), poly(dioxanone), poly(butylene succinate), and poly(butylene adipate). [0045] Useful aliphatic polyesters include those derived from semicrystalline polylactic acid. Poly(lactic acid) or polylactide has lactic acid as its principle degradation product. The aliphatic polyester polymer may be prepared by ring-opening polymerization of the lactic acid dimer, lactide. Lactic acid is optically active and the dimer appears in four different forms: L,L-lactide, D,D-lactide, D,L-lactide (meso lactide) and a racemic mixture of L,L- and D,D-. [0046] The polylactide preferably has a high enantiomeric ratio to maximize the intrinsic crystallinity of the aliphatic polyester polymer. The degree of crystallinity of a poly(lactic acid) is based on the regularity of the aliphatic polyester polymer backbone and the ability to crystallize with other aliphatic polyester polymer chains. If relatively small amounts of one enantiomer (such as D-) is copolymerized with the opposite enantiomer (such as L-) the aliphatic polyester polymer chain becomes irregularly shaped, and becomes less crystalline. If crystallinity is favored, it is desirable to have a poly(lactic acid) that is at least 85% of one isomer, at least 90%, or at least 95% in order to maximize the crystallinity. [0047] An approximately equimolar blend of D-polylactide and L-polylactide is also useful. This blend forms a unique crystal structure having a higher melting point (˜210° C.) than does either the D-poly(lactide) and L-(polylactide) alone (˜190° C.), and has improved thermal stability, see H. Tsuji et. al., Polymer, 40 (1999) 6699-6708. [0048] Copolymers, including block and random copolymers, of poly(lactic acid) with other aliphatic polyesters may also be used. Useful co-monomers include glycolide, beta-propiolactone, tetramethylglycolide, beta-butyrolactone, gamma-butyrolactone, pivalolactone, 2-hydroxybutyric acid, alpha-hydroxyisobutyric acid, alpha-hydroxyvaleric acid, alpha-hydroxyisovaleric acid, alpha-hydroxycaproic acid, alpha-hydroxyethylbutyric acid, alpha-hydroxyisocaproic acid, alpha-hydroxy-beta-methylvaleric acid, alpha-hydroxyoctanoic acid, alpha-hydroxydecanoic acid, alpha-hydroxymyristic acid, and alpha-hydroxystearic acid. [0049] Blends of poly(lactic acid) and one or more other aliphatic polyesters, or one or more other polymers may also be used. Examples of useful blends include poly(lactic acid) and poly(vinyl alcohol), polyethylene glycol/polysuccinate, polyethylene oxide, polycaprolactone and polyglycolide. [0050] The molecular weight of the degradable aliphatic polyester polymer should be chosen so that the aliphatic polyester polymer may be processed as a melt. For polylactide, for example, the molecular weight may be from about 10,000 to 1,000,000 daltons, and is preferably from about 30,000 to 300,000 daltons. By “melt-processable” it is meant that the degradable aliphatic polyesters are fluid or can be pumped or extruded at the temperatures used to process the articles (e.g. fibers, nonwovens or films) and do not degrade or gel at those temperatures to the extent that the physical properties are unusable for the intended disposable absorbent article. Materials used to form the invention absorbent disposable articles may be made into films by extrusion, casting, thermal pressing, and the like. The materials used to form the invention disposable absorbent articles can be made into fibers or nonwovens using melt processes such as spun bond, blown microfiber, melt spinning and the like. Certain embodiments also may be injection molded. Generally, weight average molecular weight (M w ) of the aliphatic polyester polymers is above the entanglement molecular weight, as determined by a log-log plot of viscosity versus number average molecular weight (M n ). Above the entanglement molecular weight, the slope of the plot is about 3.4, whereas the slope of lower molecular weight aliphatic polyester polymers is 1. [0051] The aliphatic polyester typically comprises at least 50 weight percent, preferably at least 60 weight percent, and most preferably at least 65 weight percent of the degradable aliphatic polyester polymer compositions. [0052] For melt processing, preferred antimicrobial components have low volatility and do not decompose appreciably under melt process conditions. The preferred antimicrobial components contain less than 2 wt. % water, and more preferably less than 0.10 wt. % (determined by Karl Fischer analysis). [0053] The antimicrobial component content in the degradable aliphatic polyester polymer composition (as it is ready-to-use) is typically at least 1 wt. %, 2 wt. %, 5 wt. %, 10 wt. % and sometimes greater than 15 wt. %. In certain embodiments, in which a low tensile strength is desired or acceptable, the antimicrobial component comprises greater than 20 wt. %, greater than 25 wt. %, or even greater than 30 wt. % of the degradable aliphatic polyester polymer composition. [0054] The antimicrobial component may include one or more fatty acid esters of a polyhydric alcohol, fatty ethers of a polyhydric alcohol, or alkoxylated derivatives thereof (of either or both of the ester and/or ether), or combinations thereof. More specifically, the antimicrobial component is selected from the group consisting of a (C 7 -C 14 ) saturated fatty acid ester of a polyhydric alcohol (preferably, a (C 8 -C 12 ) saturated fatty acid ester of a polyhydric alcohol), an (C 7 -C 22 ) unsaturated fatty acid ester of a polyhydric alcohol (preferably, an (C 8 -C 18 ) unsaturated fatty acid ester of a polyhydric alcohol), a (C 7 -C 22 ) saturated fatty ether of a polyhydric alcohol (preferably, a (C 7 -C 18 ) saturated fatty ether of a polyhydric alcohol), an (C 7 -C 22 ) unsaturated fatty ether of a polyhydric alcohol (preferably, an (C 8 -C 18 ) unsaturated fatty ether of a polyhydric alcohol), an alkoxylated derivative thereof, and combinations thereof. Preferably, the esters and ethers are monoesters and monoethers, unless they are esters and ethers of sucrose in which case they can be monoesters, diesters, monoethers, or diethers. Various combinations of monoesters, diesters, monoethers, and diethers can be used in a composition of the present invention. [0055] Preferably the (C 7 -C 14 ) saturated and (C 7 -C 22 ) unsaturated monoesters and monoethers of polyhydric alcohols are at least 80% pure (having 20% or less diester and/or triester or diether and/or triether), more preferably 85% pure, even more preferably 90% pure, most preferably 95% pure. Impure esters or ethers would not have sufficient, if any, antimicrobial activity. [0056] Useful fatty acid esters of a polyhydric alcohol may have the formula: [0000] (R 1 —C(O)—O) n —R 2 [0000] wherein R 1 is the residue of a (C 7 -C 14 ) saturated fatty acid (preferably, a (C 8 -C 12 ) saturated fatty acid), or a (C 7 -C 22 ) unsaturated (preferably, a C 8 -C 18 ) unsaturated, including polyunsaturated) fatty acid, R 2 is the residue of a polyhydric alcohol (typically and preferably, glycerin, propylene glycol, and sucrose, although a wide variety of others can be used including pentaerythritol, sorbitol, mannitol, xylitol, etc.), and n=1 or 2. The R 2 group includes at least one free hydroxyl group (preferably, residues of glycerin, propylene glycol, or sucrose). Preferred fatty acid esters of polyhydric alcohols are esters derived from C 8 , C 9 , C 10 , C 11 , and C 12 saturated fatty acids. For embodiments in which the polyhydric alcohol is glycerin or propylene glycol, n=1, although when it is sucrose, n=1 or 2. In general, monoglycerides derived from C 10 to C 12 fatty acids are food grade materials and GRAS materials. [0057] Fatty acid monoesters, such as glycerol monoesters of lauric, caprylic, capric, and heptanoic acid and/or propylene glycol monoesters of lauric, caprylic, capric and heptanoic acid, are active against Gram-positive bacteria, fungi, yeasts and lipid coated viruses but alone are not generally as effective against Gram-negative bacteria. When the fatty acid monoesters are combined with the enhancers described below, the composition can have greater efficacy against Gram-negative bacteria. [0058] Exemplary fatty acid monoesters include, but are not limited to, glycerol monoesters of lauric (monolaurin), caprylic (monocaprylin), and capric (monocaprin) acid, and propylene glycol monoesters of lauric, caprylic, and capric acid, as well as lauric, caprylic, and capric acid monoesters of sucrose. Other fatty acid monoesters include glycerin and propylene glycol monoesters of oleic (18:1), linoleic (18:2), linolenic (18:3), and arachonic (20:4) unsaturated (including polyunsaturated) fatty acids. 18:1, for example, means the compound has 18 carbon atoms and 1 carbon-carbon double bond. Preferred unsaturated chains have at least one unsaturated group in the cis isomer form. In certain preferred embodiments, the fatty acid monoesters that are suitable for use in the present composition include known monoesters of lauric, caprylic, and capric acid, such as that known as GML or the trade designation LAURICIDIN (the glycerol monoester of lauric acid commonly referred to as monolaurin or glycerol monolaurate), glycerol monocaprate, glycerol monocaprylate, propylene glycol monolaurate, propylene glycol monocaprate, propylene glycol monocaprylate, and combinations thereof. [0059] Exemplary fatty acid diesters of sucrose include, but are not limited to, lauric, caprylic, and capric diesters of sucrose as well as combinations thereof. [0060] A fatty ether of a polyhydric alcohol is preferably of the formula: [0000] (R—O) n —R 4 , [0000] wherein R 3 is a (C 7 -C 14 ) saturated aliphatic group (preferably, a (C 8 -C 12 ) saturated aliphatic group), or a (C 7 -C 22 ) unsaturated (preferably, (C 8 -C 18 ) unsaturated, including polyunsaturated) aliphatic group, R 4 is the residue of a polyhydric alcohol. Preferred polyhydric alcohols include glycerin, sucrose, or propylene glycol. For glycerin and propylene glycol n=1, and for sucrose n=1 or 2. Preferred fatty ethers are monoethers of (C 7 -C 14 ) alkyl groups (more preferably, (C 8 -C 12 ) alkyl groups). [0061] Exemplary fatty monoethers include, but are not limited to, laurylglyceryl ether, caprylglycerylether, caprylylglyceryl ether, laurylpropylene glycol ether, caprylpropyleneglycol ether, and caprylylpropyleneglycol ether. Other fatty monoethers include glycerin and propylene glycol monoethers of oleyl (18:1), linoleyl (18:2), linolenyl (18:3), and arachonyl (20:4) unsaturated and polyunsaturated fatty alcohols. In certain preferred embodiments, the fatty monoethers that are suitable for use in the present composition include laurylglyceryl ether, caprylglycerylether, caprylyl glyceryl ether, laurylpropylene glycol ether, caprylpropyleneglycol ether, caprylylpropyleneglycol ether, and combinations thereof. Unsaturated chains preferably have at least one unsaturated bond in the cis isomer form. [0062] The alkoxylated derivatives of the aforementioned fatty acid esters and fatty ethers (e.g., one which is ethoxylated and/or propoxylated on the remaining alcohol groups) also have antimicrobial activity as long as the total alkoxylate is kept relatively low. Preferred alkoxylation levels are disclosed in U.S. Pat. No. 5,208,257. If the esters and ethers are ethoxylated, total moles of ethylene oxide are preferably less than 5, more preferably less than 2. The fatty acid esters or fatty ethers of polyhydric alcohols can be alkoxylated, preferably ethoxylated and/or propoxylated, by conventional techniques. Alkoxylating compounds are preferably selected from the group consisting of ethylene oxide, propylene oxide, and mixtures thereof, and similar oxirane compounds. [0063] The degradable aliphatic polyester polymer compositions typically include a total amount of fatty acid esters, fatty ethers, alkoxylated fatty acid esters, or alkoxylated fatty ethers of at least 1 weight percent (wt. %), at least 2 wt. %, greater than 5 wt. %, at least 6 wt. %, at least 7 wt. %, at least 10 wt. %, at least 15 wt. %, or at least 20 wt. %, based on the total weight of the ready-to-use composition or the degradable thermoplastic aliphatic polyester composition. The term “ready-to-use” means the composition in its intended form for use and is generally the degradable thermoplastic aliphatic polyester composition. In a preferred embodiment, they are present in a total amount of no greater than 60 wt. %, no greater than 50 wt. %, no greater than 40 wt. %, or no greater than 35 wt. %, based on the total weight of the ready-to-use composition. Alternatively, these proportions may be considered relative to the aliphatic polyester (based on 100 parts by weight of the aliphatic polyester), i.e., no greater than 150 parts fatty acid ester, 100 parts fatty acid ester, 67 parts fatty acid ester and 54 parts fatty acid ester. Certain compositions may be higher in concentration if they are intended to be used as a “masterbatch” for additional processing. As used herein, the term, “masterbatch” refers to a concentrate that is added to a composition that is melt processed [0064] Degradable aliphatic polyester polymer compositions or antimicrobial compositions of the present invention that include one or more fatty acid monoesters, fatty monoethers, hydroxyl acid esters of alcohols or alkoxylated derivatives thereof can also include a small amount of a di- or tri-fatty acid ester (i.e., a fatty acid di- or tri-ester), a di- or tri-fatty ether (i.e., a fatty di- or tri-ether), or alkoxylated derivative thereof. Preferably, such components comprise no more than 10 wt. %, no more than 7 wt. %, no more than 6 wt. %, or no more than 5 wt. %, of the total weight of the antimicrobial component to preserve the antimicrobial efficacy of the antimicrobial component as discussed above. [0065] An additional class of antimicrobial component is a fatty alcohol ester of a hydroxyl functional carboxylic acid preferably of the formula: [0000] R 5 —O—(—C(O)—R 6 —O) n H, [0000] wherein R 5 is the residue of a (C 7 -C 14 ) saturated alkyl alcohol (preferably a (C 8 -C 12 ) saturated alkyl alcohol) or a (C 8 -C 22 ) unsaturated alcohol (including polyunsaturated alcohol), R 6 is the residue of a hydroxycarboxylic acid wherein the hydroxycarboxylic acid has the following formula: [0000] R 7 (CR 8 OH) p (CH 2 ) q COOH, [0000] wherein: R 7 and R 8 are each independently H or a (C 1 -C 8 ) saturated straight, branched, or cyclic alkyl group, a (C 6 -C 12 ) aryl group, or a (C 6 -C 12 ) aralkyl or alkaryl group wherein the alkyl groups are saturated straight, branched, or cyclic, wherein R 7 and R 8 may be optionally substituted with one or more carboxylic acid groups; p=1 or 2; and q=0-3; and n=1, 2, or 3. The R 6 group may include one or more free hydroxyl groups but preferably is free of hydroxyl groups. Preferred fatty alcohol esters of hydroxycarboxylic acids are esters derived from branched or straight chain C 8 , C 9 , C 10 , C 11 , or C 12 alkyl alcohols. The hydroxyacids typically have one hydroxyl group and one carboxylic acid group. [0066] In one aspect, the antimicrobial component includes a (C 7 -C 14 , preferably C 8 -C 12 ) saturated fatty alcohol monoester of a (C 2 -C 8 ) hydroxycarboxylic acid, a (C 8 -C 22 ) mono- or poly-unsaturated fatty alcohol monoester of a (C 2 -C 8 ) hydroxycarboxylic acid, an alkoxylated derivative of either of the foregoing, or combinations thereof. The hydroxycarboxylic acid moiety can include aliphatic and/or aromatic groups. For example, fatty alcohol esters of salicylic acid are possible. As used herein, a “fatty alcohol” is an alkyl or alkylene monofunctional alcohol having an even or odd number of carbon atoms. [0067] Exemplary fatty alcohol monoesters of hydroxycarboxylic acids include, but are not limited to, (C 8 -C 12 ) fatty alcohol esters of lactic acid such as octyl lactate, 2-ethylhexyl lactate (Purasolv EHL from Purac, Lincolnshire Ill., lauryl lactate (Chrystaphyl 98 from Chemic Laboratories, Canton Mass.), lauryl lactyl lacate, 2-ethylhexyl lactyl lactate; (C 8 -C 12 ) fatty alcohol esters of glycolic acid, lactic acid, 3-hydroxybutanoic acid, mandelic acid, gluconic acid, tartaric acid, and salicylic acid. [0068] The alkoxylated derivatives of the fatty alcohol esters of hydroxy functional carboxylic acids (e.g., one which is ethoxylated and/or propoxylated on the remaining alcohol groups) also have antimicrobial activity as long as the total alkoxylate is kept relatively low. The preferred alkoxylation level is less than 5 moles, and more preferably less than 2 moles, per mole of hydroxycarboxylic acid. [0069] The above antimicrobial components comprising an ester linkage are hydrolytically sensitive, and may be degraded by exposure to water, particularly at extreme pH levels (less than 4 or more than 10) or by certain bacteria that can enzymatically hydrolyze the ester to the corresponding acid and alcohol, which may be desirable in certain applications. For example, an article may be made to degrade rapidly by incorporating an antimicrobial component comprising at least one ester group. If extended persistence of the disposable article is desired such as for a multiple use household wipe, an antimicrobial component, free of hydrolytically sensitive groups, may be used. For example, the fatty monoethers are not hydrolytically sensitive under ordinary processing conditions, and are resistant to microbial attack. [0070] An optional additional component that can be included in the antimicrobial composition of the degradable aliphatic polyester polymer including an antimicrobial composition includes cationic amine antimicrobial compounds, which include antimicrobial protonated tertiary amines and small molecule quaternary ammonium compounds. [0071] Exemplary small molecule quaternary ammonium compounds include benzalkonium chloride and alkyl substituted derivatives thereof, di-long chain alkyl (C 8 -C 18 ) quaternary ammonium compounds, cetylpyridinium halides and their derivatives, benzethonium chloride and its alkyl substituted derivatives, octenidine and compatible combinations thereof. Suitable small molecule quarternary ammonium compounds, typically comprise one or more quaternary ammonium group having attached thereto at least one C 6 -C 18 linear or branched alkyl or aralkyl chain. Suitable compounds include those disclosed in Lea & Febiger, Chapter 13 in Block, S., Disinfection, Sterilization and Preservation, 4 th ed., 1991. Exemplary compounds within this class are: monoalkyltrimethylammonium salts, monoalkyldimethylbenzyl ammonium salts, dialkyldimethyl ammonium salts, benzethonium chloride, alkyl substituted benzethonium halides such as methylbenzethonium chloride and octenidine. Additional examples of quaternary ammonium antimicrobial components are: benzalkonium halides having an alkyl chain length of C 8 -C 18 , preferably C 12 -C 16 , more preferably a mixture of chain lengths, e.g., benzalkonium chloride comprising 40% C 12 alkyl chains, 50% C 14 alkyl chains, and 10% C 16 chains (available as Barquat MB-50 from Lonza Group Ltd.); benzalkonium halides substituted with alkyl groups on the phenyl ring (available as Barquat 4250); dimethyldialkylammonium halides having C 8 -C 18 alkyl groups, or mixtures of such compounds (available as Bardac 2050, 205M and 2250 from Lonza); and cetylpyridinium halides such as cetylpyridinium chloride (Cepacol Chloride available as Cepacol Chloride from Merrell Labs); benzethonium halides and alkyl substituted benzethonium halides (available as Hyamine 1622 and Hyamine 10× from Rohm and Haas). Useful protonated tertiary amines have at least one C 6 -C 18 alkyl group. When used the cationic antimicrobial components are typically added to the degradable aliphatic polyester polymer compositions at a concentration of at least 1.0 wt. %, preferably at least 3 wt. %, more preferably greater than 5.0 wt. %, still more preferably at least 6.0 wt. %, even more preferably at least 10 wt. % and most preferably at least 20.0 wt. %, in some cases exceeding 25 wt. %. Preferably, the concentration is less than 50 wt. %, more preferably less than 40 wt. %, and most preferably less than 35 wt. %. The cationic amine antimicrobial compounds can be added to the antimicrobial composition of the degradable aliphatic polyester polymer may be added to serve as preservatives and in some cases may enhance the antimicrobial activity of the degradable aliphatic polyester polymer including an antimicrobial composition. [0072] The degradable aliphatic polyester polymer compositions include an enhancer (preferably a synergist) to enhance the antimicrobial activity especially against Gram-negative bacteria, e.g. Escherichia coli and Pseudomonas sp. The enhancer component may include an alpha-hydroxy acid, a beta-hydroxy acid, other carboxylic acids, a (C 2 -C 6 ) saturated or unsaturated alkyl carboxylic acid, a (C 6 -C 16 ) aryl carboxylic acid, a (C 6 -C 16 ) aralkyl carboxylic acid, a (C 6 -C 12 ) alkaryl carboxylic acid, a phenolic compound (such as certain antioxidants and parabens), a (C 5 -C 10 ) monohydroxy alcohol, a chelating agent, a glycol ether (i.e., ether glycol), or oligomers that degrade to release one of the above enhancers. Examples of such oligomers are oligomers of glycolic acid, lactic acid or both having at least 4 or 6 repeat units. Various combinations of enhancers can be used if desired. [0073] The alpha-hydroxy acid, beta-hydroxy acid, and other carboxylic acid enhancers are preferably present in their protonated, free acid form. It is not necessary for all of the acidic enhancers to be present in the free acid form; however, the preferred concentrations listed below refer to the amount present in the free acid form. Additional, non-alpha hydroxy acid, betahydroxy acid or other carboxylic acid enhancers, may be added in order to acidify the formulation or buffer it at a pH to maintain antimicrobial activity. Preferably, acids are used having a pKa greater than about 2.5, preferably greater than about 3, and most preferably greater than about 3.5 in order to avoid hydrolyzing the aliphatic polyester component. Furthermore, chelator enhancers that include carboxylic acid groups are preferably present with at least one, and more preferably at least two, carboxylic acid groups in their free acid form. The concentrations given below assume this to be the case. The enhancers in the protonated acid form are believed to not only increase the antimicrobial efficacy, but to improve compatibility when incorporated into the aliphatic polyester component. [0074] One or more enhancers are used in the compositions of the present invention at a suitable level to produce the desired result. Enhancers are typically present in a total amount greater than 0.1 wt. %, preferably in an amount greater than 0.25 wt. %, more preferably in an amount greater than 0.5 wt. %, even more preferably in an amount greater than 1.0 wt. %, and most preferably in an amount greater than 1.5 wt. % based on the total weight of the ready-to-use degradable aliphatic polyester polymer composition. In a preferred embodiment, the enhancers are present in a total amount of no greater than 20 wt-%, or 15 wt-%, based on the total weight of the ready-to-use degradable aliphatic polyester polymer composition. Such concentrations typically apply to alpha-hydroxy acids, beta-hydroxy acids, other carboxylic acids, chelating agents, phenolics, ether glycols, and (C 5 -C 10 ) monohydroxy alcohols. [0075] The ratio of the enhancer component relative to the total concentration of the antimicrobial component is preferably within a range of 10:1 to 1:300, and more preferably 5:1 to 1:10, on a weight basis. [0076] An alpha-hydroxy acid type of enhancer is typically a compound of the formula: [0000] R 6 (CR 17 OH) n2 COOH [0000] wherein: R 16 and R 17 are each independently H or a (C 1 -C 8 ) alkyl group (straight, branched, or cyclic), a (C 6 -C 12 ) aryl, or a (C 6 -C 12 ) aralkyl or alkaryl group (wherein the alkyl group is straight, branched, or cyclic), R 16 and R 17 may be optionally substituted with one or more carboxylic acid groups; and n2=1-3, preferably, n2=1-2. [0077] Exemplary alpha-hydroxy acids include, but are not limited to, lactic acid, malic acid, citric acid, 2-hydroxybutanoic acid, mandelic acid, gluconic acid, glycolic acid, tartaric acid, alpha-hydroxyethanoic acid, ascorbic acid, alpha-hydroxyoctanoic acid, and hydroxycaprylic acid, as well as derivatives thereof (e.g., compounds substituted with hydroxyls, phenyl groups, hydroxyphenyl groups, alkyl groups, halogens, as well as combinations thereof). Preferred alpha-hydroxy acids include lactic acid, glycolic acid, malic acid, and mandelic acid. These acids may be in D, L, or DL form and may be present as free acid, lactone, or partial salts thereof. All such forms are encompassed by the term “acid.” Preferably, the acids are present in the free acid form. Other suitable alpha-hydroxy acids are described in U.S. Pat. No. 5,665,776 (Yu). [0078] A beta-hydroxy acid enhancer is typically a compound represented by the formula: [0000] [0000] wherein: R 18 , R 19 , and R 20 are each independently H or a (C 1 -C 8 )alkyl group (saturated straight, branched, or cyclic group), (C 6 -C 12 ) aryl, or (C 6 -C 12 ) aralkyl or alkaryl group (wherein the alkyl group is straight, branched, or cyclic), R 18 and R 19 may be optionally substituted with one or more carboxylic acid groups; m=0 or 1; n3=1-3 (preferably, n3=1-2); and R 21 is H, (C 1 -C 4 ) alkyl or a halogen. [0079] Exemplary beta-hydroxy acids include, but are not limited to, salicylic acid, beta-hydroxybutanoic acid, tropic acid, and trethocanic acid. In certain preferred embodiments, the beta-hydroxy acids useful in the compositions of the present invention are selected from the group consisting of salicylic acid, beta-hydroxybutanoic acid, and mixtures thereof. Other suitable beta-hydroxy acids are described in U.S. Pat. No. 5,665,776. [0080] One or more alpha or beta-hydroxy acid enhancers may be incorporated in the degradable aliphatic polyester polymer compositions, and/or applied to the surfaces of articles comprising the degradable aliphatic polyester polymer composition, in an amount to produce the desired result. They may be present in a total amount of at least 0.25 wt-%, at least 0.5 wt-%, and at least 1 wt-%, based on the total weight of the ready-to-use composition. They may be present in a total amount of no greater than 20 wt-%, no greater than 10 wt-%, or no greater than 5 wt-%, based on the total weight of the ready-to-use degradable aliphatic polyester polymer composition. [0081] The weight ratio of alpha or beta-hydroxy acid enhancer to total antimicrobial component is at most 50:1, at most 30:1, at most 20:1, at most 10:1, at most 5:1 or at most 1:1. The ratio of alpha-hydroxy acid enhancer to total antimicrobial component may be at least 1:120, at least 1:80, or at least 1:60. Preferably the ratio of alpha-hydroxy acid enhancer to total antimicrobial component is within a range of 1:60 to 4:1. [0082] In systems with low concentrations of water transesterification may be the principle route of loss of the fatty acid monoester and alkoxylated derivatives of these active ingredients and loss of carboxylic acid containing enhancers may occur due to esterification. Thus, certain alpha-hydroxy acids (AHA) and beta-hydroxy acids (BHA) are particularly preferred since these are believed to be less likely to transesterify the ester antimicrobial or other ester by reaction of the hydroxyl group of the AHA or BHA. For example, salicylic acid may be particularly preferred in certain formulations since the phenolic hydroxyl group is a much more acidic alcohol and thus much less likely to react. Other particularly preferred compounds in anhydrous or low-water content formulations include lactic, mandelic, malic, citric, tartaric, and glycolic acid. Benzoic acid and substituted benzoic acids that do not include a hydroxyl group, while not hydroxyl acids, are also preferred due to a reduced tendency to form ester groups. [0083] Carboxylic acids other than alpha- and beta-carboxylic acids are also suitable enhancers. They include alkyl, aryl, aralkyl, or alkaryl carboxylic acids typically having equal to or less than 12 carbon atoms. A preferred class of these can be represented by the following formula: [0000] R 22 (CR 23 2 ) n2 COOH [0000] wherein: R 22 and R 23 are each independently H or a (C 1 -C 4 ) alkyl group (which can be a straight, branched, or cyclic group), a (C 6 -C 12 ) aryl group, a (C 6 -C 12 ) group containing both aryl groups and alkyl groups (which can be a straight, branched, or cyclic group), R 22 and R 23 may be optionally substituted with one or more carboxylic acid groups; and n2=0-3, preferably, n2=0-2. The carboxylic acid may be a (C 2 -C 6 ) alkyl carboxylic acid, a (C 6 -C 16 ) aralkyl carboxylic acid, or a (C 6 -C 16 ) alkaryl carboxylic acid. Exemplary acids include, but are not limited to propionic acid, sorbic acid, benzoic acid, benzylic acid, and nonylbenzoic acid. [0084] One or more such carboxylic acids may be used in the compositions of the present invention in amounts sufficient to produce the desired result in generally the same amounts as discussed above for the alpha or beta-hydroxy acids based on the total weight of the ready-to-use composition. [0085] A chelating agent (i.e., chelator) is typically an organic compound capable of multiple coordination sites with a metal ion in solution. Typically these chelating agents are polyanionic compounds and coordinate best with polyvalent metal ions. Exemplary chelating agents include, but are not limited to, ethylene diamine tetraacetic acid (EDTA) and salts thereof (e.g., EDTA(Na) 2 , EDTA(Na) 4 , EDTA(Ca), EDTA(K) 2 ), sodium acid pyrophosphate, acidic sodium hexametaphosphate, adipic acid, succinic acid, polyphosphoric acid, sodium acid pyrophosphate, sodium hexametaphosphate, acidified sodium hexametaphosphate, nitrilotris(methylenephosphonic acid), diethylenetriaminepentaacetic acid, 1-hydroxyethylene, 1,1-diphosphonic acid, and diethylenetriaminepenta-(methylenephosphonic acid). Certain carboxylic acids, particularly the alpha-hydroxy acids and beta-hydroxy acids, can also function as chelators, e.g., malic acid and tartaric acid. [0086] Also included as chelators are compounds highly specific for binding ferrous and/or ferric ion such as siderophores, and iron binding proteins. Iron binding protein include, for example, lactoferrin, and transferrin. Siderophores include, for example, enterochlin, enterobactin, vibriobactin, anguibactin, pyochelin, pyoverdin, and aerobactin. [0087] In certain embodiments, the chelating agents useful in the compositions of the present invention include those selected from the group consisting of ethylenediaminetetraacetic acid and salts thereof, succinic acid, and mixtures thereof. Preferably, either the free acid or the mono- or di-salt form of EDTA is used. [0088] One or more chelating agents may be used in the compositions of the present invention at a suitable level to produce the desired result. They may be used in amounts similar to the carboxylic acids described above. [0089] The ratio of the total concentration of chelating agents (other than alpha- or beta-hydroxy acids) to the total concentration of the antimicrobial component is preferably within a range of 10:1 to 1:100, and more preferably 1:1 to 1:10, on a weight basis. [0090] A phenolic compound enhancer is typically a compound having the following general structure: [0000] [0000] wherein: m is 0 to 3 (especially 1 to 3), n is 1 to 3 (especially 1 to 2), each R 24 independently is alkyl or alkenyl of up to 12 carbon atoms (especially up to 8 carbon atoms) optionally substituted with O in or on the chain (e.g., as a carbonyl group) or OH on the chain, and each R 25 independently is H or alkyl or alkenyl of up to 8 carbon atoms (especially up to 6 carbon atoms) optionally substituted with O in or on the chain (e.g., as a carbonyl group) or OH on the chain, but if R 25 is H, n preferably is 1 or 2. [0091] Examples of phenolic enhancers include, but are not limited to, butylated hydroxy anisole, e.g., 3(2)-tert-butyl-4-methoxyphenol (BHA), 2,6-di-tert-butyl-4-methylphenol (BHT), 3,5-di-tert-butyl-4-hydroxybenzylphenol, 2,6-di-tert-4-hexylphenol, 2,6-di-tert-4-octylphenol, 2,6-di-tert-4-decylphenol, 2,6-di-tert-butyl-4-ethylphenol, 2,6-di-tert-4-butylphenol, 2,5-di-tert-butylphenol, 3,5-di-tert-butylphenol, 4,6-di-tert-butyl-resorcinol, methyl paraben (4-hydroxybenzoic acid methyl ester), ethyl paraben, propyl paraben, butyl paraben, 2-phenoxyethanol, as well as combinations thereof. One group of the phenolic compounds is the phenol species having the general structure shown above where R 25 is H and where R 24 is alkyl or alkenyl of up to 8 carbon atoms, and n is 0, 1, 2, or 3, especially where at least one R 24 is butyl and particularly tert-butyl, and especially the non-toxic members thereof being preferred. Some of the phenolic synergists are BHA, BHT, methyl paraben, ethyl paraben, propyl paraben, and butyl paraben as well as combinations of these. [0092] An additional enhancer is a monohydroxy alcohol having 5-10 carbon atoms, including C 5 -C 10 monohydroxy alcohols (e.g., octanol and decanol). In certain embodiments, alcohols useful in the compositions of the present invention are selected from the group n-pentanol, 2 pentanol, n-hexanol, 2 methylpentyl alcohol, n-octanol, 2-ethylhexyl alcohol, decanol, and mixtures thereof. [0093] An additional enhancer is an ether glycol. Exemplary ether glycols include those of the formula: [0000] R—O—(CH 2 CHR″″O) n (CH 2 CHR′O)H, [0000] wherein R═H, a (C 1 -C 8 ) alkyl, or a (C 6 -C 12 ) aralkyl or alkaryl; and each R′ is independently ═H, methyl, or ethyl; and n=0-5, preferably 1-3. Examples include 2-phenoxyethanol, dipropylene glycol, triethylene glycol, the line of products available under the trade designation DOWANOL DB (di(ethylene glycol) butyl ether), DOWANOL DPM (di(propylene glycol)monomethyl ether), and DOWANOL TPnB (tri(propylene glycol) monobutyl ether), as well as many others available from Dow Chemical Company, Midland Mich. [0094] Oligomers that release an enhancer may be prepared by a number of methods. For example, oligomers may be prepared from alpha hydroxy acids, beta hydroxy acids, or mixtures thereof by standard esterification techniques. Typically, these oligomers have at least two hydroxy acid units, preferably at least 10 hydroxy acid units, and most preferably at least 50 hydroxy acid units. For example, a copolymer of lactic acid and glycolic acid may be prepared as shown in the Examples section. [0095] Alternatively, oligomers of (C 2 -C 6 ) dicarboxylic acids and diols may be prepared by standard esterification techniques. These oligomers preferably have at least 2 dicarboxylic acid units, preferably at least 10 dicarboxylic acid units. [0096] The enhancer releasing oligomeric polyesters used typically have a weight average molecular weight of less than 10,000 daltons and preferably less than 8,000 daltons. [0097] These oligomeric polyesters may be hydrolyzed. Hydrolysis can be accelerated by an acidic or basic environment, for example at a pH less than 5 or greater than 8. The oligomers may be degraded enzymatically by enzymes present in the composition or in the environment in which it is used, for example from mammalian tissue or from microorganisms in the environment. [0098] Compositions of the present invention can include one or more surfactants to promote compatibility of the degradable aliphatic polyester polymer compositions and to help wet the surface and/or to aid in contacting and controlling or killing microorganisms or preventing toxin production. As used herein the term “surfactant” means an amphiphile (a molecule possessing both polar and nonpolar regions which are covalently bound) capable of reducing the surface tension of water and/or the interfacial tension between water and an immiscible liquid. The term is meant to include soaps, detergents, emulsifiers, surface active agents, and the like. The surfactant can be cationic, anionic, nonionic, or amphoteric. A variety of conventional surfactants may be used; however, it may be important in selecting a surfactant to determine that it is compatible with the finished degradable aliphatic polyester polymer compositions and does not inhibit the antimicrobial activity of the antimicrobial composition. One skilled in the art can determine compatibility of a surfactant by making the formulation and testing for antimicrobial activity as described in the Examples herein. Combinations of various surfactants can be used. Preferred surfactants are selected from the surfactants based on sulfates, sulfonates, phosphonates, phosphates, poloxamers, alkyl lactates, carboxylates, cationic surfactants, and combinations thereof and more preferably is selected from (C 8 -C 22 ) alkyl sulfate salts, di(C 8 -C 18 )sulfosuccinate salts, C 8 -C 22 alkyl sarconsinate, and combinations thereof. [0099] One or more surfactants may be used in and/or on the degradable aliphatic polyester polymer compositions of the present invention at a suitable level to produce the desired result. In some embodiments, when used in the composition, they are present in a total amount of between about 0.1 wt. % to about 20 wt-%, based on the total weight of the degradable aliphatic polyester polymer composition. [0100] Additionally, the compositions may further comprise organic and inorganic fillers. These materials may help to control the degradation rate of the aliphatic polyester polymer composition. For example, many calcium salts and phosphate salts may be suitable. Exemplary fillers include calcium carbonate, calcium sulfate, calcium phosphate, calcium sodium phosphates, calcium potassium phosphates, tetracalcium phosphate, .alpha.-tricalcium phosphate, beta-tricalcium phosphate, calcium phosphate apatite, octacalcium phosphate, dicalcium phosphate, calcium carbonate, calcium oxide, calcium hydroxide, calcium sulfate dihydrate, calcium sulfate hemihydrate, calcium fluoride, calcium citrate, magnesium oxide, and magnesium hydroxide. Particularly suitable filler is tribasic calcium phosphate (hydroxy apatite). [0101] Disposable absorbent articles comprising the invention degradable aliphatic polyester polymer composition may be made by processes known in the art for making these products using sheet, webs or fibers formed from the invention degradable aliphatic polyester polymer composition. These degradable aliphatic polyester polymer compositions are used to form webs and the like that are directly formed into disposable absorbent articles without special treatments or converting processes. The degradable aliphatic polyester polymer composition webs or fibers prior to use are dry and in a stable form and remain so until in the end use environment. By dry it is meant that there is no significant added moisture and it is in equilibrium with its environment. Generally the disposable absorbent articles would be packaged in a dry environment with no added moisture and would not be exposed to moisture until opened and used by the end use consumer. When in the end use environment, upon absorption of a fluid or exposure to moisture, the antimicrobial activity of the degradable aliphatic polyester polymer composition webs or fibers is expressed and the degradable aliphatic polyester polymer composition starts or accelerates decomposition. This decomposition continues after disposal following use. [0102] The degradable aliphatic polyester polymer compositions are particularly suitable for use in feminine tampons due to their unique combination of properties. For example, the antimicrobial compositions as described herein are particularly effective in reducing toxic shock syndrome toxin (TSST) at levels that do not necessarily kill bacteria. This allows the article to be used without killing potentially helpful bacteria but still providing protection against TSST. This is usually done at a lower loading levels of the antimicrobial composition and/or enhancer component. [0103] The invention degradable aliphatic polyester polymer compositions have also been found to significantly reduce unpleasant odors and as such are useful in wipes or disposable absorbent garments where there is often odor generated, such as by conversion of urea to ammonia by Proteus mirabilis . The invention degradable aliphatic polyester polymer compositions also can be used to reduce microbial activity on the skin when in contact for extended periods of time. These applications are usually done at a higher loading level of the antimicrobial composition or component. The invention degradable aliphatic polyester polymer compositions can be used as an absorbent fibrous material or as additive fibers in an absorbent material or as a cover web or film adjacent an absorbent material, or as a cover web that is in contact with the skin. These uses include a topsheet for a diaper, a bed pad or a feminine pad. In these uses the invention degradable aliphatic polyester polymer compositions could be formed into a spunbond web or like nonwoven and used in a body contacting environment. In this case the loading levels should be sufficient to kill or inhibit bacterial growth over an extended period of time. The invention degradable aliphatic polyester polymer compositions when used as, in or adjacent an absorbent core can have relative high loading levels of the antimicrobial compositions to kill microbes to inhibit odor production. [0104] Non-woven webs and sheets comprising the inventive compositions can also have good tensile strength, which is particularly important with wipe applications; and can have high surface energy to allow wettability and fluid absorbency. Additional melt additives (e.g., fluorochemical melt additive) can be added to the degradable aliphatic polyester polymer composition to decrease surface energy (increase the contact angle) and impart repellency. When repellency is desired the contact angle measured on a flat film using the half angle technique is preferably greater than 70 degrees, preferably greater than 80 degrees and most preferably greater than 90 degrees. [0105] The rate of release of antimicrobial components from the aliphatic polyester may be affected by incorporation of plasticizers, surfactants, emulsifiers, enhancers, humectants, wetting agents as well as other components. Suitable humectants and/or wetting agents may include polyhydric alcohols such as polypropylene glycol and polyethylene glycol. [0106] The level of antimicrobial activity in a given use environment is related to the finished composition, including the weight percents of the antimicrobial component and the enhancer, as well as the presence and weight percent of additional components such as surfactants and wetting agents. The level of antimicrobial activity is also related to the amount of the invention degradable thermoplastic aliphatic polyester material that is present in the disposable absorbent articles as well as where and how the material is incorporated into the disposable article. An additional aspect potentially impacting the level of antimicrobial activity is the total surface area of the degradable thermoplastic aliphatic polyester within the disposable absorbent article. Thus one way to increase the antimicrobial activity as a given weight of degradable thermoplastic aliphatic polyester material within a disposable absorbent article is to use nonwovens or fibers with a smaller fiber diameters, and thus more surface area per unit weight. [0107] In a preferred embodiment the articles of the present invention are kept dry until use. This protects the aliphatic polyester from potential degradation as well as any antimicrobial ester that may be present from hydrolytic degradation. The amount of moisture present is preferably low. Typically, the amount of water in the packaged article prior to use is less than 10% by weight, preferably less than 8% by weight and usually less than 5% by weight. Packaging may be used that protects the article from absorbing moisture in humid environments. For example, the articles may be packaged with a protective film of polyolefin, polyester (e.g. polyethylene terephalate, polyethylene naphthylate etc.), fluoropolymers (e.g. Aclar available from Allied Signal Morristown, Pa.), PVDC, PVC, ceramic barrier coated films, as well as laminates and blends thereof. [0108] In one process for making the inventive antimicrobial composition, the aliphatic polyester in a melt form is mixed in a sufficient amount relative to the antimicrobial component to yield an aliphatic polyester polymer composition having measurable antimicrobial activity. An enhancer and optionally a surfactant can be added to the melt of the aliphatic polyester polymer composition and/or coated on the surface of an article comprising the degradable aliphatic polyester polymer composition to enhance the antimicrobial component. [0109] A variety of equipment and techniques are known in the art for melt processing aliphatic polyester polymeric compositions. Such equipment and techniques are disclosed, for example, in U.S. Pat. No. 3,565,985 (Schrenk et al.), U.S. Pat. No. 5,427,842 (Bland et. al.), U.S. Pat. Nos. 5,589,122 and 5,599,602 (Leonard), and U.S. Pat. No. 5,660,922 (Henidge et al.). Examples of melt processing equipment include, but are not limited to, extruders (single and twin screw), Banbury mixers, and Brabender extruders for melt processing the degradable aliphatic polyester polymer composition. To maximize the antimicrobial activity of any given degradable thermoplastic aliphatic polyester composition at a given weight of inclusion in a disposable absorbent article it may be desirable to use fibers with very small fiber diameters, such as micro or nanofibers. Methods of producing nanofibers with thermoplastic materials are known, for example as taught in U.S. Pat. Nos. 4,536,361, 6,382,526, and 6,695,992. It is also known to make polylactic acid based micro and nanofibers, and nonwoven webs of such fibers, using various methods, e.g. as taught in U.S. Patent Application 2006/0084340 A1. Thus for some disposable absorbent articles of the present invention it may be preferred to make the article with nonwovens and/or fibers of degradable thermoplastic aliphatic polyester composition wherein the fiber diameter is about 1 micron or preferably less. [0110] The ingredients of the degradable thermoplastic aliphatic polyester composition may be mixed in and conveyed through an extruder to yield a material having measurable antimicrobial activity, preferably without polymer degradation or side reactions in the melt. The processing temperature is sufficient to mix the biodegradable aliphatic polyester and antimicrobial component, and allow extruding the composition as a film, nonwoven or fiber. Potential degradation reactions include transesterification, hydrolysis, chain scission and radical chain decomposition, and process conditions should minimize such reactions. [0111] The invention will be further clarified by the following examples which are exemplary and not intended to limit the scope of the invention. EXAMPLES Examples 1 and 2 [0112] Samples were prepared using a batch Brabender mixing apparatus in which pelletized polylactic acid (PLA polymer obtained from NatureWorks LLC as Polymer 4032 D and 4060 D) was added to the Brabender mixer and blended at 180° C. until the mixing torque stabilized. The other ingredients were then added to the mixer, and the total composition was blended until it appeared homogeneous. The mixture was then pressed into sheets using a hydraulic press the platens of which were at the 177° C. Samples of the sheets were tested for microbial activity using Japanese Industrial Standard test number Z 2801: 2000 using a Gram-positive bacteria ( Staphylococcus aureus ATCC #6538) and a Gram-negative bacteria ( Pseudomonas aeruginosa ATCC #9027). The same test was performed on a control sheet of polylactic acid without the added ingredients. The data from this testing is presented in Table 1 below. Antimicrobial Testing of Film Samples: [0113] The following test protocol, adapted from JIS Z2801 (Japanese Industrial Standard—Test for Antimicrobial Activity), was used to assess antimicrobial properties of extruded or pressed films. Approximately 4 cm×4 cm squares of test material were wiped with isopropanol or 70% ethanol and placed into sterile Petri dishes. Duplicate test samples were each inoculated with 0.4 mL of challenge organisms ( Staphlyococcus aureus ATCC #6538 or Pseudomonas aeruginosa ATCC #9027 diluted 1:5000 from overnight cultures into 0.2% TSB). 2 cm×2 cm squares of polyester film were then placed onto the inoculum. Samples were then incubated 18-24 h at 37° C. in 80% relative humidity or higher. After incubation, test samples were removed from the Petri dishes and each transferred into 10 mL sterile Difco Dey Engley Neutralizing Broth (NB). The tubes containing the NB and test material were placed into an ultrasonic bath for 60 s then mixed for 60 s to release the bacteria from the materials into the NB. Viable bacteria were then enumerated by diluting the NB into phosphate-buffered saline (PBS), plating onto TSB agar, incubating plates at 37° C. for 24-48 h, and counting colony forming units (CFUs). Sensitivity limit for this test method was deemed to be 100 CFU/sample. [0000] TABLE 1 Microbe Count (cfu/ml) PML P. S. Sample PLA (g) (ml) BA (g) DOSS (g) aeruginosa aureus PLA - 55 0 0 0  >10 7  >10 5 Control 1 (4032D) Example 1 55 5 1 1 <100 <100 (4060D) Example 2 55 9 1 0 <100 <100 (4032D) PML means propyleneglycol monolaurate antimicrobial component, obtained from Abitec Corp., as Capmul PG12. BA means benzoic acid enhancer DOSS means dioctylsulfosuccinate sodium salt surfactant. PLA 4032D is semicrystalline polylactic acid from Natureworks LLC. PLA 4060D is amorphous polylactic acid from Natureworks LLC. [0114] The above data show the broad-spectrum efficacy of the degradable aliphatic polyester polymer composition in sheet form in killing both a Gram-positive and a Gram-negative bacteria. Preparation of Oligomeric Lactic Acid Enhancer and Master Batches: [0115] An oligomeric enhancer was used in Examples 3-14 and was prepared using the following procedure. A glass reactor (ambient pressure) was filled with equal parts of an 85% lactic acid aqueous solution (City Chemicals) and a 70% glycolic acid aqueous solution (Sigma-Aldrich). The water boiled was boiled away leaving the acid monomers. Reactor temperature was then increased to 163° C. initiating a condensation polymerization of the lactic and glycolic acids. Reaction was allowed to proceed for 24 hours resulting in a random copolymer or oligomer of the two acids with a molecular weight of 1,000-8,000 M w for one batch and 700-1,000 M w for another batch. [0116] Pre-compounded pellets, used in Examples 3-14 were prepared with a Werner Pfleiderer ZSK-25 twin screw extruder. The extruder had ten zones, each having a barrel section with a channel for circulating heat transfer fluid, and all but the first (feed) section having heating elements. The screw configurations were helical conveying screw sections, except that kneading sections were used in the second half of zone 2, first half of zone 3, all of zone 5, first half of zone 6, all of zone 8 and the first half of zone 9. Extruder vent plugs at zones 5 and 9 were plugged. Pellets of polylactic acid PLA 625 ID (Natureworks LLC) were added to the first zone of the extruder at a rate of 3.6 kg/hr. Antimicrobial fatty acid monoester was pumped into the fourth zone of the extruder using a Dynatec S-05 model grid-melter at a rate of 0.5 kg/hr. The grid-melter used a gear pump to meter liquid monoester through transfer tubing into the extruder. The pump and tubing were operated at room temperature when using propylene glycol monolaurate and at 70° C. when using glycerol monolaurate. The oligomeric enhancer described above was heated to 120° C. in a heated tank and gravity fed to a metering pump which delivered it to zone 7 of the extruder at a rate of 0.5 kg/hr. A metering pump was employed at the discharge of the extruder to feed a strand die having a 6.35 mm diameter opening. The extruded strand was cooled in an 2.4 meter long water trough (with continuously fed tap water) and then, at the outlet of the water bath, pelletized using a Conair pelletizer into approximately 6.35 mm length pellets. The extruder screw speed was maintained at 100 RPM and the following barrel temperature profile was used: zone 1-160° C.; zone 2-200° C.; zone 3-177° C.; zones 4 through 9-160° C. The metering pump was electrically heated and adjustable to a temperature set point, set at 177° C., and pump speed was adjusted manually to maintain a pressure of approximately 70-140 N/cm 2 (100-200 lbs/in 2 ) to the inlet of the melt pump. [0117] Three masterbatches were prepared having the compositions listed below. The pellets were dried in a forced air resin drier with frequent stirring to prevent agglomeration of the pellets. [0000] Masterbatch #1: 80% PLA 6251D, 10% glycerol monolaurate (GML) & 10% oligomeric enhancer (OLGA). Masterbatch #2: 80% PLA 6251 D, 10% propyleneglycol monolaurate (PML) & 10% oligomeric enhancer (OLGA). Masterbatch #3: 90% PLA 6251 D & 10% glycerol monolaurate (GML). Examples 3-5 [0118] Blown microfiber nonwoven webs were produced from the masterbatches described above using conventional melt blowing equipment. A 31 mm (screw diameter) conical twin screw extruder (C.W. Brabender Instruments) was used to feed a positive displacement gear pump which was used to meter and pressurize the aliphatic polyester polymer melt. A 25 cm wide drilled orifice melt-blowing die with 8 orifices per cm of width was used. Each orifice was 0.38 mm in diameter. Extruder temperature was 185° C., die temperature was 180° C., air heater temperature was 200° C., and air manifold pressure was 103 kPa. Total polymer flow rate through the die was approximately 3.6 kg/hr. A control sample, Control 2 was prepared containing no enhancer or antimicrobial component. A control sample, Control 3, was also prepared containing no enhancer but having an antimicrobial component. For samples having lower than 10% enhancer or antimicrobial additive, additional virgin PLA resin was added to the masterbatch. Characteristics of the nonwoven webs are shown in Table 2 below. [0000] TABLE 2 Basis Web Effective Fiber % wt Weight thickness Diameter* Sample % wt GML OLGA (g/m 2 ) (mm) (μm) Control 2 0 0 92 1.7 22.8 Control 3 10 0 95 1.3 20.7 Example 3 10 10 107 0.7 10.7 Example 4 5 5 94 1.1 14.9 Example 5 2.5 2.5 95 1.4 20.1 *Effective Fiber Diameter (in micrometers) was calculated as described by Davies, C. N., “The Separation of Airborne Dust and Particles”, Institution of Mechanical Engineers, London Proceedings 1B, 1952. Examples 6-8 [0119] Blown microfiber nonwoven webs were produced as in Examples 3-5 except propyleneglycol monolaurate (PML) was used as the antimicrobial component. Characteristics of the nonwoven webs are shown in Table 3 below. [0000] TABLE 3 Basis Web Effective Fiber % wt Weight thickness Diameter* Sample % wt PML OLGA (g/m 2 ) (mm) (μm) Example 6 10 10 103 0.8 12.5 Example 7 5 5 95 1.1 15.4 Example 8 2.5 2.5 94 1.1 14.9 [0120] Examples 3-5 and Control 2 and Control 3 were tested for tensile strength and stiffness properties. Peak force tensile strength was measured using an INSTRON Model 5544 universal tensile testing machine using a crosshead speed of 25.4 cm/min with a gauge length of 5.1 cm. The specimen dimensions were 10.2 cm in length. Machine (MD) and cross (CD) directions of the nonwoven webs were tested. The percent elongation of the specimen at peak force was recorded. Ten replicates were tested and averaged for each sample web. Results are shown below in Table 4. [0121] Stiffness properties of the webs were measured using a Gurley bending resistance tester model 4151E (Gurley Precision Instruments). 3.8 cm long by 2.5 cm wide specimens were cut from the webs, the long direction being in the machine direction of the web. Each specimen was tested by deflecting the specimen in both the MD and CD and calculating the average of both directions of the pendulum deflections. The tester was used to convert the pendulum deflection measurements and machine settings to Gurley stiffness readings in milligrams. Ten replicates were tested and averaged for each sample web. Results are shown below in Table 4. [0000] TABLE 4 Peak Force Peak Force MD (g/cm Elongation CD (g/cm Elongation Stiffness Sample width) MD (%) width) CD (%) (mg) Control 2 66 15.8 93 102.3 126 Control 3 120 11.4 129 90.1 100 Example 3 813 6.8 620 7.8 507 Example 4 377 2.8 375 75.8 346 Example 5 193 15.3 188 81.5 113 [0000] TABLE 5 (AATCC 100-2004 Antibacterial testing using Staphlyococcus aureus ) Sample CFU/ml CFU/sample t = 0 80000 1600000 Control 2 42000 840000 Control 3 <200 <200 Example 3 <200 <200 Example 4 <200 <200 Example 5 230 4600 [0000] TABLE 6 (AATCC 100-2004 Antibacterial testing using Pseudomonas aeruginosa ) Sample CFU/ml CFU/sample t = 0 34000 680000 Control 2 2600000 52000000 Control 3 2200 44000 Example 3 <200 <200 Example 4 <200 <200 Example 5 330000 6600000 [0000] TABLE 7 (Log Reduction vs. t = 0), summary of results presented in Table 5 and 6 Sample Staphlyococcus aureus Pseudomonas aeruginosa Control 2 0.5 −1.6 Control 3 3.9 1.2 Example 3 3.9 3.5 Example 4 3.9 3.5 Example 5 2.5 −1.0 Table 7 was calculated by taking the log of the quotient of the time-zero CFU/sample count by the final CFU/sample count. [0000] TABLE 8 (AATCC 100-2004 Antibacterial testing using Staphlyococcus aureus ) Sample CFU/ml CFU/sample t = 0 130000 2600000 Control 2 42000 840000 Example 6 <200 <200 Example 7 <200 <200 Example 8 15 300 [0000] TABLE 9 (AATCC 100-2004 Antibacterial testing using Pseudomonas aeruginosa ) Sample CFU/ml CFU/sample t = 0 70000 1400000 Control 2 2600000 52000000 Example 6 <200 <200 Example 7 <200 <200 Example 8 25 500 [0000] TABLE 10 (Log Reduction vs t = 0), summary of results presented in Tables 8 and 9 Sample Staphlyococcus aureus Pseudomonas aeruginosa Control 2 0.5 −1.6 Example 6 4.1 3.8 Example 7 4.1 3.8 Example 8 3.9 3.4 [0122] Table 10 was calculated by taking the log of the quotient of the time-zero CFU/sample count by the final CFU/sample count. [0123] The results presented in Tables 5-10 demonstrate the broad-spectrum efficacy of example compositions against both a Gram-positive and a Gram-negative bacteria. Examples 9-13 [0124] Spunbond nonwoven examples were prepared using masterbatch prepared as described above blended with neat PLA to prepare examples 9-13. The compositions of these masterbatches were: 20% PML in PLA, 30% OLGA In PLA, and 10% PEG 400 in PLA. The PLA used to make these masterbatches was PLA 6202D and the percentages reported are weight percentages of the component in the masterbatch composition. The OLGA used was prepared as described above and had a molecular weight (M w ) of about 1000. [0125] These examples were prepared with PLA 6202D resin obtained from NatureWorks, LLC. Propylene glycol monolaurate trade name Capmul PG-12 was obtained from ABITEC Corporation. Master-batches of the PLA and the additives were compounded using the procedure described above for the masterbatches used for Examples 3-8. All the materials were dried prior to use. The spunbond nonwovens were obtained using a 2.0 inch single screw extruder to feed a die. The die had a total of 512 orifice holes with a aliphatic polyester polymer melt throughput of 0.50 g/hole/min (33.83 lb/hr). The die had a transverse length of 7.875 inches (200 mm). The hole diameter was 0.040 inch (0.889 mm) and L/D ratio of 6. The melt extrusion temperature of the neat PLA was set at 215° C., while the melt extrusion temperature of PLA with the additives was dependent on the amount of additives: Example 9 (185° C.), Examples 10-12 (175° C.), and Example 13 (162° C.). [0126] The compositions of the spunbond nonwoven examples prepared are described in Table 11. In addition to the examples including propylene glycolmonolaurate as the antimicrobial component of the antimicrobial composition and OLGA as the enhancer component one example also included polyethylene glycol as a wetting agent, Also a control example spunbond nonwoven, Control 4, was prepared comprising only PLA, Some physical properties of the examples of Table 11 are described in Table 12. [0000] TABLE 11 Spunbond nonwoven samples PLA Weight PML OLGA Wetting Agent/ Sample Percent Weight Percent Weight Percent Weight Percent Control 4 100% 0% 0% 0% Example 9 90% 5% 5% 0% Example 10 85% 5% 10% 0% Example 11 83% 5% 10% 2% Example 12 80% 5% 15% 0% Example 13 75% 5% 20% 0% The wetting agent used in Example 11 was polyethylene glycol 400 [0000] TABLE 12 Physical characteristic of spunbond nonwoven samples Fiber Basis Weight Diameter* Sample (g/m2) (μm) Control 4 50 15.0 Example 9 50 13.3 Example 10 50 14.4 Example 11 50 11.2 Example 12 50 10.5 Example 13 50 12.4 *measurement of 10 fibers at 200 x Antimicrobial and Odor Reduction Testing for Spunbond Nonwoven Examples Time-Kill Method: [0127] The following test protocol, adapted from AATCC 100-2004 (Assessment of Antibacterial Finishes on Textile Materials), was used to assess antimicrobial properties of the nonwoven webs. Approximately 4×4 cm squares of test material were placed into sterile Petri dishes. Duplicate test samples were each inoculated with 1 ml of challenge organisms ( Staphlyococcus aureus ATCC #6538 or Pseudomonas aeruginosa ATCC #9027 diluted 1:5000 from overnight cultures into 0.2% [v/v] tryptic soy broth (TSB) or Proteus mirabilis ATCC #14153 diluted 1:5000 into artificial urine [Sarangapani et al., J. Biomedical Mat. Research 29:1185]). Samples were then incubated 18-24 h at 37° C. in 80% relative humidity or higher. After incubation, test samples were removed from the Petri dishes and each transferred into 20 mL sterile Difco Dey Engley Neutralizing Broth (NB). The tubes containing the NB and test material were placed into an ultrasonic bath for 60 s then mixed for 60 s to release the bacteria from the materials into the NB. Viable bacteria were then enumerated by diluting the NB into phosphate-buffered saline (PBS), plating onto TSB agar, incubating plates at 37° C. for 24-48 h, and counting colony forming units (CFUs). Sensitivity limit for this test method was 200 CFU/sample. Odor Control Testing Method: [0128] Overnight culture of Proteus mirabilus ATCC #14153 was diluted 1:50,000 into artificial urine (prepared according to Sarangapani et al., J. Biomedical Mat. Research 29:1185) with 5% [v/v] TSB to achieve a cell concentration of approximately 10 6 per mL. 5 mL of this inoculum was pipetted onto approximately 1 g non-woven materials in 100 mL Pyrex jars. The bottles were sealed and incubated for 24 h at 37° C. Four people were asked to briefly open the jars under their noses and smell for ammonia odor. In some experiments, samples were inoculated with a more dilute suspension of bacteria, approximately 10 3 per mL. In some experiments, bovine serum albumin (BSA) was added to 1% in the artificial urine to determine material efficacy in the presence of additional protein. In some experiments, remaining viable bacteria in the samples were measured by adding 50 mL NB to the samples which were then ultrasonically mixed in a water bath for 10 min. Dilutions of these samples were plated out on TSB agar, incubated overnight at 37° C. and CFUs counted. TSST-1 Inhibition: Nonwoven Extracts [0129] 4.5 g of indicated nonwoven examples were incubated approximately 24 h in 100 mL PBS at 37° C. w/shaking to obtain an extract. Brain-heart infusion (BHI, Difco) was added to the extracts to achieve final concentration of 1×BHI. These extracts with BHI were sterile filtered using a 0.2 μm pore size membrane. Five mL of the extracts with BHI were inoculated with an overnight culture of TSST-producing S. aureus strain FRI1169 diluted 1:500. After incubation with shaking at 37° C. for 24 h, cultures were centrifuged at 3200×g for 10 min to remove cells and the supernatant tested for TSST according to the Toxin Technology (Sarasota, Fla.) TSST EIA kit directions. TSST Inhibition: Tampon Sac Method [0130] The following test protocol was adapted from the tampon sac method described by Reiser et al. (J. Clin. Microbiol. 25:1450). Dry test materials were added to rinsed dialysis membrane (Spectra/Por, 10,000 molecular weight cut-off, 32 mm width) and immersed in approximately 50° C. molten 1% brain-heart infusion (BHI) agar. The membranes had been inoculated with 100 μl of an overnight culture of TSST-producing S. aureus strain FRI1169 diluted to approximately 10 6 cells per mL. Weights of test material equivalent to commercially available tampon weight were used. After 24 h incubation, samples were removed, their weight gain measured, and were placed into a zip-loc bag and sterile phosphate-buffered saline added to bring total weight gain up to 4× that of the dry weight. Fluid was extracted by kneading the test material in the zip-loc bag for approximately one minute. The resulting extract was diluted and plated for viable count and TSST was quantified according to the Toxin Technology TSST EIA kit directions. [0131] FIG. 1 shows antimicrobial activity of Examples 10, 11 and 13 against Staphlyococcus aureus using method AATCC 100. The time-kill curves exemplify the tunable nature of the antimicrobial polymer system. The ratio of the antimicrobial composition components can be adjusted to slowly reduce viable microorganisms over time or to quickly reduce the number of viable organisms to undetectable levels. The values represent averages from duplicate samples. [0132] FIG. 2 shows the viable P. mirabilis recovered from Examples 9-13 after 24 hours when challenged with high numbers of the organism in the presence of artificial urine using modified method AATCC 100. The data illustrate that the composition of the antimicrobial polymer can be tuned to either inhibit growth without significantly reducing the number of viable microorganisms or to kill microorganisms even when challenged with relatively high numbers of microorganisms (approximately 10 6 CFU/sample). Whereas Control 4 and Examples 9 and 10 allowed growth of P. mirabilis as compared to the initial inoculum (t=0), Examples 11 and 12 inhibited growth, and Example 13 reduced viable P. mirabilis to undetectable levels. The values represent averages from duplicate samples. [0133] FIG. 3 shows the viable P. mirabilis recovered from Examples 11 and 13 after 24 hours when challenged with low numbers of the organism in the presence of artificial urine using modified method AATCC 100. The data illustrate that the composition of the antimicrobial polymer can also be tuned to either inhibit growth or to kill microorganisms when challenged with a low inoculum of organisms (approximately 10 3 CFU/sample). Whereas Control 4 allowed growth of P. mirabilis as compared to the initial inoculum, Example 11 inhibited growth and Example 13 reduced viable P. mirabilis to undetectable levels. [0134] FIG. 4 shows the viable P. mirabilis recovered after odor testing of Examples 11-13 in the presence of artificial urine are reduced when exposed to certain ratios of the antimicrobial composition components. The reduced number of viable bacteria recovered from Examples 12 and 13 correlates with the lack of odor in these samples (Table 13). [0135] FIG. 5 shows TSST production by S. aureus incubated in the presence of extracts from material examples adjusted for toxin production per optical density unit and expressed as a percentage of TSST produced in a control culture with no added extract. The data demonstrate that TSST production is reduced when S. aureus cultures are grown in the presence of extracts from antimicrobial polymer examples. The ratio of the antimicrobial composition components can be adjusted such that toxin production is nearly eliminated as compared to a control S. aureus culture containing no extract from the antimicrobial polymers. There was little effect of the extracts on growth of the S. aureus cultures, with less than two-fold difference in optical density among all cultures shown (data not shown). [0136] FIG. 6 shows reduced TSST production by S. aureus in Example 12 compared to a standard tampon when tested using the tampon sac method. Values are normalized to TSST produced in Example 12 and are averages of three replicates. [0000] TABLE 13 Odor Testing Results High Inoculum Low Inoculum High Inoculum + Sample (10 6 ) (10 3 ) BSA Control 4 + + + Example 9 − Example 10 − Example 11 + − Example 12 − − Example 13 − [0137] The results in Table 13 demonstrate the efficacy of the material examples in controlling odor using the described method (+ indicating strong odor and − indicating little or now odor). This efficacy is maintained even in the presence of higher protein concentrations (such as BSA) that may neutralize other antimicrobial chemistries. A higher ratio of the antimicrobial composition to the overall polymer composition may be required to control high numbers of organisms, while lower ratios may be sufficient to control lower numbers of organisms. Examples 14 [0138] Antimicrobial extruded films were produced using the following procedure. The co-rotating twin screw extruder, used to compound masterbatch pellets described above, was used to melt, blend and feed the aliphatic polyester polymer and additives. The screw sections were set up with kneading blocks at zones 2, 4 and 6. The extruder had 9 temperature controllable barrel zones, with an input port for dry pellets at zone 1 and liquid injection ports at zones 3 and 5. A weight loss gravimetric feeder (K-tron) was used to feed dry pellets at zone 1. 4032D semicrystalline polylactic acid (PLA) (Natureworks LLC) pellets were first dried overnight at 60° C. in a resin dryer. A grid-melter, (Dynatec) was used to melt and feed propylene glycol monolaurate (PML), (Capmul PG-12, Abitec), into zone 3 of the extruder. A metering pump (Zenith pump), was used to feed enhancer (OLGA) into zone 5 of the extruder. The enhancer was gravity fed from a heated pot directly above the pump. The melt from the extruder was fed to a metering pump, and then into a 15.24 cm wide coat-hanger die. The extrudate was extruded horizontally onto a 15.24 cm diameter temperature controlled roll. The resulting web was pulled around the roll at a 270° wrap angle. The web was then wrapped around a second 15.2 cm diameter temperature controlled roll at a 180° wrap. The web was then pulled with a nip and wrapped onto a core. Film caliper was measured with a micrometer to the nearest 2.5 microns. Film caliper was maintained to +/−15 microns using die adjustment bolts. The compositions of the films are shown below in Table 14. [0000] TABLE 14 Sample PLA % PML % OLGA % Control 5 100 0 0 Example 14 80 10 10 Control 6 90 10 0 Control 7 90 0 10 Example 15 [0139] Extruded films were prepared as in Examples 14 except polycaprolactone (PCL, type FB 100, Solvay Chemicals) was used as the base aliphatic polyester polymer. The compositions of the films are shown below in Table 15. [0000] TABLE 15 Sample PCL % PML % OLGA % Control 8 100 0 0 Example 15 90 5 5 [0140] Antimicrobial properties of the extruded films are shown in Tables 16, 17 and 18 below. [0000] TABLE 16 (Antibacterial testing using Staphlyococcus aureus ) Sample CFU/ml CFU/sample t = 0 39000 390000 Control 5 4950 49500 Example 14 <100 <100 Control 6 1150 11500 Control 7 4500 45000 Control 8 490000 4900000 Example 15 0 0 Values of 0 in Tables 16-17 indicate results below the detection limit of the test: approximately 100 CFU/sample. [0141] These results show that the addition of the PML without enhancer (Control 6) reduces the Gram-positive bacteria counts over the control (Control 5). The addition of OLGA without antimicrobial component had little antimicrobial effect (Control 7). However, the addition of both PML and OLGA (Examples 14 and 15, produced a composition with exceptional antimicrobial activity, reducing the viable bacteria to levels below detection. [0000] TABLE 17 (Antibacterial testing using Pseudomonas aeruginosa ) Sample CFU/ml CFU/sample t = 0 72000 720000 Control 5 1650000 16500000 Example 14 <100 <100 Control 6 8000000 80000000 Control 7 1262500 12625000 Control 8 3700000 37000000 Example 15 <100 <100 [0142] These results show that the addition of the PML without enhancer (Control 6) did not reduce Gram-negative bacteria counts over the control (Control 5). The addition, of OLGA without antimicrobial component had little antimicrobial effect (Control 7). However, the addition of both PML and OLGA (Examples 14 and 15) produced a composition with exceptional antimicrobial activity, reducing the viable bacteria to levels below detection. [0000] TABLE 18 (Log reduction versus t = 0), summary of results from Tables 16 and 17 Sample Staphlyococcus aureus Pseudomonas aeruginosa Control 5 −0.1 −1.4 Example 14 3.6 3.9 Control 6 1.5 −2.0 Control 7 0.9 −1.2 Control 8 −1.1 −1.7 Example 15 3.6 3.9 [0143] Table 18 was calculated by taking the log-base-10 of the quotient of the time-zero CFU/sample count by the final CFU/sample count. [0144] While certain representative embodiments and details have been discussed above for purposes of illustrating the invention, various modifications may be made in this invention without departing from its true scope, which is indicated by the following claims.
Disposable absorbent articles comprising an absorbent material and a degradable thermoplastic polymer composition comprising an aliphatic polyester and an antimicrobial composition. The antimicrobial composition includes an antimicrobial component and an enhancer component. The aliphatic polyester and antimicrobial composition are formed into webs by melt extrusion, such as nonwovens and films, that are incorporated into disposable absorbent articles, such as disposable infant diapers, adult incontinence articles, feminine hygiene articles such as sanitary napkins, panty liners and tampons, personal care wipes and household wipes to provide odor control, control of microbial growth, and control of microbial toxin production.
8
FIELD OF THE INVENTION [0001] The present invention relates to a device for power factor correction and electrical wide band filtering in electrical systems. BACKGROUND OF THE INVENTION [0002] Filtering out undesired harmonic frequencies and reducing high frequency voltages from the current in power systems is advantageous in order to reduce damage or improper operation of electrical equipment connected to the power system. In closed electrical systems, such as on board fishing ships, such disturbances cause increased use of oil to produce the desired amount of energy, which is followed by heat generation in all the electricity system and wear on the system it self and the electrical equipment connected to the system. [0003] U.S. Pat. No. 3,555,291 discloses a harmonic filter for an AC power system, designed for converter installations, having of a plurality of conventional LC shunt filters tuned to the expected harmonic frequencies. U.S. Pat. No. 3,555,291 uses damping to diminish the effects of parallel resonance and this system can also contain static capacitors for power factor correction. This system further comprises an additional filter, being a LC filter with a resistor connected in parallel with the inductance, which is tuned to provide damping at the harmonic frequency at which parallel resonance may occur. The resistor in this setup provides damping and therefore reducing the amplitude of oscillations under parallel resonant conditions. SUMMARY OF THE INVENTION [0004] It is an object of the present invention to provide an improved device and method. [0005] The object of the invention is achieved by the features of the claims and/or the following aspects of the present invention. [0006] In particular, it is a preferred advantage of the present invention to provide a device for reducing considerably voltages and current of frequencies higher than 110 Hz on power systems rated for 10 Hz to 60 Hz and/or to improve power factor. [0007] In particular, the electric correction unit and the method for reducing voltages and current of undesired frequencies of the present invention improves power factor by injecting reactive power into the system. A preferred embodiment of the device (in the following also labelled as electric correction unit) of the present invention provides a combination of inductors and capacitors in such a manner that a low pass filter is connected in series with a band-stop filter unit, which also acts as power factor correction unit, an the electric correction unit is connected to the system in parallel to the load. [0008] The electric correction unit reduces voltages of undesired frequencies carried on the carrier frequency and thereby reduces heat-formation in the power system. As the band-stop filter unit is serially connected behind/after the low pass filter, the high frequencies are drawn into the low pass filter and eliminated there, whereas the distortion in the lower frequency range is corrected or eliminated in the band-stop filter unit. The band-stop filter unit draws fifth harmonic frequencies towards it and the voltages of undesired frequencies are carried on the fifth harmonic. As the band-stop filter unit is serially connected behind/after the low pass filter, the high frequencies are pulled into the low pass filter and eliminated there. The band-stop filter unit of the present invention is designed such that the capacitors are connected in a delta connection and inductor units (reactors) are connected in a star (Y or Wye) connection. [0009] The band-stop filter unit is preferably loaded with the tuned frequency (frequencies) that shall be reduced, e.g. 250 Hz on a system rated 50 Hz. In this case the 250 Hz current is a carrier for voltages of higher frequencies, e.g., from 10 3 Hz to 10 10 Hz that are preferably considerably reduced in the low pass filter. [0010] In a first aspect of the present invention an electric correction unit is provided for an electrical system. The electric correction unit comprises a low pass filter and a band-stop filter unit, where the band-stop filter unit is serially connected to the low pass filter and the electric correction unit is connected in parallel with load on the system. [0011] In a second aspect of the present invention a method is provided for reducing voltages of undesired frequencies and improving power factor in power systems, the method comprising placing an electric correction unit adjacent to a major load in the system, the electric correction unit comprises a low pass filter and a band-stop filter unit. The band-stop filter unit is serially connected to the low pass filter and the unit is connected in parallel with load on the system. [0012] The operating frequency of combined filter is preferably 110 Hz to 10 10 Hz, preferably from 110 to 10 9 Hz, or from 250 to 10 8 Hz, or from 110 to 10 8 Hz, or from 250 to 10 9 Hz, or from 110 to 10 7 Hz, where the operating frequency of the reactive power unit preferably ranges from 10 Hz to 400 Hz, depending on the rated frequency of the power system. [0013] In an embodiment of the present invention the electric correction unit, which may also acts as band-stop filter unit is detuned closed to the frequencies that shall be eliminated, e.g. close to 250 Hz in case of 5 th harmonic (for a system rated 50 Hz). [0014] In an embodiment of the present invention the operating frequency of the low pass filter assembly is preferably from 10 3 to 10 1 ° Hz, preferably from 10 4 to 10 9 Hz, or from 10 4 to 10 8 Hz, or from 10 3 to 10 8 Hz, or from 10 4 to 10 9 Hz, or from 10 3 to 10 7 Hz. [0015] In an embodiment of the present invention the operating frequency of the band-stop filter unit is preferably from Hz from 110 to 910 Hz, or from 110 to 810 Hz, or from 110 to 740, or from 310 to 710 Hz, from 410 to 610 Hz. or from 110 to 310 Hz. [0016] In a specific embodiment of the present invention the operating frequency of the one or more band-stop filter unit is that it passes through frequencies in the range from 180 to 290 Hz, such as 180 to 240 Hz for a system with operating frequency of 50 Hz and preferably 210 Hz or 230 to 290 Hz for a system with operating frequency of 60 Hz and preferably 260 Hz. [0017] In a specific embodiment of the present invention the electric correction unit is operating in a 10 to 800 Hz power system, such as in a 10 to 400 Hz power system, or 10 to 200 Hz power system, or 10 to 60 Hz power system, such as 50 Hz power system or a 60 Hz power system. [0018] In an embodiment of the present invention the rated voltage can range from 100 V to 750 kV and the rated current can range from 1 A to 100 kA. [0019] In a specific embodiment of the present invention the low pass filter used in the assembly of the electric correction unit is a 3-line EMC filter of the series B84143B* S020 . . . . S024 obtainable from EPCOS AG. [0020] In an embodiment of the present invention the electric correction unit relates to a device for conditioning the power system. In the present context the term “conditioning” refers to filtering out voltages of undesired frequencies, improving the power factor or correcting the power factor in the system. [0021] In an embodiment of the present invention the electric correction unit is installed in a closed electrical system such as a fishing vessel. Devices such as winches for pulling fishing nets use an enormous amount of electricity and therefore increase the use of oil, which is used for generating electricity for the vessel. When winces and other electricity demanding devices are in use, disturbances in the form of low and high frequency voltages are being generated in the system. The electric correction unit is installed close to an electricity demanding device, such as a winch, in order to prevent distribution of reducing voltages and current of undesired frequencies throughout the system. [0022] In the present context the term “low pass filter” or “low pass filter unit” refers to a filter that passes low-frequency signals but attenuates, or reduces the amplitude of signals with frequencies within the bandwidth of the filter (but attenuates, or reduces the amplitude of signals with frequencies) being higher than the cut-off frequency for said filter. The actual amount of attenuation for each frequency varies from filter to filter. Furthermore, a low-pass filter assembly refers to a plurality of low-pass filters, which are identical, i.e. having the same bandwidth and same lower and upper cut-off frequencies. [0023] In the present context the term “band-stop filter unit” refers to an assembly of reactors (inductor units) and capacitors in a three-phase system (see FIG. 3 ), where the capacitors are connected in a delta connection and inductor units (reactors) are connected in a star (Y or Wye) connection. The band-stop filter unit attenuates, or reduces the amplitude of signals with frequencies within the operating frequency of the filter. DESCRIPTION OF THE DRAWINGS [0024] The present invention will now be disclosed in reference to the drawings illustrating the specific embodiments of the invention. The specific embodiments disclosed herein should not be limiting to the invention as described in the claims and the description. [0025] FIG. 1 is a schematic diagram of a power system according to an embodiment of the present invention where the electrical correction unit is connected in parallel with load on the system. [0026] FIG. 2 is a schematic drawing of a prior art low pass filter used in the device of the present invention. [0027] FIG. 3 is a schematic drawing of band-stop filter unit according to one embodiment the present invention. [0028] FIG. 4 is a schematic drawing of the electrical correction unit of the present invention [0029] FIG. 5 shows the current load, under variable load condition, with and without the correction unit. [0030] FIG. 6 shows actual power, under variable load condition, with and without the correction unit. [0031] FIG. 7 shows the voltage, under variable load condition, with and without the correction unit. [0032] FIG. 8 shows current disturbance in percentage, under variable load condition, with and without the correction unit. [0033] FIG. 9 shows voltage disturbance in percentage, under variable load condition, with and without the correction unit. [0034] FIG. 10 shows current, power, and frequency disturbance, under normal load condition, with and without the correction unit. [0035] FIG. 11 shows kvar, kVA, and the percentage of disturbance of kVA and frequency, under normal load condition, with and without the correction unit. [0036] FIG. 12 shows percentage of disturbance of, under normal load condition, with and without correction unit. [0037] FIG. 13 shows percentage of disturbance of, under normal load condition, with and without correction unit. [0038] FIG. 14 shows system frequency, and WW, under normal load condition, with and without correction unit. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0039] FIG. 1 shows a schematic diagram of a power system 1 in a ship having a generator 2 , which generates voltages at a 50 Hz or 60 Hz frequency for winches 4 , and other devices 5 , 6 , and 12 which depend on electricity. The system shown in FIG. 1 also comprises an AC/DC converter 7 . The electrical correction unit 8 comprises a low pass filter assembly 9 and a band-stop filter unit 10 . The low pass filter 9 is connected in parallel to the load as shown in FIG. 1 . The band-stop filter unit 10 that also acts as power factor correction unit, is connected in series with the low pass filter 9 . [0040] FIG. 2 is a schematic drawing of one of many suitable commercially of the shelf available high frequency EMC filter units. A suitable EMC filter unit from EPCOS© was select for the particular system setup and test will be elaborated on in this section. Other test systems with different configuration have also been tested. [0041] FIG. 3 is a schematic drawing of band-stop filter unit according to an embodiment of the present invention with a capacitor connected behind each inductor unit. The band-stop filter unit is designed with the tuned frequency (frequencies) that shall be reduced, e.g. 250 Hz on a system rated 50 Hz. In this case the 250 Hz is the carrier frequency for voltages of higher frequencies, from 10 3 Hz to 10 10 Hz that are considerably reduced in the low pass filter. As can be seen in FIG. 3 the capacitors are connected in a delta connection and inductor units (reactors) are connected in a star connection. The calculation for the size of the reactor units depends on the frequency and the voltage of the system. [0042] FIG. 4 is a schematic drawing of an electrical correction unit according to a preferred embodiment having three low pass filter units ( 9 ( 1 ), 9 ( 2 ), 9 ( 3 ) and six band-stop filter units ( 10 ( 1 )- 10 ( 6 ). The third set of low pass filter unit 9 ( 3 ) and band-stop filter units ( 10 ( 5 )- 10 ( 6 ) are shown as broken lines as an alternative embodiment. Each low pass filter unit and band-stop filter unit are connected to all lines in the three-phase electrical system (L 1 -L 3 ) as shown in FIGS. 2 and 3 . Under different conditions where based on the load on the system one or more low pass filter units 9 are switched on as well as two band-stop filter units 10 . A computer is connected to all the units and switches on the additional band-stop filter units when the load on the system increases. [0043] In the following examples, variable high load situations will now be discussed with reference to FIGS. 5-9 . Generally, when the winches haul in the fishing gear, the generator load varies considerably. One of the reasons for this is the vertical motion of the ship, caused by rough seas. The performance of the electrical correction unit was tested in these conditions, as is shown in the following text. The first half of each plot in FIGS. 5-9 demonstrates the electrical system operation when the electrical correction unit is switched ON and the second half of the plot with the correction unit switched OFF. [0044] The system phase current is shown in FIG. 5 and the power load in FIG. 6 . In the first half, when the correction unit is ON, it can be seen that the ampere load fluctuates at about 400 A and in accordance with the power load. In the second half, the current rises to about 700 A and is not in accordance with the power load. This stems from the fact that the generator is hyper magnetized and the voltage regulator is not functioning properly because of high frequency interference, as shown in FIG. 7 . [0045] FIG. 8 shows the Total Harmonic Distortion (THD) of the current sinusoidal wave form. When the correction unit is switched ON, the THD level of the current wave form ranges between 15-25% and varies in accordance with the ampere load of FIG. 5 . Once the correction unit is switched OFF, the THD level of the wave form rises to about 30% and fluctuates slightly, because of limited fluctuation in the ampere load. [0046] FIG. 9 shows the THD of the voltage sinusoidal wave form. Again, when the correction unit is switched ON, the THD level of the curve is relatively small, i.e. around 6-7%, and varies in accordance with the voltage of FIG. 7 . When the correction unit is switched OFF the THD of the voltage wave form rises to approximately 13%. [0047] Similarly, FIGS. 10-14 show the system of the same fishing vessel under low load with and without the electrical correction unit switched ON. In all the figures the horizontal axis shows time in 10 minute intervals. In FIG. 10 the vertical axis shows the current [A], the active power [KW] and power factor. During the first 20 minutes the electrical correction unit is ON. The current is quite stable around 110 A as is the power load of 57 KW. The power factor is also fairly good, around 0.75. Then, when the electrical correction unit is switched OFF at 7:38, the system enters an unbalanced state with a lot of interference and the power factor goes down to 0.3, which is far too low. FIG. 11 shows reactive power, apparent power, phase current symmetry and phase voltage symmetry. The plot shows how the correction unit reduces reactive power and stabilizes the system. [0048] FIG. 12 shows the THD percentage level of the phase currents during the same period. With the correction unit ON, the THD in each phase current is approximately 5%, while it rises to 14-16% with the correction unit switched OFF. [0049] FIG. 13 similarly shows the THD percentage level of the phase voltage. With the correction unit on the THD level is approximately 4% and without the correction unit it is approximately 10%. [0050] The electrical system frequency is the first plot of FIG. 14 . The frequency is clearly very stable at 50.5 Hz with the correction unit switched ON. Once the correction unit is switched OFF the frequency starts fluctuating. The two other plots show the active power in 5 th and the 11 th Harmonic Frequency. Attention should be drawn to the fact that when the correction unit is switched ON, almost no power is in harmonic frequencies, but when the unit is switched OFF; power is clearly detected in these harmonic frequencies. [0051] High frequency distortion in electrical systems is largely caused by AC/DC converters and many other devices. The most common solution to eliminate these high frequency distortions is to filter them out and convert them to heat. The uniqueness of the design of the electrical correction unit is not to convert these distortions to heat but to remove them through a process of elimination. [0052] One of the main advantages of the electrical correction unit is that it significantly corrects the Power Factor (PF) of the electrical system. By correcting the PF, the phase lag between voltage and current is eliminated. This will be demonstrated in Table 1, here below, and it can also be seen in FIG. 10 . The table reflects the same power reading, when the correction unit is switched OFF, but the current rises significantly from 270 A to 640 A and the PF drops from about 0.87 to 0.35. [0000] TABLE 1 Electrical Electrical Correction Unit Correction Unit On Off Generator 35-45° C. 60-80° C. Temperature Real Power 160 KW 160 KW Current 270 A 640 A Power Factor 0.85-0.9 0.3-0.4 Reactive Power 90 KVAr 380 KVAr Apparent Power 190 KVA 410 KVA [0053] By correcting the PF, eliminating high frequency and harmonic distortions, the electrical correction unit significantly reduces the generator load and thus saves a lot of energy. This can be seen in Table 1, when the correction unit reduces the apparent power by 220 KVA (54%) and the generator temperature drops by 30° C. (57%). [0054] In an example of the function and the generation of the device of the present invention, for the disclosed electric correction unit is in an electrical system distant from the main power grid. The example shows the calculation of component values of a specific system. This is a 400V, 50 Hz system with an output of 217.5 A. [0055] Instead of the electrical shocks of a local system distant from the main grid forcing the main system into some imbalanced state, the distortion of the local system is injected into the local system and the main frequency of the system becomes the carrier frequency of the distortion. Experiments of the inventors have shown that due to high impedance on the grid, load on the system, distant from the local load can cause similar effects as in a smaller system such as in a ship. This of course can be calculated for each system as shown here below by a calculation of the components values used in the band-stop filter unit of the present invention. The unit both corrects the phase shift between the voltage potential in each phase of the system and the current. This indeed is revolutionary for the current practice. [0056] Requirements for the band-stop filter unit: [0057] Connection of capacitor in a delta connection and inductor unit (reactor) in a star connection. [0000] Size of capacitor   996 micro F Frequency 50 Hz Size of reactor 0.136 mH Voltage 400 On 50 Hz: Xc=3,198 ohm (in a delta-connection) Xl=0.043 ohm (in a star-connection) [0059] Capacitor recalculated for star-connection—By using 3 capacitors (MKK400-d-50-21 (3×332 micro F) in each system (smt.4 system) [0000] On 50 Hz: Xc = 1.066 ohm Xl = 0.043 ohm Ztot = 1.023 ohm 3-phase power: 150.5 kVAr Phase current: 217.5 A Size of capacitor 2988 micro F Size of reactor 0.136 mH [0060] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and non-restrictive; the invention is thus not limited to the disclosed embodiments. Variations to the disclosed embodiments can be understood and effected by those skilled in the art and practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. A single processor or other unit may fulfil the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be considered as limiting the scope.
The present invention relates to a device for power factor correction and electrical wide band filtering in electrical systems for reducing considerably voltages of frequencies higher than 110 Hz on power systems rated for 10 Hz to 60 Hz and to improve power factor by injecting reactive power into the system. The device of the present invention provides a combination of inductors and capacitors which effectively corrects the power factor and filters out voltages of high frequencies.
8
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to stage monitors for musical instruments, and more specifically to improvements in such monitors for minimizing feedback problems arising therein by electronic filtering. 2. Prior Art The use of electronic circuits in conjunction with musical instruments has become well known in the art. Such circuitry is typically used in various synthesizers, where variable filters are provided for achievement of particularly desired special effects. Such a system is disclosed in Whittington et al. U.S. Pat. No. 4,106,384. Active multiple-stage distributed filters are similarly used in conjunction with electric pianos, organs, and other keyed instrument to attain desired voicing characteristics, tone coloration, and the like. Uetrecht U.S. Pat. No. 4,218,950 illustrates such use, in which undesirable upper harmonics, as well as frequencies below the fundamental are rejected to decrease intermodulation distortion and to increase isolation between the filter stages. A further use of active filters, having amplifiers connected to capacitive networks, to provide a voltage controlled arrangement for an electronic synthesizer is disclosed in Luce U.S. Pat. No. 3,974,461. Stage monitors for all, or a selected portion, of a musical program are used to enhance a performer's ability to adjust his own instrument to that of the overall program. For drum systems, however, such monitors introduce significant problems, such as sustained low-frequency feedback. A typical prior art approach to the feedback problem is to stuff a bass drum with pillows, blankets, or drapes, or to provide other forms of mechanical damping therefor. The use of mechanical devices, however, tends to affect the tonal quality of the music produced by a drum, or other musical instrument, since such music is itself inherently a mechanical vibration. While prior usage of electronic filtering circuits is known, no such circuits have been devised for minimization of a particular broad band of frequencies contributing to the feedback problem in stage monitors. As is apparent from the above described publications, typical use of electronic circuitry is in enhancement or modification of instrument output, and not in interference with a feedback loop, particularly of the type arising in a stage monitor for a percussive instrument. SUMMARY AND OBJECTS OF THE INVENTION It is accordingly an object of the present invention to overcome the difficulties of the prior art and to provide an improved structure for elimination of feedback in stage monitors. It is a more specific object of the invention to provide an electronic circuit, utilizing active filtering techniques, for attenuation of a broad band of frequencies contributing to feedback in stage monitors for percussive instruments. It is yet another object of the invention to provide an improved stage monitor in which active filtering stages are used both to attenuate a band of frequencies contributing to feedback effects and to attenuate another band of frequencies which may provide destructive mechanical oscillation to the monitor speaker. Still another object of the invention is to provide circuitry for a stage monitor to pass a pair of frequency bands: a first band corresponding to the fundamental frequency produced by a musical instrument, as well as the second harmonic thereof, and a second band corresponding to a second, distinctive sound generated by the instrument. Still a further object of the invention is to provide electronic circuitry having a specific frequency characteristic, in which specified components provide alternating attenuating and pass bands. It is an additional object of the invention to provide a method for stage monitoring a selected portion of a musical program by attenuating a broad frequency band which contributes to feedback problems in such monitoring. In accordance with the foregoing objects, an electronic circuit is provided having a plurality of filter stages for minimizing feedback from a speaker to an input of a stage monitor. The filter stages include frequency pass components for fundamental components of the selected portion of a musical program, and frequency attenuation components for particular frequency bands. The circuit includes components for attenuating extremely low frequencies, for passing a first frequency band above the extremely low frequencies, for attenuating a second frequency band above the first band and including therein the feedback frequencies, and for passing a third band above the second band. The circuit components include operational amplifiers and associated frequency selective networks used to determine the particular frequencies for the above described frequency bands. An input buffer is provided, which itself includes both high and low-frequency attenuation. The buffer output is provided to a pair of parallel branches, each branch having at least one active filter stage therein. The outputs of the parallel branches are provided to a summing amplifier which includes additional high-pass filtration. BRIEF DESCRIPTION OF THE DRAWING The foregoing and other objects, features and advantages of the invention will become more readily apparent upon reference to the following detailed description of the preferred embodiment, when taken in conjunction with the accompanying drawings in which like numbers refer to like parts. FIG. 1 shows a preferred embodiment of a circuit in accordance with the present invention; FIG. 2 shows the frequency characteristic of the circuit of FIG. 1; and FIG. 3 shows the environment in which the invention is typically used. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The circuit shown in FIG. 1 provides a solution to a problem experienced by musical performers attempting to adjust their particular instrument to that of the overall program. Such adjustment is typically required in musical performances wherein high sound pressure levels are created by the musical program electronically amplified for the benefit of the patrons. The use of electronic amplification makes it difficult for the performers to distinguish their own instruments for proper adjustment. Soundspeaker systems, known as stage monitors, are accordingly available to performers to enable better instrument and vocal definition and clarity. A typical stage monitor system is shown in FIG. 3 of the drawing, in which a detecting means 10, which may be a microphone, for example, is used to detect a selected portion of the musical program being performed. Thus, where a specific instrument is desired to be monitored, detecting means 10 is placed adjacent that instrument. Of course, with the availability of directional microphones, the detecting means need not be placed immediately adjacent the specific instrument or instruments to be monitored. The use of electrical pickup devices may eliminate the microphone in its entirety. Thus, any type of detecting means may be used which provides the desired selectivity to enable monitoring the selected portion of the program material, whether a single instrument, a group of instruments or the entire program. The detecting means 10 provides an output signal representative of the musical program portion to be monitored. The signal is transmitted along a wire 12 to an amplifying means 14. It is recognized that transmission may be by means of acoustic or radio frequencies, and that wire 12 may not be present. The wire is intended to symbolize a means for communicating the signal representing the selected portion to the electronic processing circuitry therefor. Amplifying means 14 processes the signals output by the detecting means 10 and amplifies them sufficiently to drive a speaker 16, oriented to enable the performer or performers to hear their own instrument or instruments, and to take appropriate adjustment measures as necessary. In the environment of FIG. 3, wherein the disclosed stage monitor is used to monitor a drum system 18, specific problems are presented. After research conducted under the auspices of the assignee hereof, it has been determined that frequencies in the approximate range of 100 Hz to 700 Hz lead to undesirable and harmful feedback. It is known to musical performers, and particularly to drummers, that the low frequencies which the stage monitor system is required to reproduce for drum systems often interact with the drum system itself. Specifically, the sound output of the speaker causes vibration of the drum, leading to oscillations having a long decay time constant. This form of low frequency feedback is perceived as a low frequency "ringing" of the drum. Typical approaches to minimizing this low frequency feedback utilize mechanical damping of the vibrations. This is usually done by stuffing the drum with pillows, blankets, drapes, or other mechanical damping means. Obviously, such mechanical damping of the instrument's vibrations detracts from its musical output sound, as well as reducing the feedback oscillations. Having determined that the feedback phenomenon is due to frequencies in the broad range of 100 to 700 Hz, the present invention was developed to attenuate the entire range of frequencies, rather than to provide some narrow band equalization therefor. Moreover, the invention includes components to protect the speaker 16 of the stage monitor by attenuating an additional band of extremely low frequencies. The invention thus provides electronic equipment optimized for specifically controlling bass drum feedback in a drum monitor system. The circuitry provided is used to pass the fundamental frequency output of the bass drum, which is in the approximate range of 50-60 Hz. Additionally, for more realistic reproduction by the monitor, the circuitry passes the second harmonic of the drum output. Thus, the entire range of approximately 50-100 Hz is passed by the present system. In order to avoid the possibility of damage to the speaker by large mechanical excursions at extremely low frequencies, the system includes components for attenuating frequencies below approximately 50 Hz. Rapid (approximately 15 db per octave) attenuation of frequencies above 100 Hz, at a maximum attenuation of approximately 22 db, is provided by the present system to eliminate the broad frequency band determined to cause the objectionable low frequency feedback. The entire band of frequencies between approximately 100 Hz and 700 Hz is thus eliminated. The present invention, rather than merely providing circuitry for eliminating frequencies at or above a particular value, provides further components for assuring that the sound output of the speaker is realistic. Specifically, in addition to the attenuation circuitry for frequencies above 100 Hz, high-pass circuits are provided to assure that frequencies above 700 Hz, up to approximately 3.5 KHz, are also passed, thus allowing the percussive sound of the drum beater hitting the bass drum head to be heard. The present invention thus provides a substantially fixed response shape, as described below, requiring a minimum of electronic tuning and protecting the monitor system while passing the specific sounds of interest to the musician. Referring now to FIG. 1, the inventive circuit is generally shown at 20, including an input buffer 22 and a main filter board 24. Buffer 22 receives an input signal and provides isolation for the source thereof, which may be detecting means 10, from the main filter board 24. The buffer includes frequency selective circuits 26 and 28, comprised of RC networks R8-C8 and R9-C9, respectively, to provide first order filtering functions for both low-frequency and high-frequency attenuation. An operational amplifier 30 is connected with its output fed back to its negative input 32, while the frequency selective circuits 26 and 28 are connected to a non-inverting input 34 thereof. The main filter board 24 includes a pair of parallel paths. A first path 36 includes a third order high pass filter, having an operational amplifier 38 and a frequency selective network 40. The network 40 includes filter capacitors C10, C11 and C12 along with resistors R10, R11 and R12 to shape the frequency characteristic of the filter. Output 42 of amplifier 38 is fed back to the inverting, or negative input 44 thereof, as well as to a junction 46 between capacitors C11 and C12. Capacitor C12, at its other terminal, is connected to non-inverting, or positive input 48 of amplifier 38, and to resistor R11 connected therebetween and ground. Resistor R10 is connected between the junction of capacitors C10 and C11, on the one side, and ground on the other. A second path in the main filter board 24, generally shown at 50, includes a fourth-order high-pass filter 52 and a third-order low-pass filter 54. The fourth-order high-pass filter 52 is itself comprised of a pair of second-order high-pass filters 56 and 58 having substantially identical structures. A second order frequency selective network is provided in conjunction with an operational amplifier for each of the filters. For brevity, only filter 56 is described in detail. The input signal to the filter, provided from the output of buffer 22, is passed through capacitor C1 to a junction 60 of capacitor C1, resistor R1, and capacitor C2. The frequency selective network includes, in addition to resistor R1 and capacitors C1 and C2, a resistor R2 from the non-inverting input 62 of operational amplifier 64 to ground. Output 66 of amplifier 64 is fed back to inverting input 68 and to resistor R1, for feedback to the non-inverting input 62. A similar frequency selective network, comprising resistors R3, R4 and capacitors C3, C4 is provided for operational amplifier 70 to form filter 58. Third-order low-pass filter 54 includes a frequency selective network comprising resistors R5, R6, and R7, and capacitors C5, C6 and C7, and an operational amplifier 72. The output signal of filter 58 passes through resistor R5 to junction 74, between resistor R6 and capacitor C5, the latter connected at its other terminal to ground. A further junction 76 is formed among capacitor C7 and resistor R7 and the other terminal of resistor R6. Output 78 of amplifier 72 is fed back to its inverting input 80 as well as to capacitor C7 for feedback to the positive, non-inverting input 82. The outputs of both paths 36 and 50 are resistively connected to be summed at an input of a summing output amplifier for the invention, shown at 84. Resistors R13 and R14, respectively, are used to connect the outputs of amplifiers 38 and 72 to a non-inverting input 86. Output 88 of amplifier 84 is fed back to inverting input 90 thereof by means of an RC network comprised of resistor R15 and capacitor C13, thus providing the summing output amplifier 84 with a first-order low-pass filter function. A resistor R16 is connected between inverting input 90 and ground. A limiting resistor R17 is connected to receive the output of amplifier 84, which is used as the drive source for any suitable power amplifier whose input impedance is high in relation to the output impedance of the present device. The present circuit may be connected to receive the output of detecting means 10 and to provide the input to amplifying means 14 of FIG. 3, or may be included within the amplifying means as an input stage or as an intermediate stage. Advantageously, by providing the circuit as a separate structure, existing stage monitors may be adapted for monitoring bass drums without objectionable low-frequency feedback by a simple connection between the detecting means and the amplifying means, without the necessity of restructuring the entire monitor, or of purchasing an entire new monitor. Moreover, by using active filters comprised of operational amplifiers, the various filtering stages are isolated from one another, thus enabling variation of specific components to alter particular portions of the frequency response without affecting other portions. Preferably, however, the system components are fixed at specific values, requiring minimal tuning or alteration. For the presently contemplated use, wherein a percussive instrument, and particularly a bass drum, is monitored, the desired attenuation of extremely low frequencies as well as frequencies in the feedback range, along with passage of first and second harmonic frequencies of the drum and the higher order percussive sound frequencies is achieved by the use of the following components in the circuit of FIG. 1. Operational amplifiers 30 and 84 are each one half of an operational amplifier type 4558. The amplifiers 38, 64, 70 and 72 are each preferably of the type 4741 CP. The remaining components are illustratively provided in the following table. ______________________________________COMPONENT VALUE______________________________________C1, C2, C3C4, C8 0.1 μfC9-C12, C4C15 0.033 μfC13 470 μfC5 0.047 μfC6 0.0068 μfC7 0.15 μfR1 28 K*R2, R16 33 KR3 12.1 K*R4 82.5 KR5-R7 47 K*R8 1 KR9 100 KR10 4.7 KR11 31.6 K*R12 1.82 K*R13-R15 68 KR17 0.68 KD1, D2 1N4148______________________________________ *1% tolerance Referring now to FIG. 2, the amplitude vs. frequency response of the described system is seen to provide specific attenuation of the range between 100 Hz and 700 Hz, to minimize bass drum-to-bass drum monitor feedback. The region below 50 Hz provides rapid attenuation in order to provide the previously described protection to the drum monitor system for extremely low frequencies. Between the two attenuated ranges is the range between approximately 50 Hz and 100 Hz, passing the fundamental frequency and the second harmonic. Finally, the region between 700 Hz and approximately 3.5 KHz passes high frequency percussive timbre of the bass drum beater action. It is thus seen that steep slopes of the frequency characteristic of the device provide for sharp attenuation of frequencies in two undesired ranges, below 50 Hz and between 100 Hz and 700 Hz. Frequencies above 3.5 KHz, not of particular concern, are attenuated at a less steep rate. The inventive device thus provides the multiple frequency range operation for achieving the desired operating characteristics and objectives set forth therefor. The preceeding specification describes the preferred embodiment of the invention as an illustration and not a limitation of the invention. It is appreciated that equivalent variations and modifications of the invention will occur to those skilled in the art. Such modifications, variations and equivalents are within the scope of the invention as recited with greater particularity in the appended claims, when interpreted to obtain the benefits of all equivalents to which the invention is fairly and legally entitled.
Apparatus for eliminating feedback in stage monitors for selected musical instruments includes filter networks for attenuation of a broad frequency range including the entire range of frequencies contributing to the feedback. A combination of high order low-pass and high-pass filters is used to pass fundamental and second order components of a selected instrument, while attenuating the undesired feedback frequencies as well as extremely low range frequencies capable of damaging a speaker. A pair of passbands is provided, and a pair of frequency bands is suppressed, the two pairs providing alternate attenuation and pass-bands. Active filters having operational amplifiers and frequency selective circuits are used, along with buffering and summing circuits, to attain the desired frequency characteristic.
8
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sewing machine drive apparatus which causes a sewing machine to generate holding force to keep a machine needle from moving and sticking into a cloth, or an object to be stitched, during a stop of the sewing machine. 2. Description of the Background Art FIG. 17(a) shows the arrangement of a conventional sewing machine drive apparatus, wherein the numeral 1 indicates a sewing machine, 2 denotes drive means, e.g., a motor, which drives the sewing machine 1, 3 designates a sewing machine pulley, 4 represents a motor pulley, 5 indicates a belt which couples the pulleys 3 and 4, 6 designates a needle position detector fitted to the sewing machine 1 to detect the needle position of the sewing machine 1, 7 represents a detector which detects the position or velocity of the motor 2, 8 denotes a control box which controls the motor 2 to operate the sewing machine 1, 9 indicates a pedal operated by a worker to operate the sewing machine 1, and 10 represents a lever unit which converts the operation value of the pedal 9 into an electrical signal (for example, a velocity command value) and inputs the signal to the control box 8. In the apparatus designed as described above, when the worker depresses the pedal 9, its depression value is converted into a velocity command value by the lever unit 10, the control box 8 operates the motor 2 at variable speed according to that velocity command value, and its drive force is transmitted to the motor pulley 4, the belt 5 and the sewing machine pulley 3 to operate the sewing machine 1. When, for example, the worker attempts to take out the cloth on completion of stitching after the operation of the sewing machine 1 through the control of the pedal 9, the sewing machine 1 must be stopped at a needle UP position to keep its needle from sticking into the cloth. In some sewing machines 1 which utilize a presser bar plate spring, the spring is designed to be unloaded at a stop point in the needle UP position, shown at an 11 o'clock position of spindle rotation in FIG. 17(b). At other positions, the spring tends to bring the spindle back to the needle UP position, and is at a maximum compression at top dead center, shown as the 12 o'clock position. For example, because of the force of the spring (the force of motion is hereinafter referred to as the "machine load"), the sewing machine will rotate in the forward direction (counterclockwise) when the spindle is in a position after the 12 o'clock position, and will rotate in a reverse direction (clockwise) when the spindle is in a position prior to the 12 o'clock position. Accordingly, after a stop, this conventional sewing machine 1 continues to move and the needle position shifts. As a result, in an extreme case, the needle will stick into the cloth, and the cloth cannot be taken out. For this reason, the conventional system may implement the position control of the motor 2 such that, during a stop of the sewing machine 1, the position control generates a torque for the motor 2 which is opposite to the direction in which the sewing machine 1 attempts to move, thereby providing holding force. Further, if there is a position deviation which exceeds a set value, the position control is designed to be cleared so that the worker can shift the needle position of the sewing machine 1 by hand in order to, for example, check the piercing position of the needle while such holding force control is being executed. These methods are described in details in, for example, Japanese Laid-Open Patent Publication No. SHO 62-106798. FIG. 18 is a block arrangement diagram of a conventional sewing machine drive apparatus, wherein the numeral 11 indicates velocity command value changing unit, e.g., a selector switch, which is connected to point "a" in FIG. 18 to perform a variable-speed operation under the control of a velocity command from the lever unit 10 and is moved to a position control position at point "b" at the time of a stop to generate holding force during a stop (a position control during a stop is hereinafter referred to as a "soft brake"). 12 designates a velocity/torque conversion section which converts any velocity deviation, determined by the differences between the velocity command value and a velocity feedback value, into a torque command value. 13 represents a torque limiter which limits the torque command value to keep it from exceeding a set value. 14 denotes a driver consisting of power transistors, etc., to drive the motor 2 according to the torque command value. 15 indicates a detector, which may comprise an encoder within the motor 2, for detecting (conventionally by means of a light source, a light sensor, and rotary discs fitted to the motor shaft and provided with slits at predetermined locations) the angular value (travel) of the shaft of the motor 2. It is generally known that two sensors, which are disposed to electrically provide two phase pulse signals A and B with a phase difference of approximately 90° , allow a rotation direction also to be detected. 16 represents a velocity detection section which detects velocity from such phased pulse signals A, B. The velocity detected thereby (hereinafter referred to as the "velocity feedback") is further converted into a positive or a negative value according to the rotation direction determined by using the method. 17 denotes a position detection section from which the direction of travel is output as a value whose polarity (positive or negative) is determined according to the rotation direction detected by the velocity detection section 16. 18 designates a position control section which exercises position control according to the movement value (hereinafter referred to as the "position feedback") from the position detection section 17. 20 indicates a position/velocity conversion section which converts the output of the position control section 18 into a velocity command value. The operation of the sewing machine drive apparatus designed as described above will now be described in accordance with FIGS. 17(a) and (b), 18 and 19(a) and (b). FIGS. 19(a) and (b) show a relationship between position deviation and torque that is pertinent to the operation of the apparatus. First, when the worker depresses the pedal 9, its depression value is converted into an electrical signal (velocity command value) by the lever unit 10. The velocity feedback from the velocity detection section 16 is subtracted from the electrical signal at the summing node 8a in the control box 8 and results in a velocity deviation value. The velocity deviation is converted into a torque command value by the velocity/torque conversion section 12. According to this torque command value, the driver 14 operates the motor 2. This is the typical movement performed during the operation of the sewing machine 1. When the pedal 9 is set to a neutral position (a state wherein the worker does not depress the pedal), the velocity command value is zeroed, the motor 2 comes to a stop, and the sewing machine 1 is also brought to a stop. It is to be understood that some sewing machine drive apparatuses have an orientation function which allows the sewing machine to be positioned to a stop at its needle UP or DOWN position under the control of the signal from the needle position detector 6, but such sewing machines will not be described here. When the sewing machine 1 comes to a stop, the selector switch 11 is moved from point "a" to the position control position at point "b" to provide soft brake processing. At the beginning of this change-over, as seen in FIGS. 19(a) and 19(b), the position deviation is zero and therefore torque is also zero. Shortly thereafter, because of the machine load, for example, the needle attempts to fall from top to bottom. Due to the coupling that exists, this also causes the motor 2 to move in a similar fashion, whereby a change occurs in the pulse signals A, B from the encoder 15. This change is converted by the position detection section 17 into a value with a sign related to the rotation direction, i.e., a position feedback signal which is a positive value for forward rotation or a negative value for reverse rotation, and is output to the position control section 18. The position control section 18 integrates this position feedback signal, converts it into a value representative of the position deviation from a home position immediately after the stop of the sewing machine 1, and outputs the result of the conversion. The position/velocity conversion section 20 inverts the sign of this output, converts the output into a velocity command value, and outputs the result of conversion to switch terminal "b". Thereafter, the motor 2 is driven to generate torque to return the sewing machine 1 to the home position as earlier described in the operation of the sewing machine. A case where a position displacement has further occurred hereafter will now be described. This is a part wherein as described previously, the position deviation in excess of the set value is cleared so that the worker can shift the needle position of the sewing machine 1 by hand. When the position deviation, which is generated by the integration of the position feedback in the position control section 18 as described previously, has exceeded an optional first set value P, e.g., a travel of 5 degrees on the motor shaft, the position control section 18 clears the position deviation to zero. Accordingly, the torque is also zeroed (point h in FIG. 19(a)). The relationships between the travel and torque at that time are shown in FIGS. 19(a) and 20(a). It should be noted that the value of +P shown in FIGS. 19(a) and 20(a) is a set value in excess of which the position deviation is cleared as described previously. Also, -T in FIGS. 19(b) and 20(b) indicates the holding force that exists at a time when the position deviation has exceeded the set value of +P and its value is a maximum torque value. In the meantime, a set value of -P and maximum holding force of +T, (which will not be described here, but are indicated by alternate long and short dash lines in the drawings) will exist when the sewing machine 1 is operated in the opposite direction. Region A shown in FIG. 19(a) indicates an interval from when the position deviation is zero until it is cleared, i.e., an interval from zero holding force to the maximum torque value. As is indicated by the fact that the sewing machine 1 can be turned by hand, the machine load generally is smaller than the force required for moving the sewing machine 1 by hand, and moves the sewing machine 1 comparatively slowly. On the other hand, when the sewing machine 1 is moved by hand, the sewing machine 1 moves faster than when it is moved under the machine load. On the basis of the explanation provided above, FIG. 20(b) can be seen to illustrate the case where the sewing machine 1 is moved fast at constant velocity and corresponds to the manual movement of the sewing machine 1. Similarly, FIG. 19(b) shows the case where the sewing machine 1 is moved slowly at constant velocity and corresponds to the movement of the sewing machine 1 under machine load. It should be noted that, since the machine load is smaller than the force required for manually moving the sewing machine 1 as described previously and the value of maximum torque -T of the holding force is actually set to balance them at a stop in region A. Unlike the case illustrated in FIG. 19(a), the region A is not exceeded (actually, the sewing machine stops at a position like point "j" with the holding force and the machine load balanced). FIG. 19(a) shows an operation wherein the region A has been exceeded; this may be referenced later for the purpose of a comparison between the conventional art and the embodiment of the present invention (a portion indicated by an alternate long and two short dashes line in FIG. 19). The torque limiter 13 will now be described. FIG. 21 shows the characteristic of the torque limiter 13. In this drawing, the torque is limited to keep it from exceeding the maximum torque value (-T) of the holding force in the reverse direction when the velocity has a positive value (forward rotation), and the torque is limited to keep it from exceeding the maximum torque value (+T) of the holding force in the forward direction when the velocity has a negative value (reverse rotation). The operation of the position control section 18 will now be described in accordance with a flowchart in FIG. 22. First, when the soft brake processing is initiated, the operation starts in step 50 and the position deviation is cleared in step 60. Then, in step 70, the value of the position feedback is added to the position deviation. Here, the operation will be described for a case where the sewing machine 1 has moved slowly, as shown in FIGS. 19(a) and 19(b). Since the value of the position deviation is small at first, the value of the position deviation is output in step 100 and the execution returns to step 70. As the execution passes step 70 several times, the position deviation value increases, a judgement is made in step 80 to branch to step 110, and the position deviation value is cleared by the processing of step 110. This is point "h" in FIG. 19(a). Hereafter, the same processing is repeated again. If, for example, the sewing machine 1 does not move, the position feedback value is zero and therefore the position deviation value does not change. Accordingly, the processing of step 110 is not performed either. It should be noted that when the selector switch 11 is changed over to point "a" to enter the operation mode, the processing in FIG. 22 is terminated forcibly and operation processing is then performed. As described above, while the holding force which keeps the sewing machine 1 from being moved under machine load was provided in the conventional sewing machine drive apparatus, the position deviation was cleared if the travel, or the optional first set value P, was exceeded, whereby the worker could shift the needle position by hand. It is to be understood that in such holding force control, typically, the operation of the soft brake can be controlled by a switch incorporated in the control box 8. In the conventional sewing machine drive apparatus designed as described above, its holding force (torque) is controlled according to only the position deviation. Hence, whether the force for moving the sewing machine is machine load or worker power, the holding force (torque) was generated similarly in response to the position deviation. In addition to the power for moving the sewing machine by hand, therefore, the worker was further required to have the power to withstand the resistant force (holding force) from the motor. Moreover, since some sewing machines require an extremely large force to begin a movement, the maximum torque value of the holding force must be increased to keep the sewing machine from moving, whereby the resistant torque from the motor is increased. This poses a problem in the stitching world where there are many female workers. Also, the worker is required to provide the power found by multiplying the holding force (torque), which is generally controlled to be constant on the shaft of the drive apparatus, by the pulley ratio of the sewing machine pulley diameter to the motor pulley diameter, because the worker actually applies the power to the sewing machine pulley to shift the needle position and the motor and the sewing machine are coupled by the motor pulley, the belt and the machine pulley as described previously. Hence, the worker is required to have the physical strength greater than that required when, for example, the motor pulley diameter was reduced for a low-speed sewing machine. Furthermore, whether the sewing machine moves or not, a current flows during the soft brake processing exercised during a stop, whereby excitation noise is generated. Accordingly, even though the sewing machine is at a stop, the excitation noise of the motor continues to be generated, causing some workers to feel uncomfortable. For this reason, the soft brake had better be operated only when it is required, i.e., only when the sewing machine has moved under machine load after a stop. However, the worker had to make preparations and other work for the next stitching during the stop of the sewing machine and could not watch the sewing machine to turn on the soft brake switch when the sewing machine moved, whereby the soft brake had to be applied automatically. In view of the aforementioned problems, a first object of the present invention is to provide a sewing machine drive apparatus which exercises control to generate a holding force during a stop of a sewing machine whereby a large holding force is provided under machine load; moreover, the holding force is kept from increasing so that a worker will not become fatigued when such worker must turn the sewing machine by hand. A second object of the present invention is to provide a sewing machine drive apparatus which allows the sewing machine to be moved with predetermined force independently of the pulley ratio of the pulley diameter of the drive unit, such as a motor, to that of the sewing machine. SUMMARY OF THE INVENTION A sewing machine drive apparatus and method concerned with a preferred embodiment involves a drive apparatus which is capable of driving a sewing machine at a controlled velocity, a detector for detecting the rotary position and/or velocity of the output shaft of the drive apparatus, a control unit for controlling the speed of the drive apparatus according to a velocity command value, a holding force generating unit which generates a holding force during a stop of the sewing machine, and a holding force changing unit which changes the holding force generated by the holding force generating unit according to the speed of the drive apparatus or the sewing machine. In a sewing machine drive apparatus and method concerned with another embodiment, the holding force changing unit changes the holding force generated by said holding force generating unit according to the pulley ratio defined by the pulley diameter of the drive apparatus and the pulley diameter of the sewing machine. In a sewing machine drive apparatus and method concerned with a further embodiment, the holding force changing unit reduces the intensity of the holding force when a position deviation from a stop position exceeds a set value. A sewing machine drive apparatus and method concerned with yet another embodiment utilizes a holding force changing unit which controls the holding force only after detection of a predetermined amount of motion of the drive apparatus or sewing machine. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram illustrating the arrangement of a sewing machine drive apparatus according to a preferred embodiment of the invention. FIGS. 2(a) and 2(b) illustrate a relationship between position deviation and torque according to a first embodiment of the invention. FIG. 3 is a flowchart illustrating the operation of a position control section according to the first embodiment of the invention. FIGS. 4(a) and 4(b) illustrate a relationship between position deviation and torque according to the first embodiment of the invention. FIG. 5 illustrates a function of a torque limiter according to the first embodiment of the invention. FIG. 6 is a block diagram illustrating the arrangement of a sewing machine drive apparatus according to a second embodiment of the invention. FIG. 7 illustrates a function of a torque limiter according to the second embodiment of the invention. FIGS. 8(a) and 8(b) illustrate two relationships between a sewing machine pulley and a motor pulley according to the second embodiment of the invention. FIG. 9 is a block diagram illustrating the arrangement of a sewing machine drive apparatus according to a third embodiment of the invention. FIGS. 10(a), 10(b) and 10(c) illustrate the relationships between position deviation and torque according to the third embodiment of the invention. FIG. 11 is a flowchart illustrating the operation of a position control section according to the third embodiment of the invention. FIG. 12 illustrates a function of a torque limiter according to an alternative third embodiment of the invention. FIG. 13 is a block diagram illustrating the arrangement of a sewing machine drive apparatus according to a fourth embodiment of the invention. FIG. 14 is a flowchart illustrating the operation of a position control section according to the fourth embodiment of the invention. FIGS. 15(a), 15(b) and 15(c) illustrate two relationships between position deviation and torque according to the fourth embodiment of the invention. FIG. 16 illustrates an operation region as viewed from a motor pulley according to the fourth embodiment of the fourth invention. FIGS. 17(a) and 17(b) illustrate the arrangement of a sewing machine and operation performed due to machine load as viewed from a machine pulley. FIG. 18 is a block diagram illustrating the arrangement of a sewing machine drive apparatus known in the conventional art. FIGS. 19(a) and 19(b) illustrate a relationship between position deviation and torque according to the conventional apparatus. FIG. 20(a) and 20(b) illustrate a relationship between position deviation and torque according to the conventional apparatus. FIG. 21 illustrates the characteristic of a torque limiter employed in the conventional apparatus. FIG. 22 is a flowchart illustrating the operation of a position control section in the conventional apparatus. DESCRIPTION OF THE PREFERRED EMBODIMENTS In the sewing machine drive apparatus in accordance with a preferred embodiment of the invention, a worker can move the sewing machine with small force when the worker attempts to move it by hand. In the sewing machine drive apparatus in accordance with another embodiment of the invention, the force required for the worker to move the sewing machine by hand is not influenced by the pulley ratio. In the sewing machine drive apparatus in accordance with a further embodiment of the invention, the intensity of the holding force generated to keep the sewing machine from moving during the stop of the sewing machine is reduced when the position deviation from the stop position increases. In the sewing machine drive apparatus in accordance with yet another embodiment of the invention, the control of the holding force generated to keep the sewing machine from moving during the stop of the sewing machine is exercised on detection of the motion of the drive means, e.g., a motor, or the sewing machine. A first embodiment of the present invention will now be described in accordance with FIGS. 1, 2(a), 2(b), 17(a) and 17(b). FIG. 1 is a block diagram of a sewing machine drive apparatus according to the first embodiment of the present invention and FIGS. 2(a) and 2(b) show a relationship between position deviation and torque. The arrangement in FIG. 1 has an integrator 19, in addition to the arrangement of the conventional apparatus described in FIG. 17(a). The integrator 19 is controlled by the position control section 50. Accordingly, only the operations of the integrator 19 and the position control section 50 will be described in the following explanation. First, when the sewing machine 1 comes to a stop, the selector switch 11 is changed over from point "a" to the position control position at point "b" in FIG. 1 to provide soft brake processing. When the sewing machine 1 moves under machine load, the position control section 50 calculates the position deviation using the position feedback output by the position detection section 17 and outputs the resultant position deviation to the integrator 19. The integrator 19 integrates this position deviation in terms of time and outputs the result of the integration to the position/velocity conversion section 20. The position/velocity conversion section 20 inverts the sign of this output, converts the output into a velocity command value, and outputs the result of this conversion, whereby the motor 2 is driven to generate a torque to return the sewing machine 1 to the home position. A case where position deviation has further occurred hereafter will now be described. In this first embodiment, the position deviation in excess of the optional first set value P is cleared to zero by the position control section 50 as in the conventional apparatus. However, it should be noted in the present embodiment apparatus that when the position deviation is cleared to zero, the position control section 50 further outputs a command to halve the value of the integrator 19 in order to ensure smooth rotation. This command causes the integrator 19 to halve the value having been integrated until then, whereby the output from the integrator 19 is also halved and therefore the torque is also halved (point "a" in FIG. 2(a)). If a position displacement has further occurred, the position deviation increases again and the value of the integrator 19 also increases, whereby the torque also increases. It is to be understood that the torque is saturated at a predetermined value because it is limited by the torque limiter 13. The operation of the position control section 50 will now be described in accordance with a flowchart in FIG. 3. This flowchart has the processing of step 120 in addition to the flowchart in FIG. 22 described in the conventional art. Hence, there has been added only the operation of outputting the command to halve the value of the integrator 19 after the position deviation in excess of the optional first set value P has been cleared in step 110. This processing halves the torque when the position deviation has exceeded the optional first set value P as described previously. While FIG. 2(a) shows that the sewing machine 1 has been moved slowly to correspond to FIG. 19(a) described in the conventional art, the operation of the sewing machine 1 moved fast to correspond to FIG. 20(a) will now be described in accordance with FIG. 4(a). Although the operation of the sewing machine 1 moved fast is fundamentally identical to the operation of the sewing machine 1 moved slowly, the position deviation exceeds the set value before the integration value of the integrator 19 increases (point "b" in FIG. 4(a)) and the integration value of the integrator 19 is halved, whereby the integration value of-the integrator 19 is kept from being increased. Accordingly, the value of the torque generated by the output of the integrator 19 is smaller than the value provided when the sewing machine 1 is rotated slowly. When there is a comparison between point "a" in FIG. 2(a) and point "c" in FIG. 4(a), an overall value integrated by the integrator 19, which is found by (position deviation * time/2), is equal in both FIGS. 2(a) and 4(a), but the number of times when the integration value of the integrator 19 has been halved is 8 in FIG. 4(a) and is 1 in FIG. 2(a). This difference in the number of times when the integration value of the integrator 19 has been halved will cause the torque generated in FIG. 2(b) to be smaller than that in FIG. 4(b). Because the increase in the number of times during a predetermined length of time keeps the torque from increasing, and also because the number of times increases as the rotating velocity of the sewing machine 1 increases, the intensity of the torque in the apparatus shown in the present embodiment changes in response to the rotating velocity of the sewing machine 1. While a comparison between FIG. 2(b) and FIG. 19(b) (when the sewing machine has moved under machine load) indicates that average torque generated is approximately equal or larger in FIG. 2(b), a comparison between FIG. 4(b) and FIG. 20(b) (when the sewing machine is moved by hand) indicates apparently that the average torque is smaller in FIG. 4(b). As described above, the torque generated by the motor 2 when the worker attempts to rotate the sewing machine 1 by hand is smaller in the present embodiment than in the conventional apparatus, whereby the sewing machine 1 can be moved easily. The position deviation in excess of 5 degrees on the motor shaft was designed to be cleared in the preferred embodiment; however, the position deviation in excess of an optional angle, e.g., 5 degrees, on the shaft of the sewing machine 1 may also be cleared to produce the same effects. It should be noted that as this angle is smaller, the feeling of hand-turning the pulley is smoother. Also, while the integration value of the integrator 19 is halved when the position deviation is cleared, the value may be reduced to one-third, cleared, or reduced in any other way to provide the identical effects. In each of the previous designs, the value of the integrator 19 was halved when the position deviation was cleared to change the torque relative to the velocity of the motor 2 or the sewing machine 1; however, the value of the torque limiter 13 in the present embodiment also may be changed during soft brake processing. In particular, the limiter 13 may be changed from the function as shown in FIG. 21 to a function as shown in FIG. 5 where the maximum torque value is smaller as the rotating velocity of the sewing machine 1 is higher, in order to produce the same effects. A second preferred embodiment of the present invention will now be described in accordance with a sewing machine drive apparatus shown in FIG. 6. In the arrangement shown in FIG. 6, the torque limiter 13 in the arrangement described in the conventional apparatus is designed to be switchable between the operation mode and the soft brake mode and the torque limiter in the soft brake mode has been changed for a torque limiter 60 which has a function as shown in FIG. 7. It is to be understood that a switch 21 operates in the same way as the switch 11. FIGS. 8(a) and 8(b) are expanded views of a part where the pulley 3 of the sewing machine 1 and the pulley 4 of the motor 2 are coupled by the belt 5 as described in the conventional art. FIG. 8(a) shows that the pulley 4 of the motor 2 is larger, and FIG. 8(b) shows that the pulley 4 of the motor 2 is smaller than that of the driven pulley 3. In FIG. 8(a), when the motor 2 has generated the holding force=torque T1 during the soft brake process, torque T2 on the pulley 3 of the sewing machine 1 is T2=T1*D2/D1. Similarly, in FIG. 8(b), when the motor 2 has generated the holding force=torque T3 during the soft brake process, torque T4 on the pulley 3 of the sewing machine 1 is T4=T3*D4/D3 (where, D1 and D3 indicate the diameters of the motor 2 pulley, and D2 and D4 denote the diameters of the sewing machine 1 pulley). To allow the sewing machine 1 to be moved by constant power at any pulley ratio, the torque on the pulley 3 of the sewing machine 1 may be made constant independently of the pulley ratio. Hence, the values of T1 and T3 may be controlled to make T2 and T4 equal. (Since T1 and T3 in the conventional apparatus were constant on the shaft of the motor 2 because they were limited by, for example, the value of T shown in FIG. 7, T2 and T4 are varied, e.g., T2=T*D2/D1 and T4=T*D4/D3, on the shaft of the sewing machine 1 according to the pulley ratio.) Accordingly, when a fixed value shown in FIG. 7, e.g., torque value T, is made variable by multiplying it by the pulley ratio, i.e., T1=T*D1/D2, and the assignment of the multiplication result to said expression results in T2=(T*D1/D2)*D2/D1=T. Similarly, T4=(T*D3/D4)*D4/D3=T, and T2=T4=T. It should be noted that the gain of the position/velocity conversion section 20 must be preset such that the velocity command from the position/velocity conversion section 20 is not less than the value of the torque limiter 60 at any pulley ratio. Since multiplying the torque value by the pulley ratio as indicated by the broken line in FIG. 7 allows the torque on the sewing machine shaft to be made constant independently of the pulley ratio, the sewing machine 1 can be moved by constant power at any pulley ratio. While the function of the torque as shown in FIG. 7 was used in the second embodiment, the value of any other function allows the torque on the sewing machine shaft to be controlled independently of the pulley ratio. It should be noted that since some pulley ratios cause a problem, such as heat generated by the motor 2, due to the increased torque value calculated by multiplication, it is effective to preset the torque limiter 60 to a predetermined value. A third embodiment of the present invention will now be described in accordance with FIGS. 9, 10(a)-10(c), 17(a) and 17(b). FIG. 9 is a block arrangement diagram of a sewing machine drive apparatus according to the third embodiment of the present invention and FIGS. 10(a)-10(c) show a relationship between position deviation and torque. It is to be understood that the arrangement shown in FIG. 9 is different from the conventional apparatus in FIG. 17(a) only with respect to the use of a position control section 70. The operation of the position control section 70 will now be described in accordance with a flowchart in FIG. 11. This flowchart has the processing of step 65 and steps 71 to 75, in addition to the flowchart in FIG. 22 which is found in the conventional art. First, when the soft brake processing is initiated, the operation starts in step 50 and the position deviation is cleared in step 60. Subsequently, in step 65, the position deviation from stop position DR is cleared, as represented in FIG. 10(a). It should be noted that the position deviation from stop position DR is a total travel starting at the stop position since it is initialized only once in step 60 at the start of the processing while the position deviation is cleared at points d, e, etc., in FIG. 10(b). Then, the value of the position feedback is added to the position deviation in step 70 and the value of the position feedback is also added to the position deviation from stop position DR in step 71. Here, the operation will be described for a case where the sewing machine 1 has moved as shown in FIGS. 10(a)-(c). Since the value of the position deviation from stop position DR (FIG. 10(a)) and the value of the position deviation (FIG. 10(b)) are both small at first, the processing proceeds from step 72 to step 73 to step 80 to step 90, the value of the position deviation is output in step 100, and the execution returns to step 70. As the execution passes steps 70 and 71 several times, both the value of the position deviation from stop position DR and the value of the position deviation increase and a judgement is made in step 72 to branch to step 74. Here, since the first set value P is larger than a second set value P1, a judgement is made in step 74 to branch to step 110. With reference to FIGS. 10(a) and (b), only the position deviation value is cleared by the processing of step 110. This is point d in FIGS. 10(a) and 10(b). Since the value of the position deviation from stop position DR is not cleared, as seen in FIG. 10(a), a further judgement is made in step 72 hereafter to branch to step 74. However, since the position deviation value has been cleared once, the processing of step 110 is not performed until the position deviation value exceeds the second set value P1, and the processing progresses from step 74 to step 75 to step 100. When the position deviation value has exceeded the second lower set value P1, as seen in FIG. 10(b), a judgement is made in step 74 to branch to step 110 and the position deviation value is cleared again. This is point e in FIG. 10(b). Hereafter, the above processing is repeated again. As described above, the position control section 70 operates in a region higher than region A to clear the position deviation to zero when a value smaller than the first set value P, e.g., the travel of 2° on the shaft of the motor 2, exceeds the second set value P1. Since the second set value P1 is set to a smaller value than the first set value P, the torque value -T1 at a time when the travel has reached the second set value P1 is also smaller than the maximum torque value -T as a matter of course. According to the present embodiment apparatus, therefore, the excess of region A at a time when, for example, the sewing machine 1 is hand-turned by the worker to check the position of needle location, reduces the resistant torque from the motor 2, whereby the sewing machine 1 can be moved more easily than in the conventional apparatus. It will be appreciated that in the present embodiment, the position deviation is cleared within region A when exceeding 5 degrees on the shaft of the motor 2, and is cleared in a region higher than region A when exceeding 2 degrees on the shaft of the motor 2. However, the position deviation may be cleared when exceeding an optional angle on the shaft of the sewing machine 1 to provide the identical effects. Also, when the sewing machine 1 used can be positioned to a stop at its needle UP or DOWN position under the control of a signal from the needle position detector 6 as described previously, instead of using the angle of the motor 2 or sewing machine, the maximum torque value may be reduced in relation to the signal from the needle position detector 6, e.g., when an UP position signal or a DOWN position signal is switched off (switched off when the sewing machine is offset from the stop position), in order to produce the same effects. In the present embodiment wherein the position deviation was cleared when the optional travel of the shaft of the motor 2 was exceeded to change the torque relative to the position deviation, the value of the torque limiter 13 in the present embodiment may also be changed, for example, only during soft brake processing from a function as shown in FIG. 21 to a function as shown in FIG. 12 where the maximum torque value becomes smaller as the position deviation from stop position DR becomes larger, in order to produce the same effects. A fourth embodiment of the present invention will now be described in accordance with FIGS. 13 and 14. It is to be understood that the sewing machine drive apparatus in the fourth embodiment shown in FIG. 13 is identical to the conventional sewing machine drive apparatus shown in FIG. 17(a), with the exception that a position control section 80 can disable the operation of the driver 14. Accordingly, the operation of the present embodiment remains unchanged from the operation described in the conventional art with the exception of the soft brake, and therefore will not be described. In the present embodiment, the position control section 80 is designed to disable the operation of the driver 14 until the position deviation from the stop position DR exceeds an optional set value, e.g., a travel of 2 degrees on the shaft of the motor 2 or a third set value P2. A case where the sewing machine 1 has moved under machine load will now be described in accordance with FIGS. 15(a)-(c). In FIG. 15(a), when the position deviation from the stop position is within the travel of 2 degrees on the shaft of the motor 2 or the third set value P2, soft brake is not operated and therefore the holding force is not generated. Accordingly, as seen in FIG. 15(c), the sewing machine 1 exceeds region B shortly and reaches region C. When the sewing machine 1 has reached region C, the position control section 80 which had disabled the operation of the driver 14 until then, enables the operation of the driver 14. Hence, the driver 14 drives the motor 2 to generate the holding force corresponding to the velocity command value from the position/velocity conversion section 19, i.e., position deviation (a state similar to the case where the soft brake is operated). In region C, therefore, the torque resisting the force of the sewing machine 1 attempting to move is generated to stop the sewing machine 1. A case where a position displacement occurs thereafter is identical to that of the conventional sewing machine drive apparatus and will not be described here. The operation of the position control section 80 will now be described in accordance with a flowchart in FIG. 14. This flowchart has the processing of step 65, step 71, step 120, step 130 and step 140 in addition to the flowchart in FIG. 22 which is representative of the conventional art. First, when the soft brake processing is initiated, the operation starts in step 50, the position deviation is cleared in step 60, and the position deviation from stop position DR is cleared in step 65. Subsequently, the value of the position feedback is added to the position deviation in step 70 and the value of the position feedback is also added to the position deviation from stop position DR in step 71. Here, the operation will be described for a case where the sewing machine 1 has moved as shown in FIGS. 15(a)-(c). Since the value of the position deviation from stop position DR and the value of the position deviation are both small at first, the processing proceeds from step 80 to step 90 to step 120 to step 130 to step 140. Since an operation disable command is output to the driver 14 in the processing of step 140, the current does not flow and the torque is zero (in the part of region B as seen in FIG. 15(c)). As the execution passes steps 70 and 71 several times, both the value of the position deviation from stop position DR and the value of the position deviation increase. Since the third set value P2 (FIG. 15(a)) is smaller than the first set value P (FIG. 15(c)), before reaching P in FIG. 15(b), a judgement is made first in step 120 to branch to step 100 when DR>P2. Hence, the processing of step 140 (driver disable command output) is not performed and the operation disable command is not output to the driver 14, whereby the driver 14 starts operation and torque is generated. This is point f in FIGS. 15(a) and (c). Hereafter, as described previously, the processing that the position deviation value is cleared when it exceeds the first set value P will be performed shortly (point g in FIG. 15(c)). Accordingly, since the position deviation remains zero if the sewing machine 1 does not move, the driver 14 does not operate and the motor 2 is not energized. Namely, since the operation performed is the same as when the soft brake is not operated, excitation noise is not generated, either. This operation as viewed on the motor pulley side is shown in FIG. 16. As described above, the present embodiment is designed to disable the soft brake from being operated if the position deviation from the stop position is within 2 degrees on the shaft of the motor 2, whereby the soft brake is not operated if the sewing machine 1 does not move. Accordingly, the noise generated when the sewing machine 1 is not moving is eliminated and the sewing machine drive apparatus is quieter than the conventional machine. It will be recognized that the present embodiment will not operate the soft brake if the position deviation from the stop position is within 2 degrees on the shaft of the motor 2, but that other embodiments may be designed not to be operated if the position deviation from the stop position is within an optional angle. Also, when the sewing machine 1 used can be positioned to a stop at its needle UP or DOWN position under the control of the signal from the needle position detector 6 as described previously, the soft brake may be operated not according to the angle of the motor 2 or the sewing machine 1 but in relation to the signal from said needle position detector 6, e.g., when the UP position signal or the DOWN position signal is switched off (switched off when the sewing machine is offset from the stop position), in order to provide the same effects. It will be apparent that the present invention achieves a sewing machine drive apparatus wherein the intensity of holding force generated to keep a sewing machine from being moved during a sewing machine stop can be changed according to the speed of drive means, e.g., a motor, or the sewing machine, whereby when attempting to move the sewing machine by hand, the worker can move the sewing machine easily with small power as compared to the conventional apparatus. It will also be apparent that the present invention achieves a sewing machine drive apparatus wherein the intensity of holding force generated to keep a sewing machine from being moved during a sewing machine stop can be changed according to the pulley ratio of the pulley diameter of the drive apparatus and that of the sewing machine, whereby the power required when the worker attempts to move the sewing machine by hand is independent of the pulley ratio and the worker can move the sewing machine with constant power at any pulley ratio. It will be also apparent that the present invention achieves a sewing machine drive apparatus wherein the intensity of holding force generated to keep a sewing machine from being moved during a sewing machine stop is reduced as the position deviation from a stop position is increased, whereby when attempting to move the sewing machine by hand, the worker can move the sewing machine easily with small power as compared to the conventional apparatus. It will further be apparent that the present invention achieves a sewing machine drive apparatus wherein the control of holding force generated to keep a sewing machine from being moved during a sewing machine stop is started when the motion of drive means, e.g., a motor, or the sewing machine is detected, whereby noise generated when the sewing machine is not moving has been eliminated and a silent sewing machine drive apparatus can be provided. The entire disclosure of each and every foreign patent application from which the benefit of foreign priority has been claimed in the present application is incorporated herein by reference, as if fully set forth. Although this invention has been described in at least one preferred embodiment with a certain degree of particularity, it is to be understood that the present disclosure of the preferred embodiment has been made only by way of example and that numerous changes in the details and arrangement of components may be made without departing from the spirit and scope of the invention as hereinafter claimed.
A sewing machine apparatus driven by a motor, which is subject to velocity control on the basis of a detector for determining the rotary position and/or velocity of the motor output shaft. A controller is operative to control the speed of the motor in accordance with a velocity command value. A means for generating a holding force during a stop of the sewing machine ensures that the sewing needle does not provide unwanted movement. The holding force is changed when movement from the stop position is desired, as by changing the force in relation to the speed or amount of movement. This feature is particularly useful to reduce the load presented to an operator who wishes to manually change the machine position.
3
TECHNICAL FIELD [0001] The present invention relates to liquid coagulants and tire puncture sealant sets. BACKGROUND ART [0002] A known tire puncture sealant for repairing a punctured tire is obtained by blending a natural rubber latex with a tackifying resin emulsion and an antifreezing agent (see Patent Literatures 1 and 2, for instance). [0003] The present applicant once proposed a blend of a synthetic resin emulsion and an antifreezing agent (see Patent Literatures 3 through 6, for instance). [0004] Such a tire puncture sealant is generally injected into a tire through a portion (valve) for tire inflation, and reaches a puncture hole when the car is driven after the tire is filled with air at a specified air pressure. Rubber particles in the tire puncture sealant form aggregates in the tire by the action of a compressive or shearing force exerted on them when the rotating tire comes into contact with the ground, and the formed aggregates seal the puncture hole to enable the driving of the car. [0005] The tire as repaired with the above tire puncture sealant has the non-aggregated tire puncture sealant (liquid components) remaining therein. The tire puncture sealant normally contains an antifreezing agent such as ethylene glycol, so that the tire puncture sealant remaining in a tire needs to be recovered when the tire is changed or at the end of use of the tire. [0006] In order to meet such requirement, the present applicant has proposed as a coagulant for tire puncture sealants “an emulsion coagulant for coagulating a tire puncture sealant containing emulsion particles, comprising: a mineral which induces aggregation of the emulsion particles by either one or both of weakening of surface charge of the emulsion particles and formation of hydrogen bond between the mineral and the emulsion particles; and a gelation agent” (Patent Literature 7). CITATION LIST Patent Literature [0000] Patent Literature 1: JP 2004-035867 A Patent Literature 2: JP 3210863 B Patent Literature 3: JP 2007-224245 A Patent Literature 4: JP 2007-224246 A Patent Literature 5: JP 2007-224248 A Patent Literature 6: JP 2009-51893 A Patent Literature 7: JP 4245654 B SUMMARY OF INVENTION Technical Problems [0014] It, however, is necessary for the addition of the emulsion coagulant as disclosed in Patent Literature 7 to remove a tire in advance from the rim, and a tire puncture sealant remaining in the tire (hereafter also referred to as “residual tire puncture sealant”) may splash when the tire is removed from the rim. [0015] An object of the present invention is to provide a liquid coagulant capable of being injected into a tire without removing the tire from the rim, and capable of preventing a residual tire puncture sealant from splashing when the tire is removed from the rim. Solution to Problems [0016] As a result of diligent research, the present inventors found that the liquid coagulant with a specified pH value that comprises a urethane resin and/or an acrylic resin having a cationic functional group is capable of being injected into a tire through a valve, and capable of in-situ coagulation of a tire puncture sealant remaining within the tire, so as to complete the present invention. [0017] In other words, the present invention provides the following (1) through (13). [0018] (1) A liquid coagulant for coagulating an emulsion containing a natural rubber latex, [0019] having a pH of 2.0 to 4.0; and [0020] comprising a urethane resin and/or an acrylic resin having a cationic functional group. [0021] (2) The liquid coagulant according to (1) as above, wherein the cationic functional group is a functional group having a quaternary ammonium ion. [0022] (3) The liquid coagulant according to (1) or (2) as above, wherein the urethane resin has an alkylene oxide structure. [0023] (4) The liquid coagulant according to (3) as above, wherein the urethane resin has an ethylene oxide structure. [0024] (5) The liquid coagulant according to any one of (1) through (4) as above, wherein the acrylic resin has an acrylamide structure. [0025] (6) The liquid coagulant according to any one of (1) through (5) as above, further comprising an antifreezing agent. [0026] (7) The liquid coagulant according to (6) as above, wherein the antifreezing agent is at least one selected from the group consisting of ethylene glycol, propylene glycol, diethylene glycol, glycerin, methanol, ethanol, and isopropyl alcohol. [0027] (8) The liquid coagulant according to any one of (1) through (7) as above, wherein the emulsion is a tire puncture sealant which further contains a synthetic resin emulsion and an antifreezing agent. [0028] (9) The liquid coagulant according to (8) as above, wherein the synthetic resin emulsion is at least one selected from the group consisting of an ethylene vinyl acetate emulsion, an acrylic emulsion, and a urethane emulsion. [0029] (10) The liquid coagulant according to (8) or (9) as above, wherein the antifreezing agent is at least one selected from the group consisting of ethylene glycol, propylene glycol, diethylene glycol, glycerin, methanol, ethanol, and isopropyl alcohol. [0030] (11) A tire puncture sealant set, comprising: a tire puncture sealant which contains a natural rubber latex, a synthetic resin emulsion, and an antifreezing agent; and the liquid coagulant according to any one of (1) through (7) as above. [0031] (12) The tire puncture sealant set according to (11) as above, wherein the synthetic resin emulsion is at least one selected from the group consisting of an ethylene vinyl acetate emulsion, an acrylic emulsion, and a urethane emulsion. [0032] (13) The tire puncture sealant set according to (11) or (12) as above, wherein the antifreezing agent is at least one selected from the group consisting of ethylene glycol, propylene glycol, diethylene glycol, glycerin, methanol, ethanol, and isopropyl alcohol. Advantageous Effects of Invention [0033] As demonstrated below, the liquid coagulant according to the present invention is capable of being injected into a tire without removing the tire from the rim, and capable of preventing a residual tire puncture sealant from splashing when the tire is removed from the rim. [0034] The liquid coagulant of the invention is very useful because it not only prevents splashing of a residual tire puncture sealant when a tire is removed from the rim but ensures the safety of workers by preventing pollution due to the splashing. DESCRIPTION OF EMBODIMENTS [0035] In the following, the present invention is described in detail. [0036] The liquid coagulant of the invention is a liquid coagulant for coagulating an emulsion containing a natural rubber latex, which coagulant has a pH of 2.0 to 4.0, and contains a urethane resin and/or an acrylic resin having a cationic functional group. [0037] In the present invention, the pH value of the liquid coagulant refers to a value measured at 20° C. using a pH meter. The pH of the liquid coagulant may appropriately be adjusted with an acid, with adjustment using an organic acid (formic acid, acetic acid or oxalic acid, for instance) being preferred. [0038] While a liquid state may be based on water or a solvent, a water-based liquid state is preferable in terms of the compatibility of the liquid coagulant of the invention with the emulsion to be coagulated. [0039] Ingredients of the inventive liquid coagulant are detailed below. <Urethane Resin> [0040] The urethane resin to be used in the liquid coagulant of the invention is not particularly limited as long as it has a cationic functional group. [0041] A cationic functional group refers to a functional group having a cation. [0042] Specific examples of the cation include an ammonium ion, a phosphonium ion, an imidazolium ion, a pyridinium ion, a pyrrolidinium ion, and a piperidinium ion. Among others, a quaternary ammonium ion is preferable because of its good handleability. [0043] In the present invention, the urethane resin preferably has an alkylene oxide structure for the reason that the property of coagulating an emulsion containing a natural rubber latex (a tire puncture sealant described later, for instance) is further improved. [0044] An alkylene oxide structure refers to a structural unit represented by formula (1) below. For the reason that the property of coagulating the emulsion as above is further improved, it is preferable that the urethane resin has the ethylene oxide structure as represented by formula (1) in which n is 2. [0000] [0000] (In the formula, n is an integer of 2 to 4). [0045] In the present invention, the method of synthesizing the urethane resin is not particularly limited. In an exemplary method, a polyisocyanate compound is reacted with a polyol compound and an amine compound such that the active hydrogen groups of the polyol compound and the amine compound are excessive with respect to the isocyanate groups (NCO groups) of the polyisocyanate compound, and an acid is added to the resultant reaction product so as to generate quaternary ammonium ions. [0046] The polyisocyanate compound to be used for the synthesis of the urethane resin is not particularly limited as long as it has two or more isocyanate groups in the molecule. [0047] Specific examples of the polyisocyanate compound include aromatic polyisocyanates, such as TDIs (e.g., 2,4-tolylene diisocyanate (2,4-TDI), 2,6-tolylene diisocyanate (2,6-TDI)), MDIs (e.g., 4,4′-diphenylmethane diisocyanate (4,4′-MDI), 2,4′-diphenylmethane diisocyanate (2,4′-MDI)), 1,4-phenylene diisocyanate, polymethylene polyphenylene polyisocyanate, xylylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), tolidine diisocyanate (TODI), 1,5-naphthalene diisocyanate (NDI), and triphenylmethane triisocyanate; aliphatic polyisocyanates, such as hexamethylene diisocyanate (HDI), trimethylhexamethylene diisocyanate (TMHDI), lysine diisocyanate, and norbornane diiscyanate (NBDI); alicyclic polyisocyanates, such as trans-cyclohexane-1,4-diisocyanate, isophorone diisocyanate (IPDI), bis(isocyanate methyl)cyclohexane (H 6 XDI), and dicyclohexylmethane diisocyanate (H 12 MDI); carbodiimide-modified polyisocyanates derived from such polyisocyanates; and isocyanurate-modified polyisocyanates derived from such polyisocyanates. [0048] The above polyisocyanate compounds may be used alone or as a combination of two or more out of them. [0049] Among others, tolylene diisocyanates (TDIs) are preferable because they yield urethane resins of low viscosity, and the inventive liquid coagulant including such a urethane resin is easy to handle. [0050] The polyol compound to be used for the synthesis of the urethane resin is not particularly limited as long as it has two or more hydroxy groups. [0051] The polyol compound is exemplified by polyether polyols and polyester polyols. [0052] Exemplary polyether polyols include a polyol obtained by adding at least one selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide, and polyoxy tetramethylene oxide to at least one selected from the group consisting of ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, glycerin, 1,1,1-trimethylolpropane, 1,2,5-hexanetriol, 1,3-butanediol, 1,4-butanediol, and pentaerythritol. [0053] Specifically, polyethylene glycol (polyethylene oxide), polypropylene glycol (polypropylene oxide), polypropylene triol, an ethylene oxide/propylene oxide copolymer, polytetramethylene ether glycol (PTMEG), polytetraethylene glycol, and sorbitol-type polyols are mentioned as preferred examples. [0054] Specific examples of polyester polyols include a condensation polymer between at least one selected from the group consisting of ethylene glycol, propylene glycol, butanediol, pentanediol, hexanediol, glycerin, 1,1,1-trimethylolpropane and other low-molecular polyols, and at least one selected from the group consisting of glutaric acid, adipic acid, pimelic acid, suberic acid, sebacic acid, dimer acids and other aliphatic carboxylic acids, castor oil and other hydroxycarboxylic acids, as well as oligomer acids; and ring-opened polymers, such as propiolactone and valerolactone. [0055] The above polyol compounds may be used alone or as a combination of two or more out of them. [0056] Among others, polyether polyols, to be more specific, polyethylene glycol (polyethylene oxide), polypropylene glycol (polypropylene oxide), and ethylene oxide/propylene oxide copolymers are preferable because a resultant urethane resin has an alkylene oxide structure. [0057] The amine compound to be used for the synthesis of the urethane resin is not particularly limited, while it is preferable to use a low-molecular compound having a tertiary or secondary amine because, in that case, cations (quaternary ammonium ions) are more likely to be generated. Exemplary compounds include N-methyl diethanolamine, triethylamine, N,N-dimethyl ethanolamine, diethanolamine, dimethylamine, and diethylamine. [0058] More preferably, a compound having a tertiary amine, N-methyl diethanolamine in particular, is used because cations are even more likely to be generated. [0059] The acid to be added to the reaction product (urethane resin) as obtained by the reaction of the polyisocyanate compound with the polyol compound and the amine compound as describe above is suitably exemplified by organic acids, such as formic acid, acetic acid and oxalic acid, because such acids not only generate cations but facilitate adjusting the pH of the inventive liquid coagulant to 2.0 to 4.0. <Acrylic Resin> [0060] The acrylic resin to be used in the liquid coagulant of the invention is not particularly limited as long as it has a cationic functional group. [0061] A cationic functional group refers to a functional group having a cation, as is the case with the urethane resin as described above. [0062] In the present invention, the acrylic resin preferably has an acrylamide structure for the reason that the polymerizability between resins is improved. [0063] An acrylamide structure preferably refers to a structural unit represented by formula (5) below, which also serves as a cationic functional group (group with quaternary ammonium), while it may refer to a structural unit represented by one out of formulae (2) through (4) if the acrylic resin has another moiety as a cationic functional group. [0000] [0000] (In the formulae, R 1 through R 3 are each independently a monovalent aliphatic hydrocarbon group with 1 to 6 carbon atoms). [0064] In the present invention, the method of synthesizing the acrylic resin is not particularly limited. In an exemplary method, an acid is added to an acrylamide polymer having an amido group, so as to generate quaternary ammonium ions. [0065] Specific examples of the acrylamide polymer to be used for the synthesis of the acrylic resin include poly-N-ethyl acrylamide, poly-N-n-propyl acrylamide, poly-N-isopropyl acrylamide, poly-N-cyclopropyl acrylamide, poly-N,N-diethyl acrylamide, poly-N-methyl-N-ethyl acrylamide, poly-N-methyl-N-n-propyl acrylamide, poly-N-methyl-N-isopropyl acrylamide, poly-N-acryloyl piperidine, poly-N-acryloyl pyrrolidine, poly-N-acryloyl morpholine, poly-N-methoxypropyl acrylamide, poly-N-ethoxypropyl acrylamide, poly-N-isopropoxypropyl acrylamide, poly-N-ethoxyethyl acrylamide, poly-N-(2,2-dimethoxyethyl)-N-methyl acrylamide, poly-N-1-methyl-2-methoxyethyl acrylamide, poly-N-1-methoxymethylpropyl acrylamide, poly-N-di(2-methoxyethyl) acrylamide, poly-N-2-methoxyethyl-N-n-propyl acrylamide, poly-N-2-methoxyethyl-N-ethyl acrylamide, poly-N-2-methoxyethyl-N-isopropyl acrylamide, poly-N-methoxyethoxypropyl acrylamide, poly-N-tetrahydrofurfuryl acrylamide, poly-N-(1,3-dioxolan-2-yl)methyl acrylamide, poly-N-methyl-N-(1,3-dioxolan-2-yl)methyl acrylamide, poly-N-cyclopropyl acrylamide, poly-N-pyrrolidinomethyl acrylamide, poly-N-piperidinomethyl acrylamide, poly-N-2-morphorinoethyl acrylate, poly-N-2-morphorinoethoxyethyl acrylate, and methacrylates corresponding thereto. [0066] The acid to be added to the above acrylamide polymer is exemplified by those acids as mentioned above with respect to the urethane resin. [0067] The liquid coagulant of the invention that contains the urethane resin and/or acrylic resin (in this paragraph also referred to as “urethane resin and the like”) as described above, and has a pH adjusted to 2.0 to 4.0 is excellent in property of coagulating an emulsion containing a natural rubber latex (a tire puncture sealant described later, for instance), and is capable of being injected into a tire through a valve and coagulating a residual tire puncture sealant within the tire. [0068] The reason for an excellent coagulating property is considered to lie in that the emulsion to be coagulated is made less stable and more likely to involve aggregation by the urethane resin and the like having a cationic functional group, and that coagulation proceeds after the inventive liquid coagulant, as having a pH value falling within the range of 2.0 to 4.0, is adequately dissolved in the emulsion to be coagulated. [0069] In view of the fact that a common tire puncture sealant contains a water-soluble solvent, such as ethylene glycol and propylene glycol, as an antifreezing agent, it is very surprising that the liquid coagulant of the invention has an effect of coagulating a residual tire puncture sealant. <Water> [0070] The liquid coagulant of the invention may contain water as required from the viewpoint of the capability of being injected into a tire through a valve (handleability) or the stability of the cationic functional group of the urethane resin and/or acrylic resin as described above. [0071] In that case, the water content is preferably 50 to 300 parts by weight, and more preferably 100 to 200 parts by weight on 100 parts by weight of the urethane resin and/or acrylic resin. [0072] If the urethane resin and acrylic resin as above are to be used in combination, the water content is based on 100 parts by weight of a combination of the urethane resin and the acrylic resin. <Antifreezing Agent> [0073] The liquid coagulant of the invention may contain an antifreezing agent as required. [0074] The antifreezing agent to be contained is not particularly limited, with a conventional antifreezing agent being available. [0075] Exemplary antifreezing agents specifically include ethylene glycol, propylene glycol, diethylene glycol, glycerin, methanol, ethanol and isopropyl alcohol, which may be used alone or as a combination of two or more out of them. [0076] Use of propylene glycol is preferable because the viscosity of the inventive liquid coagulant can be designed to be low, and use of propylene glycol and methanol in combination is preferable because an excellent coagulating property of the inventive liquid coagulant can be maintained. [0077] If the above antifreezing agent is to be contained, the antifreezing agent content is preferably 50 to 500 parts by weight, and more preferably 100 to 300 parts by weight on 100 parts by weight of the urethane resin and/or acrylic resin as described above. [0078] If the urethane resin and acrylic resin as above are to be used in combination, the antifreezing agent content is based on 100 parts by weight of a combination of the urethane resin and the acrylic resin. [0079] The following description is made on the emulsion to be coagulated with the liquid coagulant of the invention. [0080] The emulsion is not particularly limited as long as it contains a natural rubber latex, but is preferably a tire puncture sealant further containing a synthetic resin emulsion and an antifreezing agent because the effects of the inventive liquid coagulant can fully be exerted thereon. [0081] Ingredients of the emulsion (tire puncture sealant) to be coagulated with the liquid coagulant of the invention are detailed below. <Natural Rubber Latex> [0082] The natural rubber latex to be used in the emulsion, or tire puncture sealant, is not particularly limited, with a conventional natural rubber latex being available. [0083] Exemplary natural rubber latices specifically include a latex collected by tapping Hevea brasiliensis, and a so-called “deproteinized natural rubber latex” obtained by removing proteins from a natural rubber latex. <Synthetic Resin Emulsion> [0084] The synthetic resin emulsion to be used in the tire puncture sealant is not particularly limited, with a conventional synthetic resin emulsion being available. [0085] Exemplary synthetic resin emulsions specifically include an ethylene vinyl acetate emulsion, an acrylic emulsion and a urethane emulsion, which may be used alone or as a combination of two or more out of them. [0086] As the above synthetic resin emulsions, their respective examples as mentioned in Patent Literature 7 may be used. [0087] The synthetic resin content preferably makes the blending ratio between the solids in the natural rubber latex and in the synthetic resin emulsion (the natural rubber latex/the synthetic resin emulsion) 5/95 to 80/20, more preferably 20/80 to 50/50. <Antifreezing Agent> [0088] The antifreezing agent to be used in the tire puncture sealant is not particularly limited, with a conventional antifreezing agent being available. [0089] Exemplary antifreezing agents include those as mentioned above with respect to the liquid coagulant of the invention. [0090] The antifreezing agent content is preferably 20 to 300 parts by weight, and more preferably 50 to 200 parts by weight on 100 parts by weight of the whole solids in the natural rubber latex and the synthetic resin emulsion. <Tackifier> [0091] The tire puncture sealant to be coagulated with the liquid coagulant of the invention may contain a tackifier from the viewpoint of the sealing property. [0092] The tackifier to be contained is not particularly limited, with a conventional antifreezing agent being available. Specific examples include rosin-based resins, such as a rosin resin, a polymerized rosin resin, a rosin ester resin, a polymerized rosin ester resin, and a modified rosin; terpene phenol resins; terpene resins, such as an aromatic terpene; hydrogenated terpene resins obtained by hydrogenation of a terpene resin; phenol resins; and xylene resins. [0093] The tackifier content is preferably 10 to 150 parts by weight, and more preferably 20 to 100 parts by weight on 100 parts by weight of the whole solids in the natural rubber latex and the synthetic resin emulsion. <Additive> [0094] Apart from the ingredients as described above, the tire puncture sealant to be coagulated with the liquid coagulant of the invention may contain, as desired or required, various additives such as a filler, an anti-aging agent, an antioxidant, a pigment (dye), a plasticizer, a thixotropic agent, an ultraviolet absorber, a flame retardant, a surfactant (including a leveling agent), a dispersant, a dehydrating agent, and an antistatic agent. [0095] As the above additives, their respective examples as mentioned in Patent Literature 7 may be used. [0096] The tire puncture sealant set of the invention is as follows. [0097] The tire puncture sealant set of the invention includes a tire puncture sealant containing a natural rubber latex, a synthetic resin emulsion and an antifreezing agent, and the liquid coagulant of the invention as described before. [0098] The tire puncture sealant in the tire puncture sealant set of the invention is such a tire puncture sealant as described to be coagulated with the inventive liquid coagulant as described before. [0099] The amount (as solids) of the liquid coagulant of the invention to be used when a puncture hole is sealed using the tire puncture sealant set of the invention is not particularly limited because the content of the tire puncture sealant which actually remains in the tire is often unknown, while the usage amount of the inventive coagulant is preferably about 50 to 200 parts by weight, and more preferably about 80 to 150 parts by weight on 100 parts by weight of the solids in the tire puncture sealant as used. [0100] The tire puncture sealant set of the invention makes it possible not only to promptly repair the punctured tire of a car using the tire puncture sealant in the set so as to continue driving the car, but readily change the tire at a service station or the like in the neighborhood depending on the influence on the roadability or the lifetime of the tire by coagulating the tire puncture sealant remaining in the tire with the liquid coagulant of the invention. EXAMPLES [0101] The present invention is illustrated in reference to the following examples, to which the present invention is in no way limited. <Preparation of Tire Puncture Sealant> [0102] A tire puncture sealant was prepared by using an agitator to mix together the ingredients of the sealant that are listed in Table 1 below in the amounts (in parts by weight) as set forth in the same table. [0000] TABLE1 Tire puncture sealant Emulsion 1 50 Emulsion 2 50 Antifreezing agent 100 Surfactant A 1.5 Surfactant B 0.45 Total amount 201.95 Solid content (%) 27.3 [0103] The tire puncture sealant ingredients as listed in Table 1 are specifically as follows. [0104] Emulsion 1: A natural rubber emulsion (HA latex; solid content, 60 wt %; manufactured by Golden Hope Corporation). [0105] Emulsion 2: An ethylene vinyl acetate emulsion (solid content, 51 wt %; Sumikaflex S-408HQE manufactured by Sumika Chemtex Co., Ltd.). [0106] Antifreezing agent: Propylene glycol (solid content, 100 wt %; manufactured by Wako Pure Chemical Industries, Ltd.). [0107] Surfactant A: Dodecyl sodium sulfate (manufactured by Wako Pure Chemical Industries, Ltd.). [0108] Surfactant B: Polyoxyethylene alkyl ether (EMULGEN 109 manufactured by Kao Corporation). Preparation of Liquid Coagulant Examples 1 Through 4, and Comparative Examples 1 Through 4 [0109] A polyisocyanate compound (TDI manufactured by Mitsui Chemicals, Inc.), a polyol compound (ethylene oxide-terminated polypropylene glycol; CMC252 manufactured by ADEKA Corporation), and an amine compound (N-methyl diethanolamine), each in the amounts (in parts by weight) as set forth in Table 2 below, were initially mixed and reacted together to obtain urethane resins each having an ethylene oxide structure and a propylene oxide structure. [0110] To the urethane resins thus obtained, an acid (formic acid) was added in the amounts (in parts by weight) as set forth in Table 2, so as to convert a tertiary amino group into a cationic functional group (group having a quaternary ammonium ion). [0111] The resultant urethane resins were cooled to a temperature of 10° C. or lower before water was added in the amounts as set forth in Table 2 to the resins in reaction vessels that were being agitated at a high speed of about 500 rpm, to thereby yield liquid coagulants with the solid contents and pH values as set forth in Table 2. [0000] TABLE 2 Example Comparative Example 1 2 3 4 1 2 3 4 Polyisocyanate 20 20 20 20 20 20 20 20 compound Polyol 145 145 145 145 145 145 145 145 compound Amine 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 compound Acid 4.5 6.0 8.0 10.0 1.6 1.9 2.5 3.0 Water 212 213 215 218 208 208 210 210 Total amount 385.6 388.1 392.1 397.1 378.7 379.0 381.6 382.1 Solid content 45.0 45.1 45.2 45.1 45.1 45.1 45.0 45.0 (%) pH 4.0 3.5 2.5 2.1 6.8 6.0 5.6 4.8 Coagulating fair good good good poor poor poor poor property 1 Examples 5 Through 8, and Comparative Examples 5 Through 8 [0112] By following the procedure of Example 1 except for the use of the urethane resin with no ethylene oxide structures that was obtained by using polypropylene glycol (manufactured by Mitsui Chemicals, Inc.) as a polyol compound in the amounts as set forth in Table 3 below, liquid coagulants with the solid contents and pH values as set forth in Table 3 were prepared. [0000] TABLE 3 Example Comparative Example 5 6 7 8 5 6 7 8 Polyisocyanate 20 20 20 20 20 20 20 20 compound Polyol 115 115 115 115 115 115 115 115 compound Amine 4.1 4.1 4.1 4.1 4.1 4.1 4.1 4.1 compound Acid 4.5 6.0 8.0 10.0 1.6 1.9 2.5 3.0 Water 174 176 179 182 171 172 173 173 Total amount 317.6 321.1 326.1 331.1 311.7 313.0 314.6 315.1 Solid content 45.2 45.2 45.1 45.0 45.1 45.0 45.0 45.1 (%) pH 4.0 3.5 2.5 2.1 6.8 6.0 5.6 4.8 Coagulating fair fair fair fair poor poor poor poor property 1 Example 9 [0113] By following the procedure of Example 1 except for the use of diethanolamine as an amine compound in the amount as set forth in Table 4 below, a liquid coagulant with the solid content and pH value as set forth in Table 4 was prepared. Example 10 [0114] By following the procedure of Example 1 except for the use of oxalic acid as an acid in the amount as set forth in Table 4 below, a liquid coagulant with the solid content and pH value as set forth in Table 4 was prepared. Comparative Example 9 [0115] The urethane resin as prepared in Example 1 that had no acid (formic acid) added thereto was taken in itself as a liquid coagulant. [0000] TABLE 4 Comparative Example Example 9 10 9 Polyisocyanate 20 20 20 compound Polyol compound 145 145 145 Amine compound 3.5 4.1 4.1 Acid 4.5 4.5 — Water 212 212 204 Total amount 385.0 385.6 373.1 Solid content (%) 43.8 43.8 45.3 pH 3.5 3.5 9.0 Coagulating property 1 fair fair poor Examples 11 Through 17 [0116] To the liquid coagulant as prepared in Example 2, the antifreezing agents as listed in Table 5 below (propylene glycol and methanol) were further added in the amounts as set forth in the same table, to thereby yield liquid coagulants. [0000] TABLE 5 Example 11 12 13 14 15 16 17 Polyisocyanate 20 20 20 20 20 20 20 compound Polyol compound 145 145 145 145 145 145 145 Amine compound 4.1 4.1 4.1 4.1 4.1 4.1 4.1 Acid 6.0 6.0 6.0 6.0 6.0 6.0 6.0 Water 213 213 213 213 213 213 213 Propylene glycol 70 50 50 35 20 20 20 Methanol 0 0 20 35 50 30 20 Total amount 458.1 438.1 458.1 458.1 458.1 438.1 428.1 Solid content (%) 38.2 40.0 38.2 38.2 38.2 40.0 40.9 pH 3.5 3.5 3.5 3.5 3.5 3.5 3.5 Coagulating property 2 fair fair fair good good good good Appearance at minus liquid solid liquid liquid liquid liquid liquid 20° C. Examples 18 and 19, and Comparative Examples 10 Through 12 [0117] To an acrylic resin emulsion having an acrylamide structure (solid content, 45%; manufactured by Asahi Kasei Chemicals Corporation) in the amounts (in parts by weight) as set forth in Table 6 below, an acid (formic acid) was added in the amounts (in parts by weight) as set forth in the same table, so as to convert an amido group of the acrylic resin into a cationic functional group (group having a quaternary ammonium ion). [0118] Then, the antifreezing agents as listed in Table 6 were added in the amounts as set forth in the same table, to thereby yield liquid coagulants with the solid contents and pH values as set forth in Table 6. [0000] TABLE 6 Example Comparative Example 18 19 10 11 12 Acrylic resin emulsion 100 100 100 100 100 Acid 3.5 4.0 1.0 1.5 2.5 Propylene glycol 10 10 10 10 10 Methanol 10 10 10 10 10 Total amount 123.5 124.0 121.0 121.5 122.5 Solid content (%) 36.4 36.3 37.2 37.0 36.7 pH 2.5 2.2 6.8 5.5 4.3 Coagulating property 2 good good poor poor poor Appearance at minus liquid liquid liquid liquid liquid 20° C. <Evaluation> [0119] (1) Coagulating Property 1 [0120] Each of the liquid coagulants as prepared in Examples 1 through 10 and Comparative Examples 1 through 9 was added, in an amount of 10 g, to 100 g of the tire puncture sealant as prepared by the above method, then the mixtures were agitated at 20° C. for five minutes before the presence of liquid components was visually examined. [0121] If no liquid components were identified, the coagulant in question was evaluated as “good” in coagulating property. If the coagulant in question had practically no problem from the viewpoint of preventing the residual tire puncture sealant from splashing even though liquid components were slightly identified, it was evaluated as “fair.” If liquid components were identified in large amounts, the coagulant in question was evaluated as “poor” in coagulating property. The evaluation results are shown in Tables 2 through 4. [0122] (2) Coagulating Property 2 [0123] The liquid coagulants as prepared in Examples 11 through 19 and Comparative Examples 10 through 12 were each added in an amount of 60 ml within the tire without rim in which 600 ml of the tire puncture sealant as prepared by the above method had been placed. [0124] Then, each tire was swung in its rolling directions, forward and backward, ten times (five times per direction) and each time by about 90 degrees. [0125] Subsequently, the tires were left standing at 20° C. for five minutes before the presence of liquid components was visually examined. [0126] If no liquid components were identified, the coagulant in question was evaluated as “good” in coagulating property. If the coagulant in question had practically no problem from the viewpoint of preventing the residual tire puncture sealant from splashing even though liquid components were slightly identified, it was evaluated as “fair.” If liquid components were identified in large amounts, the coagulant in question was evaluated as “poor” in coagulating property. The evaluation results are shown in Tables 5 and 6. [0127] (3) Appearance at Minus 20° C. [0128] The liquid coagulants as prepared in Examples 11 through 19 and Comparative Examples 10 through 12 were visually observed on appearance at minus 20° C. (whether to appear solid or liquid). The results are shown in Tables 5 and 6. [0129] It was found from the results as shown in Tables 2 through 6 that the liquid coagulants with pH values not falling within the range of 2.0 to 4.0 (Comparative Examples 1 through 12) were poor in coagulating property irrespective of the presence or absence of a cationic functional group. [0130] In contrast, the liquid coagulants whose pH values fell within the range of 2.0 to 4.0 and which had cationic functional groups (Examples 1 through 19) were each found to be good in coagulating property, and capable of preventing the residual tire puncture sealant from splashing. [0131] Among the liquid coagulants with an antifreezing agent added thereto in particular, those as prepared in Examples 11 and 13 through 19 were found to remain liquid even at minus 20° C.
Disclosed is a liquid coagulant which can be injected into the inside of a tire without removing the tire from a rim and which can prevent the scattering of a residue of a tire puncture sealing material when the tire is removed from the rim. The liquid coagulant can coagulate an emulsion that contains a natural rubber latex. The liquid coagulant comprises a urethane resin and/or an acrylic resin which has a pH value of 2.0 to 4.0 and contains a cationic functional group.
2
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates generally to toothbrush and, more specifically, to a liquid dentifrice dispensing toothbrush for applying a measured dose of liquid dentifrice from a reservoir of liquid dentifrice into the toothbrush bristles by means of an integral pump. [0003] 2. Description of the Prior Art [0004] There are other tooth brushing devices designed for dispensing dentifrice. Typical of these is U.S. Pat. No. 1,676,601 issued to Cavanaugh on Jul. 10, 1928. [0005] Another patent was issued to Burgin on Apr. 24, 1956 as U.S. Pat. No. 2,743,042. Yet another U.S. Pat. No. 2,807,818 was issued to Taylor on Oct. 1, 1957 and still yet another was issued on Dec. 2, 1980 to Meyer et al. as U.S. Pat. No. 4,236,651. [0006] Another patent was issued to Hassan on Oct. 24, 1989 as U.S. Pat. No. 4,875,791. Yet another U.S. Pat. No. 5,346,324 was issued to Kuo on Sep. 13, 1994. Another was issued to Voight on Jan. 17, 1995 as U.S. Pat. No. 5,382,106 and still yet another was issued on Jun. 23, 1998 to Podolsky as U.S. Pat. No. 5,769,585. [0007] Another patent was issued to Kuo on Jun. 8, 1999 as U.S. Pat. No. 5,909,977. Yet another U.S. Pat. No. 5,918,995 was issued to Puurunen on Jul. 6, 1999. Another was issued to Spies et al. on Jun. 5, 2001 as U.S. Pat. No. 6,241,412 and still yet another was issued on Jan. 20, 2004 to Dillingham et al. as U.S. Pat. No. 6,679,642. [0008] Another patent was issued to Jang on Sep. 27, 2005 as U.S. Pat. No. 6,948,875. Yet another Canadian Patent No. CA523340 was issued to Neuls on Apr. 3 1961. Another was issued to Horitz on Apr. 6, 1961 as U.K. Patent No. GB864,439 and still yet another was issued on Sep. 27, 1989 to Douglas as U.K. Patent No. GB2215593. U.S. Pat. No. 1,676,601 Inventor: Leo C. Cavanaugh Issued: Jul. 10, 1928 [0009] This invention relates to an improvement in fountain toothbrushes. A soft, cleansing, and antiseptic brush is provided for the teeth and gums, which is antiseptically self-filled and may be easily and quickly used for cleansing the teeth. U.S. Pat. No. 2,743,042 Inventor: Luther B. Burgin Issued: Apr. 24, 1956 [0010] This invention relates in general to improvements in tooth brushes, more particular to an improved fountain tooth brush. This invention provides an improved tooth brush which includes a handle containing tooth brush, the handle having associated therewith a pump for pumping tooth paste into a hollow head portion of the tooth brush for supplying tooth paste to bristles thereof. U.S. Pat. No. 2,807,818 Inventor: Christopher L. Taylor Issued: Oct. 1, 1957 [0011] The present invention relates to improvements in toothbrushes, and more particularly to an improved combined toothbrush dentifrice dispenser. The main object to the invention is to provide an improved combination toothbrush and dentifrice dispenser which is adapted for use with either a liquid dentifrice, a powdered dentifrice, or a toothpaste. U.S. Pat. No. 4,236,651 Inventor: Walter Meyer et al. Issued: Dec. 2, 1980 [0012] A dispenser device comprising a reservoir for a flowable or fluent filled material as well as a piston pump equipped with a valve arrangement. The valve arrangement is coaxially dispositioned with regard to the pump and possesses parts connected with the piston and parts connected with the cylinder of the piston pump. U.S. Pat. No. 4,875,791 Inventor: Shawky A. Hassan Issued: Oct. 24, 1989 [0013] A liquid dispensing brush primarily used in dispensing liquid cleanser. The brush includes a reservoir which holds a predetermined amount of liquid cleanser and an arm with a longitudinal passage to deliver the cleanser from the reservoir to the head of the brush. The head of the brush comprises several sets of bristles and outlet means to allow the liquid cleanser to flow from the longitudinal passage to the bristles. In order to effectuate the flow of liquid cleanser from the reservoir to the bristles, means are provided whereby the brush is tilted to raise the reservoir higher than the head of the brush. A cap, with a flexible clip for easy storage, provides the tilting necessary to effectuate fluid flow. In use, the brush is placed on a flat surface in the tilted position for a predetermined length of time to allow a sufficient amount of liquid cleanser to flow to the bristles. U.S. Pat. No. 5,346,324 Inventor: Youti Kuo Issued: Sep. 13, 1994 [0014] A dentifrice dispensing toothbrush is described which utilizes a compressible elastic button to pump a controlled quantity of dentifrice material from a replaceable cartridge to the brush head. The toothbrush locks itself to prevent further pumping of dentifrice material when its replaceable cartridge is nearly empty. The self locking mechanism eliminates the formation of voids in the dentifrice material and consequent pump failure when the spent cartridge is replaced. In one embodiment, a cover is provided which protects the brush head, bristles, pumping mechanism and other parts of the toothbrush. The cover also seals the conduit which supplies dentifrice material to the brush head to prevent it from becoming clogged with dried dentifrice material during periods of non use and to prevent accidental compression of the button. The compressible elastic button is part of a pump assembly which also includes a pump chamber, a partition which divides the pump chamber into an intake compartment and a discharge compartment, a one way check valve for an opening in the base of the pump chamber to control the flow of dentifrice material from the cartridge to the pump chamber and an opening in the partition between the intake and discharge compartments. A plug is attached to the top of a follower disc which is positioned in the cartridge. When the cartridge is nearly depleted, the plug locks the toothbrush by blocking the dispensing movement of the dentifrice material. U.S. Pat. No. 5,382,106 Inventor: Bernard Voigt Issued: Jan. 17, 1995 [0015] An improved toothbrush with a teeth cleansing substance dispensing system is provided, which consists of a mechanism in cooperation with a compartment in an enlarged handle, which will dispense some teeth cleansing substance through a channel in a neck and head and out through at least one lateral passageway into bristle groups, so that the bristle groups can clean teeth. An apparatus is also in cooperation with the channel in the head and neck for sealing the at least one lateral passageway, when not in use. This stops the flow of the teeth cleansing substance and prevents germs, bacteria, water and other foreign elements from contaminating the teeth cleansing substance left in the channel and the compartment. U.S. Pat. No. 5,769,585 Inventor: Grigory Podolsky Issued: Jun. 23, 1998 [0016] A toothbrush is formed with a resilient annular pump having a conical chamber formed by an inner annular surface of the pump and two axially spaced and swingable flap valves inclined with respect to the longitudinal axis of the toothbrush in respective closing positions thereof and with a projection between a piston of the pump an one of the flap valves preventing automatic delivery of the paste into the chamber and creating sufficient pressure for pushing the paste toward the bristles. U.S. Pat. No. 5,909,977 Inventor: Youti Kuo Issued: Jun. 8, 1999 [0017] A dentifrice dispensing toothbrush utilizes a refillable cartridge for storing dentifrice material and a compressible elastic button for pumping dentifrice material from the cartridge to a brush head. The refillable cartridge has special adaptive features for mounting to different sized openings of toothpaste tubes to facilitate cartridge refilling and venting entrapped air. The essential components of the dentifrice dispensing toothbrush include 1) a brush head having an outlet opening therethrough and a series of bristles; 2) a pump assembly which has a pump chamber, an elastic compressible button and a base having a flap check valve; 3) a housing for attaching a refillable cartridge; 4) a refillable cartridge having an adaptive annular lip on its top opening for mating with the opening of a toothpaste tube and a plurality of shallow grooves for venting entrapped air, and a two-way follower disc for packing the dentifrice material. The dentifrice dispensing toothbrush optionally includes 5) a venting flip-cap for attachment to a toothpaste tube for releasing entrapped air when a cartridge is being refilled; and 6) a brush cover which seals the outlet opening of the brush head. U.S. Pat. No. 5,918,995 Inventor: Juha-Pekka Puurunen Issued: Jul. 6, 1999 [0018] A pump toothbrush includes a brush portion, a grip portion and an intermediate arm portion. The grip portion includes a container portion for dental cleansing medium and is connected to the brush portion by way of a pump device to feed the dental cleansing medium into the brush portion through the intermediate arm portion. The pump device includes a frame portion that is arranged between the container portion and the arm portion. The frame portion is provided with a recess located perpendicularly with respect to the longitudinal axis of the pump toothbrush. An adjusting body forming an inner portion of the pump device is fitted into the recess in the frame portion. The adjusting body possesses an axial outwards open intermediate space that functions as a chamber in the pump device. The intermediate space in the adjusting body is closed by a flexible pressure membrane. In addition, inlet and outlet valves are arranged in the adjusting body to enable connection between and transfer of dental cleansing medium from the container portion to the brush portion through the inlet and outlet valves when pressure is applied to the flexible pressure membrane. U.S. Pat. No. 6,241,412 Inventor: Norbert Spies et al. Issued: Jun. 5, 2001 [0019] An improved toothbrush is disclosed having a supply of liquid dentifrice located within the handle of the toothbrush, and a dispenser mechanism for dispensing the stored dentifrice to the bristles of the toothbrush when the need arises. The dentifrice-dispensing toothbrush is adapted to utilize replaceable, dentifrice-storing cartridges. In another preferred embodiment a dentifrice-dispensing toothbrush is provided which is effective in operation, durable, attractive in appearance, and relatively inexpensive to manufacture. U.S. Pat. No. 6,679,642 Inventor: John B. Dillingham et al. Issued: Jan. 20, 2004 [0020] A toothbrush having a water reservoir in the handle and squeezable to force water therefrom through a plurality of spaced apart orifices located at the base of bristles that project from the head of the brush. U.S. Pat. No. 6,948,875 Inventor: Hyo Sol Jang Issued: Sep. 27, 2005 [0021] A toothbrush device is provided, which includes a brush, a toothpaste storing case, and a push-button pump disposed between the brush and the toothpaste storing case; a first check valve disposed between the toothpaste storing case and the pump, a second check valve disposed between the first check valve and the toothpaste storing case, and a first spring disposed between the first and second check valves; wherein the first check valve includes a second spring and a piston in sequence in a direction away from the pump, and has a working element which includes a rod with movement grooves at a first end thereof and a securing part at a second end thereof. Canada Patent Number CA523340 Inventor: Albert W. Neuls Published: Apr. 3, 1956 [0022] Our invention relates to new and useful improvements in tooth brushes, the principal object and essence of our invention being to provide a relatively simply structure whereby the dentifrice is adapted to be stored within a disposable receptacle which acts as the handle of the tooth brush and is dispensed by plunger action to the bristle area. U.K. Patent Number GB864,439 Inventor: Karel Horitz Published: Apr. 6, 1961 [0023] Dentifrice is discharged to the bristles G of a toothbrush from a pressurized container P forming the handle of the brush by screwing the container into a socket F integral with the rear of the stem B of the brush so that the valve M is forced clear of the valve seating N in the discharge nozzle J of the container when the fluted head K of the valve contacts a sealing flange E of a flexible tube C extending through and beyond a bore S in the stem and head of the brush. The valve head and stem are surrounded by a tube of resilient material H that is compressed when the container is screwed into the stem to form with the flange an adequate seal between the container and the stem. U.K. Patent Number GB2215593 Inventor: George Clark Douglas Issued: Sep. 27, 1989 [0024] The invention relates to a dispensing and applicator device particularly suited for use by handicapped persons. Where a paste is to be applied to a brush or other applicator, say toothpaste onto a brush head, difficulties may be encountered by the disabled or blind. The device comprises a hollow body portion ( 2 ) forming a handle, said body portion adapted to contain compositions having a paste or cream-like consistency and to permit extrusion of said compounds from an outlet ( 6 ) of said body portion by a manually operated lever or press-button ( 4 ), wherein the outlet of the body portion communicates with a hollow dispensing portion ( 8 ) the latter being provided with applicator means ( 14 ), such as a brush head, there being provided apertures ( 12 ) through a wall area of the dispensing portion at said applicator means; giving communication between the interior of the hollow dispensing portion and the applicator means. While these toothbrushes may be suitable for the purposes for which they were designed, they would not be as suitable for the purposes of the present invention, as hereinafter described. SUMMARY OF THE PRESENT INVENTION [0025] A primary object of the present invention is to provide a liquid dentifrice dispensing toothbrush. [0026] Another object of the present invention is to provide a liquid dentifrice dispensing toothbrush that dispenses a measured amount of liquid dentifrice to the bristles of the toothbrush. [0027] Yet another object of the present invention is to provide a liquid dentifrice toothbrush having housing comprising a handle portion with a removable cap and a head portion. [0028] Still yet another object of the present invention is to provide a liquid dentifrice toothbrush wherein said head portion is removably attached. [0029] A further object of the present invention is to provide a liquid dentifrice toothbrush wherein said head portion has an internal conduit extending from one distal end to at least one aperture located in the bristles of the head portion. [0030] A yet further object of the present invention is to provide a liquid dentifrice toothbrush wherein said handle portion has a reservoir of liquid dentifrice and a pump assembly for dispensing a predetermined amount of the liquid dentifrice. [0031] A still yet further object of the present invention is to provide a liquid dentifrice toothbrush wherein said reservoir of liquid dentifrice is a collapsible bag. [0032] An additional object of the present invention is to provide a liquid dentifrice toothbrush wherein said collapsible bag has a one way valve on one end for refilling the bag and an aperture sealably mateable to the pump thereby forming an airtight reservoir of liquid dentifrice. [0033] Another object of the present invention is to provide a liquid dentifrice toothbrush wherein said pump assembly comprises housing having a nipple, a plurality of chambers and one way valves all in conduit communication and an actuator for creating positive and negative pressure within said pump and thereby moving a predetermined amount of liquid dentifrice from the collapsible bag to a pump egress port. [0034] Yet another object of the present invention is to provide a liquid dentifrice toothbrush wherein said actuator is a pliable button. [0035] Still yet another object of the present invention is to provide a liquid dentifrice toothbrush wherein said pump nipple provides means for attaching the collapsible bag to the pump. [0036] A further object of the present invention is to provide a liquid dentifrice toothbrush wherein said plurality of chambers comprises a dosage chamber and a holding chamber. [0037] A yet further object of the present invention is to provide a liquid dentifrice toothbrush wherein said dosage chamber incorporates the pliable button and a pair of one way valves positioned on each end so that when the button is depressed positive pressure moves the contents of the dosage chamber through an egress one way valve into the holding chamber and upon button release creates a vacuum within the dosage chamber drawing a predetermined amount of liquid dentifrice from the collapsible bag through the ingress one way valve into the dosage chamber. [0038] A still yet further object of the present invention is to provide a liquid dentifrice toothbrush wherein said holding chamber has a one way valve situated on its egress end preventing contamination of its contents between usage's of the liquid dentifrice dispensing toothbrush. [0039] An additional object of the present invention is to provide a liquid dentifrice toothbrush wherein said handle portion has a removable cap providing access to a collapsible bag refill fitting for refilling the liquid dentifrice reservoir. [0040] Another object of the present invention is to provide a liquid dentifrice toothbrush having an attachable refill canister mateable to the collapsible bag refill fitting sealably engaging one to the other for transferring the contents of the dentifrice refill canister into the toothbrush's liquid dentifrice reservoir. [0041] Additional objects of the present invention will appear as the description proceeds. [0042] The present invention overcomes the shortcomings of the prior art by providing a dentifrice dispensing toothbrush which dispenses a predetermined measured amount of liquid dentifrice by means of a pump. [0043] The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying drawings, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views. [0044] The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims. BRIEF DESCRIPTION OF THE DRAWING FIGURES [0045] In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawing in which: [0046] FIG. 1 is a perspective view showing the main components of the present invention including end cap, handle, pump button, head and bristles; [0047] FIG. 2 is a block diagram of the toothbrush showing the detailed components of the present invention including position of liquid dentifrice refill, check valves, dosage chamber, holding chamber, actuator pump and flow direction; [0048] FIG. 3 is a side view of the toothbrush showing the toothbrush hand grip on the handle of the toothbrush; [0049] FIG. 4 is a side sectional view of the toothbrush showing the internal components of the present invention with pump assembly; [0050] FIG. 5 is a side view of the toothbrush pump assembly showing the pump assembly components including dentifrice bag, inlet, pump button and outlet; [0051] FIG. 6 is a side exploded view of the toothbrush pump assembly showing the one way valves; [0052] FIG. 7 is a side detailed view of the toothbrush pump assembly showing the path the dentifrice follows once the push button of the pump assembly is pressed; [0053] FIG. 8 is a side detailed view of the toothbrush pump assembly showing the collapsible bag refilling the pump assembly with fresh dentifrice; and [0054] FIG. 9 is a side detailed view of the toothbrush pump assembly showing a depressed push button when the liquid dentifrice refill needs to be replaced. DESCRIPTION OF THE REFERENCED NUMERALS [0055] Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate the Liquid Dentifrice Dispensing Toothbrush of the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures. [0056] Liquid Dentifrice Dispensing Toothbrush of the present invention [0057] 12 handle housing [0058] 14 pump actuator [0059] 16 removable brush head [0060] 18 brush bristles [0061] 20 end cap [0062] 22 check valve [0063] 24 flow direction [0064] 26 liquid dentifrice [0065] 28 conduit [0066] 30 brush [0067] 32 holding chamber [0068] 33 dosage chamber [0069] 34 dentifrice collapsible bag [0070] 35 dentifrice bag aperture [0071] 36 brush bristle aperture [0072] 38 liquid dentifrice refill [0073] 39 liquid dentifrice refill fastener [0074] 40 grip [0075] 42 pump assembly [0076] 44 cavity [0077] 45 pump egress port [0078] 46 inlet [0079] 48 pump nipple [0080] 50 pressure [0081] 52 vacuum DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0082] The following discussion describes in detail one embodiment of the invention (and several variations of that embodiment). This discussion should not be construed, however, as limiting the invention to those particular embodiments, practitioners skilled in the art will recognize numerous other embodiments as well. For definition of the complete scope of the invention, the reader is directed to appended claims. [0083] FIG. 1 is a perspective view of the present invention 10 . Shown is a perspective view of the present invention 10 comprising a toothbrush having a handle portion 12 with end cap 20 and a removable brush head 16 having bristles 18 and a pump assembly 42 with pump actuator 14 for displacing and holding liquid dentifrice 26 integrated into its handle 12 . [0084] FIG. 2 is a block diagram of the toothbrush of the present invention 10 . Shown is a block diagram of the present invention 10 comprising a toothbrush having a handle 12 portion and a removable brush head portion 18 . The handle 12 houses a dentifrice collapsible bag 34 , a plurality of check valves 22 and reservoirs, including a dosage chamber 33 and holding chamber 32 , each chamber using check valves as ingress and egress one way valves in fluid communication with a removable brush head 18 conduit 28 terminating in a plurality of apertures 36 located at the base of the brush 30 . Also shown is a liquid dentifrice bag refill 38 having liquid dentifrice refill fastener 39 mateable to the handle end check valve 22 once the end cap 20 is removed. [0085] FIG. 3 is a side view of the liquid dentifrice dispensing toothbrush. Shown is a side view of the present invention 10 depicting the liquid dentifrice dispensing toothbrush comprising a handle 12 portion and a removable brush head 18 portion with the handle 12 portion housing a pump assembly 42 having a pump actuator 14 within the wall of the handle 12 . Also shown is the handle 12 having an end cap 20 providing access for refilling the liquid dentifrice reservoir. [0086] FIG. 4 is a side sectional view of the present invention 10 . Shown is a side sectional view of the present invention 10 displaying the internal components of the device including a pump assembly 42 within a cavity 44 provided by the handle 12 housing for holding, pumping and delivering dentifrice through a provided conduit 28 and to the use via its apertures 36 . [0087] FIG. 5 is a side view of the pump assembly of the present invention 10 . Shown is a side view of the pump assembly 42 having a nipple 48 for attachment thereto of a liquid dentifrice collapsible bag 34 , via aperture 35 , for holding and supplying liquid dentifrice 24 to the pump assembly 42 when needed. [0088] FIG. 6 is a side exploded view of the pump assembly 42 of the present invention 42 . Shown is a side exploded view of the pump assembly 42 comprising housing having a plurality of chambers and one way valves 22 with a pump actuator 14 providing means for moving the liquid dentifrice from the reservoir of liquid dentifrice to the brush bristles. [0089] FIG. 7 is a side detailed view of the pump assembly 42 of the present invention 10 . Shown is a side detailed view of the pump assembly 42 of the present invention 10 depicting that when the pump actuator 14 is depressed, pressure 54 moves the liquid dentifrice 24 from the dosage chamber 33 to the holding chamber 32 with the holding chamber contents moved to the brush bristles. [0090] FIG. 8 is a side detailed view of the pump assembly 42 of the present invention 10 . Shown is a side detailed view of the pump assembly 42 of the present invention 10 depicting that when the pump actuator 14 returns to its original position a vacuum is created within the dosage chamber causing the dosage chamber 33 to refill with fresh liquid dentifrice 24 from the reservoir of liquid dentifrice. [0091] FIG. 9 is a side detailed view of the pump assembly 42 of the present invention 10 . Shown is a side detailed view of the pump assembly 42 of the present invention 10 depicting that when the pump actuator 14 is depressed with no dentifrice remaining in dentifrice collapsible bag 34 , the vacuum created will keep the pliable button 14 in the depressed position thereby serving as an indicator that the dentifrice collapsible bag needs to be refilled.
A dentifrice dispensing toothbrush for applying a predetermined measured amount of liquid dentifrice from a reservoir of liquid dentifrice into the toothbrush bristles by means of an in integral pump. Liquid dentifrice may be refilled using the handle portion of the toothbrush.
0
CROSS REFERENCES TO RELATED APPLICATION This is a division of application Ser. No. 07/446,826 filed 12/06/89, which is a continuation-in-part of Ser. No. 07/299,174 filed 01/19/89 now U.S. Pat. No. 4,961,752. FIELD OF THE INVENTION The present invention relates to processes for oxidative (using hydrogen peroxide) and reductive bleaching of fibers, and fibers bleached by the aforementioned processes. BACKGROUND AND SUMMARY OF THE INVENTION The occurrence of dark (i.e. pigmented and/or stained) fibers often gives rise to annoying and expensive problems for manufacturers at all stages of fiber processing. For example, extensive literature is available on the occurence of dark fibers in white wool, see e.g.: Fleet, M. R., Pigmented Fibres in White Wool, Wool Technology and Sheep Breeding 33, 5-13 (1985); Fleet, M. R., Stafford, J. E., Dawson, K. A., and Dolling, C. H. S., Contamination of White Wool by Melanin-pigmented Fibres when Pigmented and White Sheep Graze Together, Aust. J. Exp. Agric. 26, 159-163 (1986); Foulds, R. A., Wong, P., and Andrews, J. W., Dark Fibres and Their Economic Importance, Wool Technology and Sheep Breeding 32(2), 91-100 (1984), and; Nolan, C., and Foulds, R., Dark-fibre Contamination in Wool, Queensland Agricultural J. Nov.-Dec., 305-307 (1985). The degree of contamination of white wool by colored fibers has a significant influence on its commercial value, especially when the wool is to be processed into light or pastel-colored articles. The manual removal of dark fibers is an extremely work- and cost-intensive, eye-straining job. If the contents of dark fibers in white wool are above an acceptable level for white or pastel end uses, then those dark fibers need to be lightened to improve the appearance and to increase the value of the goods (see in this regard Turner, T. R., and Foulds, R. A., Decision Schemes for Assessing Dark Fiber Concentration in Top, Textile Res. J. 57(12), 710-720 (1987). It is often found that the fibers and silver of yarn are not tested properly for dark fiber content, and hence these impurities are first seen as dark fibers interwoven into the fabric matrix or in the end product. In such cases the dark fibers have to be removed manually with tweezers. A more convenient and economical alternative is given by the possibility of a wet treatment, which is much more productive and in many cases also less expensive. The color of dark (i.e. pigmented) fibers ranges from black through shades of brown to light yellow, and the lightening of black fibers needs more severe wet treatment than those of the lighter fibers. Wet treatment conditions, however, should not be so severe as to damage the fibers excessively at the expense of lightening a few black fibers. Therefore, the present invention utilizes a treatment which is selective for areas of high dark fiber content. There have been numerous publications on the bleaching of hair (see e.g. Wolfram, L. J., and Albrecht, L., Chemical and Photo-bleaching of Brown and Red Hair, J. Soc. Cosmet. Chem. 82, 179-191 (1987); Wolfram, L. J., Hall, K., and Hui, I., The Mechanism of Hair Bleaching, J. Soc. Cosmet. Chem. 21, 875-900 (1970), and; Zahn, H., Hilterhaus, S., and Strussman, A., Bleaching and Permanent Waving Aspects of Hair Research, J. Soc. Cosmet. Chem. 37, 159-175 (1986) and dark wool fibers (see for example, Bereck, A., Bleaching of Dark Fibres in Wool, Proc. 7th Int. Wool Res. Conf., Tokyo, vol. IV, 152-162 (1985); Bereck, A., and Kaplin, J. J., Electron-microscope Observations on the Disintegration of Melanin Granules in Chemically Treated Karakul Wool, J. Textile Inst. 74, 44-47 (1983); Bereck, A., Zahn, H., and Schwarz, S., Das Selective Bleichen von Pigmentierten Haaren in Rohweisser Wolle, Textil Praxis Int. 37, 621-629 (1982); Finnimore, E., and Bereck, A., Verhalten von selectiv gebleichter Wolle, Melliand Textilberichte 68, 669-672 (English translation, E291-292) (1987); Kriel, W. J., Albertyn, D., and Swanepoel, O. A., Melanin-bleeding of Pigmented Karakul Wool, SAWTRI [South African Wool Textile Research Institute] Bulletin 3(1), 16-20 (1969); laxer, G., and Whewell, C. S., Some Physical and Chemical Properties of Pigmented Animal Fibres, Proc. Int. Wool Res. Conf. Australia vol. F, 186-200 (1955); Teasdale, D. C., and Bereck, A., The Measurement of the Color of Bleached and Natural Karakul Wool, Textile Res. J. 51, 541-549 (1981), and; Van Heerden, N., Becker, J., van der Merwe, J. P., and Swanepol, O. A., Bleaching of Karakul Wool, SAWTRI [South African Wool Textile Research Institute] Bulletin 3(4), 21-23 (1969)). Laxer and Whewell, Ibid, first realized that black-brown pigmented fibers absorb iron from ferrous sulfate solutions more rapidly and to a greater extent than white fibers, probably owing to the formation of a metal complex with the melanin of the pigment granules. Union between the iron and the fiber is reasonably firm and this bound iron is a useful catalyst for promoting bleaching when the iron-containing fibers are immersed in solutions of hydrogen peroxide. All known processes for bleaching pigmented dark fibers are based on the use of peroxy compounds, Bereck (1985), Ibid. Wolfram et al (1970), Ibid, have studied the mechanism of hair bleaching in detail. They found that the bleaching reaction occurs in two steps; the initial solubilization of the granules is followed by the decolorization of the dark brown solubilized pigment. The pigment granules are distributed within the cortex (laxer, Ibid) and therefore the bleaching of the granules is a diffusion-controlled reaction. Some oxidation of the keratin matrix does occur during the bleaching process due to diffusion. Wolfram et al (1970) Ibid, showed that neither reducing agents such as thioglycolic acid; borohydride, sulfide and sulfite, nor some oxidizing agents such as persulfate, perchlorate, iodate and permanganate, produce any apparent physical change in the melanin pigment. A different behavior was displayed by hydrogen peroxide. Dilute aqueous solutions of this reagent caused disintegration of the pigment granules, which slowly dissolved in the reaction system. The dark brown solution gradually become lighter over a long period of time. The second step (decolorization) of the malanin granules) is therefore much slower than the first step (solubilization of the malanin pigment) and hence the former is the rate-determining step in the overall process. It was pointed out that the disintegration process alone is unlikely to affect the color of hair significantly; it may cause only a slight change in hue. The dissolution of melanin in alkali, observed for example in the "bleeding" of pigmented fibers even at only slightly alkaline pH, is a well-known phenomenon, Kriel et al, Ibid. Bereck and Kaplin, Ibid, have studied the disintegration of melanin granules in chemically treated karakul wool using an electron microscope. Their studies revealed the following interesting features. Under identical bleaching conditions, the destruction of the melanin granules was virtually complete in the mordanted wool whereas in the untreated wool the granules were only partly dissolved. These workers have also observed that the electron micrographs of bleached wool were not unlike those of the samples treated with alkali. However, the change in luminosity due to the alkali treatment was negligible compared with the relatively high luminosity of the bleached wool. This strongly supports the view of Wolfram et al. (1970), Ibid, that melanin disintegration does not significantly influence fiber color. It may be said that the solubilized melanin stains the fibers in the same way as a black dyestuff, Bereck and Kaplin, Ibid. A mixture of hydrogen peroxide and ammonium and/or potassium persulfate has been used successfully in the bleaching of melanin granules, as described in Corbett, J. F., The Chemistry of Hair-care Products, J. Soc. Dyers Colour. 92, 285-303 (1976). There had been extensive research carried out on the selective bleaching of dark fibers using Bereck's iron mordanting technique (as described in Bereck (1985), Ibid), and the process was adopted successfully by many West German textile mills. This process consists of 3 stages, namely (i) mordanting, (ii) rinsing, and (iii) bleaching. Bereck particularly pointed out the importance of a proper choice of reducing agents in the application of ferrous salts to wool during mordanting and the thorough rinsing of the "loosely bound" ferrous and ferric ions from wool. Of the many reducing agents tested in Bereck (1985), hypophosphorous and phosphorous acids proved to be the best stabilizing agents for minimizing damage to the wool fiber. Giesen and Ziegler in Die Absorption von Eisen durch Wolle und Haar, Melliand Textilberichte, 62, 482-483 (English translation, E622-625) (1981), provide a study of the absorption of iron by wool and hair and concluded that optimum conditions for selective absorption of iron by dark fibers in wool were achieved within a pH range of 3.0-3.5, using a treatment time of 60 minutes at 80° C. Within the pH range mentioned above, the pigmented karakul wool absorbed the greatest amount of iron. At higher pH values, the absorption of iron by pigmented karakul wool diminished as the maximum uptake of iron by nonpigmented merino wool was reached at pH 4.5 . Here, it would be disadvantageous to work at pH values greater than 3.5 due to an increase in iron uptake by nonpigmented wool, which may cause extensive damage and discoloration during bleaching. Even though the aforementioned three-step process may be carefully conducted, there always remains some residual trivalent iron, which tends to give an overall undesirable reddish-brown discoloration or cast to the wool (apparently due to oxidation of ferrous to ferric ions during bleaching). Bereck et al 1982, Ibid, already have shown that selective bleaching hardly alters the natural cream color of wool. However, increasing demand for "bleached white" material led Finnimore and Bereck, Ibid, to investigate the further bleaching of selectively bleached material. Selectively bleached wool was given a second step reductive or oxidative bleaching to yield whiter material. German Offenlegungsschrift 3,433,926 (3/27/86) to Streit et al discloses a single bath reductive and oxidative bleaching process, in which the reductive bleaching with thiourea dixoide precedes an oxidative hydrogen peroxide bleaching, whereas in the processes of the present invention the reductive bleaching is subsequent to the oxidative bleaching. Japanese patent 51-64082 (6/3/76) is drawn to a reductive bleaching process in which hydrogen peroxide and thiourea are mixed at the start of the bleaching processes (i.e., bleaching with a single mixture which contains both hydrogen peroxide and thiourea), while by contrast the instant invention utilizes separate steps of oxidative bleaching followed by reductive bleaching. It has unexpectedly and surprisingly been discovered that the process of the present invention provides greatly improved results (including, a higher Whiteness Index, lower Yellowness Index, and lower degree of damage) as compared to the results achieved by either of these two prior art processes. It is a first object of the present invention to provide bleaching greatly superior to that of prior art processes, said bleaching providing fibers which are essentially pigment free, essentially free of iron residue (i.e. without the aforementioned undesirable reddish-brown discoloration or cast) and/or of a surprising and unexpectedly high degree of whiteness, low degree of yellowness and low degree of fiber damage. It is a second object of the present invention to provide processes which may provide oxidative and reductive bleaching in a single bath, and thereby provide the advantages of: (a) avoiding the two or three step treatment processes normally required by conventional processes, thereby simplifying the process; (b) reducing the amount of time and energy required to provide effective bleaching; and (c) reducing the amount of equipment required to perform the bleaching. Other objects and advantages of this invention will become readily apparent from the ensuing description. The aforementioned objects and advantages are achieved by several processes of the instant invention. Two processes of the instant invention which employ mordanting utilize the initial steps of: bringing both pigmented and unpigmented fibers into contact with ferrous ions under conditions which provide adsorption of the ferrous ions by the pigmented an unpigmented fibers; removing (as for example by rinsing) a portion of the ferrous ions from the pigmented and unpigmented fibers with at least a portion of the ferrous ions remaining on the pigmented fibers, and; contacting the pigmented and unpigmented fibers with hydrogen peroxide under conditions which provide oxidative bleaching of both the pigmented and unpigmented fibers, including oxidative bleaching of the pigmented fibers by interaction of the hydrogen peroxide with ferrous ions remaining on the pigmented fibers, to produce bleached fibers in contact with unspent hydrogen peroxide. In a first process of the present invention and initial steps are followed by the steps of: adding to the bleached fibers in contact with unspent hydrogen peroxide a material which combines with hydrogen peroxide to form a reductive bleaching agent in an amount sufficient to produce a reductive bleaching media; and maintaining the bleached fibers in the reductive bleaching media under conditions providing reductive bleaching of the bleached fibers. In a second process of the present invention said initial steps are followed by the steps of: adding to the bleached fibers in contact with unspent hydrogen peroxide, an inactivating material in an amount at least sufficient to inactivate all of said unspent hydrogen peroxide to form an inactivated media; and subsequent to said inactivation of all said unspent hydrogen peroxide, reductively bleaching said bleached fibers by addition of a reductive bleaching agent to said inactivated media. Additionally the present invention encompasses processes employing hydrogen peroxide and at least one persulfate containing compound, rather than the aforementioned iron-mordanting i.e.: first process which comprises, contacting fibers with hydrogen peroxide and at least one persulfate containing compound under conditions which provide oxidative bleaching of the fibers to produce bleached fibers in contact with unspent hydrogen peroxide; adding to the bleached fibers in contact with unspent hydrogen peroxide (from the previous step), a material which combines with hydrogen peroxide to form reductive bleaching agent (e.g. thiourea, substituted thiourea (e.g. 1,3-dimethyl-2-thiourea, 1,3-diphenyl-2-thiourea, 1,1,3,3-tetramethyl-2-thiourea), compounds containing thiol (for example, 1-dodecanethiol, 1-octadecanethiol, thioglycolic acid, thiophenol)), in an amount sufficient to produce a reductive bleaching media; and maintaining the oxidatively bleached fibers in said reductive bleaching media under conditions providing reductive bleaching of the bleached fibers, and; A second process of the present invention which comprises, contacting fibers with hydrogen peroxide and at least one persulfate containing compound under conditions which provide oxidative bleaching of the fibers to produce bleached fibers in contact with unspent hydrogen peroxide; adding to the bleached fibers in contact with unspent hydrogen peroxide (from the previous step), an inactivating material in an amount at least sufficient to inactivate all of the unspent hydrogen peroxide to form an inactivated media; and susbsequent to the inactivation of all the unspent hydrogen peroxide, reductively bleaching the bleached fibers by addition of a reductive bleaching agent to the inactivated media. The aforementioned process unexpectedly and surprisingly provide fibers of superior whiteness, and by virtue of preventing deposition of ferric species provide fibers having surprising, highly advantageous and desirable properties e.g. fibers which are essentially pigment free as well as stain-free, essentially free of iron residue (thereby avoiding the aforementioned undesirable reddish-brown cast) and characterized by a high degree of whiteness with low degree of damage. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a line graph of Whiteness Index versus thiourea concentration, for a process of the present invention with in situ formation of a reductive bleaching substance using conditions referred to in example 1and table I. FIG. 2 is a line graph of Whiteness Index versus bleaching time after thiourea addition, for a process of the present invention (using conditions as described in example 2 and table II), showing the effect of varying bleaching time. FIG. 3 is a line graph of Whiteness Index versus hydrogen peroxide bleaching time for conditions as referred to in example 3 and table III. FIG. 4 is a line graph of Whiteness Index versus bath temperature: showing a comparison between conventional alkaline hydrogen peroxide bleaching and bleaching of the present invention; as referred to in example 4 and table IV. FIG. 5 is a line graph of Whiteness Index versus Bleachit D concentration for a process of the present invention as referred to in example 6 and table VI. FIG. 6 is a line graph of Whiteness Index versus thiourea dioxide concentration for a process of the present invention as referred to in example 6 and table VI. FIG. 7 is a graph of hydrogen peroxide remaining versus bleaching time in minutes, showing decomposition of hydrogen peroxide in the bleach bath during bleaching of wool. DETAILED DESCRIPTION OF THE INVENTION Both of the bleaching process of the present invention may be utilized to great advantage with any of a wide variety of fiber compositions, including animal hair fibers, plant fibers, synthetic fibers, and blends of two or more of the aforementioned (notably, fibers consisting essentially of wool, fibers consisting of cotton, and blends of wool with either materials). Said fibers may be in any suitable form which permits bleaching, including: loose fibers, yarns (twisted, woven, wrapped, etc.), fabric (e.g. woven, matted, felted), etc. Also, the fibers may be pigmented or unpigmented, and/or stained (e.g. urine-stained). Contamination of wool by urine-stained and black-pigmented fibers is viewed as a major problem of American wool. It is also a great advantage of the present invention that the processes may be carried out over a wide range of temperatures, e.g. 20° to 100° C. Both of the bleaching processes of the present invention permit either: (1) all steps to be carried out batch-wise in a single bath; or (2) all steps to be carried out continuously using a continuous pad system ("padding" is a process well known in the art, and is for example defined on page 109 of Textile Terms and Definitions, Fifth Edition, published by Textile Institute, August 1963). Either of the processes of the present invention may produce novel and highly advantageous fibers having unexpectedly superior properties, such as a degree of whiteness as measured by ASTM E-313 of at least about 43 with a degree of damage indicated by an alkali solubility of 30% of less as measured by IWTO-4-60, preferably said degree of whiteness being at least 44 with a said solubility of 25% or less, and more preferably a said degree of whiteness of at least about 46. When the aforementioned first process of the present invention is carried out employing thiourea as the material which combines with hydrogen peroxide to form a reductive bleaching agent, it is preferred to: add the thiourea in a stoichiometric ratio to the unspent hydrogen peroxide of at least about 1 to 4, i.e. at least one mole of thiourea for each 4 moles of unspent hydrogen peroxide (more preferably in a said ratio of at least about 2 to 4, i.e. at least about 2 moles of thiourea for each 4 moles of unspent hydrogen peroxide, and most preferably in a said ratio of about 2 to 4 i.e. about 2 moles of thiourea for each 4 moles of unspent hydrogen peroxide), and; adjust the reductive bleaching media to a pH of about 6 to about 9, more preferably about 7 to about 8. The addition of thoiurea to hydrogen peroxide creates a reducing medium in situ. This will not only enhance bleaching (i.e. further whiten the fibers), but also reduces any ferric ions that may have been oxidized by hydrogen peroxide to ferrous ions which have a much lower affinity for wool than ferric ions and therefore may easily be washed away. Also, in regard to said first process, it is preferred to carry out the bleaching of fibers in the reductive bleaching media for a time period of from about 25 to about 35 minutes. In carrying out the aforementioned second process of the present invention, it is preferred to: utilize as the inactivating material a material selected from the group consisting of: (1) catalysts which catalyze decomposition of hydrogen peroxide, such as transition metals preferably used at a pH of from about 6 to about 10 (e.g. if necessary a suitable chemical is added to the oxidatively bleached fibers in contact with unspent hydrogen peroxide, in order to bring the pH into the range of from about 6 to about 10). Optionally, after the transition metal(s) have completed deactivation of the unspent hydrogen peroxide, a chelating agent may be added in order to chelate excess transition metal ions (if any) prior to the reductive bleaching; (2) enzymes which decompose hydrogen peroxide; preferably the pH of the bleached fibers in contact with unspent hydrogen peroxide is adjusted to be from about 3 to about 10 prior to adding the enzyme. For example, suitable enzymes include catalase (which preferably is used at a pH of from about 5 to about 8.5) and enzymes referred to in chapter 8 of Hydrogen Peroxide, W. C. Schumb et al, editors, published by Reinhold Pub. Corp., New York, 1955; (3) materials which react with hydrogen peroxide to render the hydrogen peroxide inactive, such as cerium (which may be provided in chemical combination with other materials, but which upon addition to the oxidatively bleached fiber and unspent hydrogen peroxide makes cerium available for reaction with hydrogen peroxide) or quinones. While any suitable reductive bleaching agent may be utilized in said second process, it is preferred to utilize as the reductive bleaching agent either thiourea dioxide or sodium hydroxymethanesulfinate. It is preferred, in carrying out the present invention, to carry out the step of bringing the pigmented and unpigmented fibers into contact with ferrous ion in the presence of an iron reducing agent. Examples of such agents which may be utilized in the present invention include hypophosphorous acid, phosphorous acid and sodium bisulfite. Persulfate containing compounds useable in the present invention include salts of persulfate. Examples of specific persulfate containing compounds useable in the present invention include, ammonium persulfate, sodium persulfate and potassium persulfate. EXAMPLES The following examples are intended only to further illustrate the invention and are not intended to limit the scope of the invention which is defined by the claims. In the following examples, bleaching of wool fabric was performed using an Ahiba Texomat (Ahiba Inc., Charlotte, N.C.) laboratory dyeing apparatus. Oxidation potential was monitored on a voltmeter using a Corning Platinum Redox Combination electrode (Fisher Scientific Co., Springfield, N.J.); pH was monitored on an E & K pH meter (E & K Scientific product, Saratoga, Calif.) using a combination glass electrode (Cole-Parmer International, Chicago, Ill.). All bleaching treatments were carried out at a liquor to wool ratio of 30 milliliters liquor: 1 gram of fabric. Wool samples (10 g) were bleached in various bleach bath compositions and conditions. Whiteness (ASTM; E-313) and Yellowness (ASTM; D-1925) Indices were measured with a Colorgard System 1000 tristimulus colorimeter (Pacific Scientific Co., Silver Spring, Md.). Sample illumination was by a quartz-halogen lamp at color temperature of 2854 degrees Kelvin with 360° circumferential illumination (CIE Source C, 1931 Standard Observer Illuminant) geometry that is 45° from the sample's normal direction, sample viewing being at 0°. The equations used in the Colorgard System for the calculations of Whiteness and Yellowness Indices are: WI=3.387Z-3Y YI=[100(1.277X-1.06Z)]/Y where X, Y and Z are the measured tristimulus values; WI is the Whiteness Index, and YI is the Yellowness Index. The extent of degradation of the wool caused by bleaching was determined by measuring the loss in weight of the sample after immersion in 0.1M sodium hydroxide for 1 hour at 65°±0.5° C. [I.W.T.O. Technical Committee Report, 1960, IWTO-4-60(E)]. Wet tensile strength measurements of wool flannel, bleached and treated under various conditions, were carried out according to the standard method as set forth in ASTM, 1981 Book of ASTM standards, Am. Soc. for Testing and Materials: Wool flannel fabric was cut into ten equal size strips of length 140 mm and width 13 mm, 5 oriented along the warp axis (18 yarns) and the other 5 along the weft axis (14 yarns). These samples were then soaked for 24 hours in an aqueous solution containing Triton X-100 (0.5 g/L). An Instron tensile testing machine (Instron Corp., Canton, Mass.) of gauge length 90 mm was used for the measurements of breaking load and elongation. The wetted-out samples were secured between the clamps and a constant rate of load was applied along the warp or weft directions until the fabric was broken. A. OXIDATIVE HYDROGEN PEROXIDE BLEACHING FOLLOWED BY THIOUREA One aspect of the present invention relates to the formation of a reductive substance in situ when thiourea is added to an oxidative hydrogen peroxide bleach bath. When using thiourea, a strong reductive substance is preferably formed under approximately neutral or slightly alkaline conditions (e.g. pH of about 6 to about 9, preferably a pH of from about 7 to about 8). The optimum stoichiometric ratio of thiourea to hydrogen peroxide was found to be about 2 to 4. An exact amount of thiourea therefore may be calculated based on the amount of unspent hydrogen peroxide remaining after a bleaching process, and that amount of thiourea may be added to the bleach bath for maximum efficiency. In the examples a marked drop in pH (pH=2 to 3) and an increase in temperature (by 5°-7° C.) of solution were observed along with the appearance of incipient turbidity. The pH of the solution was then adjusted to a pH of from about 7 to about 8, at which point the oxidation potential of the solution changed markedly from a positive to a very negative value, indicative of the complete consumption of hydrogen peroxide. EXAMPLE 1 Bleaching experiments were done in stirred bleaching vessels immersed in a stirred thermostatic bath. The substrate was a wool flannel fabric (20.60-26.39 microns in diameter, 233 g/m 2 ) with black hair contamination and urine-stained wool, kindly supplied by Forstmann and Co., Inc., Dublin, Ga. Wool flannel fabric was bleached in the alkaline hydrogen peroxide bleach bath for 1 hour at 60° C. This was then followed by addition of thiourea and the necessary pH adjustment to attain a reductive substance in situ for the reductive bleaching part of the process. The reductive bleaching was carried out for 25 minutes at the same temperature. The bleaching conditions and the results are shown in Table I and depicted graphically in FIG. 1. TABLE I__________________________________________________________________________The effect of thiourea concentration on the oxidative/reductive bleachingof wool flannel..sup.a Warp.sup.e Weft.sup.e ReductionThiourea Whiteness Yellowness Alkali Breaking Elongation Breaking Elongation potential(g/L) Index.sup.b Index.sup.c Solubility (%).sup.d Load (N) (%) Load (N) (%) (mν).sup.f__________________________________________________________________________Unbleached 11.42 ± 0.45 23.71 ± 0.20 11.60 ± 0.43 35.62 ± 1.41 56.64 ± 1.92 24.72 ± 1.26 60.57 ± 2.79 ----.sup.g 35.85 ± 0.54 12.38 ± 0.17 22.43 ± 1.09 35.18 ± 2.58 55.32 ± 2.44 27.87 ± 0.83 55.51 ± 1.72 +2013.07 34.24 ± 0.48 13.16 ± 0.26 24.48 ± 0.49 -- -- -- -- +2263.85 38.09 ± 0.07 11.49 ± 0.03 -- -- -- -- -- -1704.61 43.15 ± 0.28 9.55 ± 0.03 22.14 ± 0.69 -- -- -- -- -6635.38 43.83 ± 0.09 9.23 ± 0.04 23.53 ± 0.37 32.43 ± 1.06 55.13 ± 1.90 22.99 ± 0.63 51.25 ± 1.88 -6986.15 43.53 ± 0.26 9.17 ± 0.16 24.00 ± 0.24 -- -- -- -- -6927.69 43.62 ± 0.05 9.23 ± 0.08 24.44 ± 0.22 32.74 ± 1.73 53.58 ± 2.37 22.39 ± 1.59 50.48 ± 2.80 -6805.38.sup.h 31.84 ± 0.40 14.51 ± 0.22 -- 43.30 ± 0.78 57.46 ± 1.72 27.82 ± 0.58 53.26 ± 0.99 -145.38.sup.i 37.14 ± 0.42 12.11 ± 0.14 -- -- -- -- -- -242__________________________________________________________________________ .sup.a Alkaline hydrogen peroxide bleaching, 60° C., 1 hr, followe by thiourea addition, pH adjustment with NaOH to pH 7.4-7.6 unless indicated, and continued bleaching, 60° C., 25 min. .sup.b As per ASTM E313; mean value ± standard deviation of 3 samples, each having 8 measurements. .sup.c As per ASTM D1925; mean value ± standard deviation of 3 samples each having 8 measurements. .sup.d As per IWTO4-60; mean value ± standard deviation of 3 samples. .sup.e As per ASTM D1682-64; mean value ± standard deviation of 5 determination. .sup.f Measured immediately after thiourea addition and pH adjustment. .sup.g I.e., alkaline hydrogen peroxide bleaching for 1 hr 25 min with no pH adjustment at 1 hr. .sup.h pH of the solution is not adjusted after the addition of thiourea (pH = 3.6). .sup.i Solution was buffered (pH = 6.8) before thiourea addition so that the reaction is carried but under neutral conditions. Below a certain thiourea concentration (FIG. 1), no improvement in whiteness of wool flannel fabric is observed, this being due to the fact that under these conditions, a reductive substance is not formed since there is not sufficient thiourea to react with all the residual hydrogen peroxide. ______________________________________Akaline bleach bath composition______________________________________Hydrogen peroxide (30% w/w) 20.0 mL/L of liquorTetrasodium pyrophosphate 10.0 g/L of liquordecahydrateTriton X-100 1.0 g/L of liquorInitial pH of bleach bath 9.4pH after oxidative bleaching for 8.31 hr at 60° C.Weight of wool flannel fabric 10 gLiquor to wool ratio 30 milliliters of liquor: 1 gram of wool______________________________________ Sufficient thiourea should be added to make certain that a reductive bleaching media is produced. Above a certain thiourea concentration, no further improvement of whiteness of wool flannel fabric is observed. It is also apparent from the results in Table I that the pH adjustment to 7-8 may be very advantageous for attaining a high negative oxidation potential and an improvement in the whiteness of wool flannel fabric. The pH may be adjusted to provide a suitable reduction potential so that an improvement in whiteness of the wool flannel fabric is achieved. EXAMPLE 2 The bleaching solution composition and conditions were the same as those of Example 1 except that bleaching time after thiourea addition following alkaline hydrogen peroxide bleaching was varied. The results are shown in Table II and depicted graphically in FIG. 2. TABLE II__________________________________________________________________________The effect of thiourea bleaching time on the oxidative/reductivebleaching of wool flannel..sup.aBleaching time Warp.sup.e Weft.sup.eafter thiourea Whiteness Yellowness Alkali Breaking Elongation Breaking Elongationaddition (min.) Index.sup.b Index.sup.c Solubility (%).sup.d Load (N) (%) Load (N) (%)__________________________________________________________________________--.sup.f 34.23 ± 0.66 13.15 ± 0.31 19.04 ± 0.33 35.32 ± 1.02 55.88 ± 1.70 28.25 ± 0.75 56.51 ± 1.0315 43.69 ± 0.18 9.18 ± 0.07 22.05 ± 0.26 -- -- -- --25 43.83 ± 0.09 9.23 ± 0.04 23.53 ± 0.37 32.43 ± 1.06 55.13 ± 1.90 22.99 ± 0.63 51.25 ± 1.8835 44.75 ± 0.07 8.87 ± 0.07 -- 31.17 ± 1.70 54.68 ± 2.82 21.97 ± 0.99 52.44 ± 1.4745 43.61 ± 0.24 9.31 ± 0.08 22.54 ± 0.72 -- -- -- --25.sup.g 44.42 ± 0.05 9.03 ± 0.01 20.63 ± 0.44 37.36 ± 1.56 58.77 ± 2.17 26.58 ± 1.36 58.04 ± 1.8525.sup.h 44.63 ± 0.63 8.93 ± 0.25 21.45 ± 0.67 36.29 ± 2.02 57.49 ± 3.41 23.57 ± 1.44 54.33__________________________________________________________________________ ± 3.78 .sup.a As per Table I except 5.38 g/L thiourea was used for various bleaching times. .sup.b As per Table I. .sup.c As per Table I. .sup.d As per Table I. .sup.e As per Table I. .sup.f I.e., alkaline hydrogen peroxide bleaching for 60 min, with neithe subsequent pH adjustment nor addition of thiourea. .sup.g pH was adjusted to 7.1 (6 mL of 30% w/v Na.sub.2 CO.sub.3 solution after thiourea addition. .sup.h pH was adjusted to 7.4 (7.5 g NaHCO.sub.3) after thiourea addition The results in Table II show that the bleaching time after thiourea addition is not critical in the time range studied (15-45 min.). Bleaching times of 25-35 minutes after thiourea addition are preferred. Alkali solubility values are seen to be well below the critical value of 30% as referred to in Ziegler, K. Textil-Praxis, 17, 376(1962). It is also shown in Table II that for the operating conditions of the instant example, that the pH of the bleach solution after thiourea addition may be raised to achieve a high negative oxidation potential; a pH of 7-8, obtained by weak alkalis such as sodium carbonate and bicarbonate, is as sufficient for achieving high bleaching efficiencies as higher values obtained with sodium hydroxide. The pH adjustment may be made with weak alkalis on large scale bleaching trials to avoid unwanted damage to wool that might occur from use of sodium hydroxide and uneven mixing. EXAMPLE 3 The bleaching solution composition and conditions were the same as those of Example 1 except the initial alkaline hydrogen peroxide bleaching time prior to thiourea addition was varied. The results, as shown in Table III and depicted graphically in FIG. 3, demonstrate that the longer the hydrogen peroxide bleaching part of the process, the whiter the bleached wool flannel fabric. TABLE III__________________________________________________________________________The effect of varying the hydrogen peroxide bleaching time on theoxidative/reductive bleaching ofwool flannel..sup.aOxidative Warp.sup.e Weft.sup.ebleaching Whiteness Yellowness Alkali Breaking Elongation Breaking Elongationtime (min.) Index.sup.b Index.sup.c Solubility (%).sup.d Load (N) (%) Load (N) (%)__________________________________________________________________________0.sup.f 31.84 ± 0.19 13.89 ± 0.02 -- -- -- -- --20 39.43 ± 0.38 10.97 ± 0.16 -- -- -- -- --40 42.46 ± 0.15 9.69 ± 0.06 20.12 ± 0.34 -- -- -- --60 43.52 ± 0.26 9.38 ± 0.04 24.00 ± 0.24 32.56 ± 1.51 54.90 ± 2.05 22.60 ± 1.20 50.95 ± 1.3080 46.82 ± 0.16 8.04 ± 0.04 24.29 ± 0.13 30.91 ± 1.30 56.31 ± 1.35 19.20 ± 1.28 48.44 ± 1.22__________________________________________________________________________ .sup.a As per Table I except 6.15 g/L thiourea is used. .sup.b As per Table I. .sup.c As per Table I. .sup.d As per Table I. .sup.e As per Table I. .sup.f Thiourea mixed with hydrogen peroxide and pH adjusted with no prio time for oxidative bleaching. Here it must be emphasized that in the process of this example, that the wool flannel fabric to be bleached should first be given an oxidative peroxide bleaching prior to thiourea addition. This is simply demonstrated by the results given in Table III where the wool flannel fabric was not given an initial peroxide bleach. Hydrogen peroxide, thiourea and all the other additives were mixed at the start of the bleaching treatment and bleaching was allowed to proceed for 20 minutes. The importance of initial hydrogen peroxide bleaching becomes more apparent when the Whiteness Index values of wool bleached for 60 minutes (with all chemicals mixed at the start i.e. as taught by Japan 51-64082) are compared with those of wool bleached for 65 minutes (40 minutes alkaline peroxide bleach followed by thiourea addition and bleaching for 25 minutes after pH adjustment). Although in both cases a high negative oxidation potential was attained, it seems that the initial oxidative hydrogen peroxide bleaching somehow modifies wool sufficiently so that a follow-up reductive bleaching further whitens wool effectively. EXAMPLE 4 The bleaching solution composition was the same as per Example 1. In the present example, a direct comparison of conventional alkaline hydrogen peroxide bleaching to that of the new invention (oxidative/reductive single-bath process) at different bleaching temperatures is made and the results are shown in Table IV and depicted graphically in FIG. 4. TABLE IV__________________________________________________________________________The effect of bleaching temperature on the oxidative/reductive bleachingof wool flannel..sup.aTreatment Thiourea Total time of Whitness Yellowness Alkalitemperature (°C.) addition bleaching (min.) Index.sup.b Index.sup.c Solubility (%).sup.d__________________________________________________________________________55 No 65 32.76 ± 0.39 13.77 ± 0.16 --55 Yes 65 40.11 ± 0.33 10.73 ± 0.15 --60 No 65 34.23 ± 0.66 13.15 ± 0.31 19.04 ± 0.3360 Yes 65 42.46 ± 0.15 9.69 ± 0.06 20.12 ± 0.34.sup. 60.sup.e Yes 60 33.89 ± 0.94 13.51 ± 0.35 --65 No 65 37.63 ± 0.33 11.57 ± 0.13 28.23 ± 0.6365 Yes 65 44.05 ± 0.31 9.00 ± 0.18 25.15 ± 0.5270 No 65 39.36 ± 0.28 10.96 ± 0.11 32.61 ± 0.9970 Yes 65 45.43 ± 0.23 8.46 ± 0.14 28.88 ± 0.37__________________________________________________________________________ .sup.a Alkaline hydrogen peroxide bleaching at different temperatures, 40 min., followed by thiourea addition (6.15 g/L; pH adjustment with NaOH to pH 7.4-7.6 only in the thiourea cases), and continued bleaching for 25 min. .sup.b As per Table I. .sup.c As per Table I. .sup.d As per Table I. .sup.e Thiourea mixed with hydrogen peroxide and pH adjusted with no prio time for oxidative bleaching. It is noteworthy that the same level of whiteness is reached at a bleaching temperature of 55° C. with the hydrogen peroxide-thiourea bleaching system (oxidative/reductive) as at 70° C. with the hydrogen peroxide system alone. Furthermore the former process is less damaging to the wool, as evidenced by lower alkali solubilities. EXAMPLE 5 ______________________________________Acidic bleach bath composition______________________________________Hydrogen peroxide (30% w/w) 20.0 mL/L of liquorPrestogen NB-W 3.43 g/L of liquorTriton X-100 1.0 g/L of liquorInitial pH of bleach bath 5.7pH after oxidative bleaching 5.2for 1 hr. at 80° C.Weight of wool flannel fabric 10 gLiquor to wool ratio 30 milliliter liquor: 1 gram of fabric______________________________________ Prestogen NB-W (BASF Chemicals Division, Charlotte, N.C.) is a mixture of organic acid salts in aqueous solution which activates hydrogen peroxide at mildly acid pH values by forming peroxy compounds. In this example, we demonstrate the effectiveness of the hydrogen peroxide-thiourea system on the bleaching efficiency under acidic oxidative bleaching with hydrogen peroxide followed by thiourea. The results are shown in Table V. TABLE V__________________________________________________________________________The effect of thiourea on the oxidative/reductive bleaching of woolflannel..sup.a Warp.sup.e Weft.sup.eThioureaTotal time of Whiteness Yellowness Alkali Breaking Elongation Breaking Elongation(g/L)bleaching (min.) Index.sup.b Index.sup.c Solubility (%).sup.d Load (N) (%) Load (N) (%)__________________________________________________________________________-- 65 29.12 ± 0.12 16.24 ± 0.30 28.49 ± 0.30 37.25 ± 2.04 66.15 ± 2.48 24.39 ± 0.47 59.33 ± 2.005.38 65 42.56 ± 0.29 10.13 ± 0.14 21.72 ± 0.84 27.97 ± 1.83 56.82 ± 3.11 17.99 ± 1.26 51.88 ± 2.84-- 85 29.26 ± 0.33 16.03 ± 0.12 -- 34.06 ± 0.31 63.11 ± 2.32 26.88 ± 1.85 63.75 ± 4.485.38 85 43.60 ± 0.21 9.51 ± 0.28 -- 24.53 ± 0.83 53.46 ± 3.18 19.72 ± 0.88 56.22 ±__________________________________________________________________________ 1.63 .sup.a Acidic hydrogen peroxide bleaching (as per experimental) for 40 or 60 min at 80° C., followed, when indicated, by thiourea addition, (pH adjustment with NaOH to pH 7.4-7.6), and continued bleaching at 80° C. for 25 min. .sup.b As per Table I. .sup.c As per Table I. .sup.d As per Table I. .sup.e As per Table I. It is seen from the results that the bleaching efficiency are markedly improved with the hydrogen peroxide-thiourea system as compared to an oxidative acidic hydrogen peroxide bleaching alone. The decrease in breaking load and elongation noted in Table V for acidic oxidative/reductive bleaching is not understood, but is inconsistent with the alkali solubility results. B. DIRECT ADDITION OF REDUCTIVE SUBSTANCE TO A DECOMPOSED OXIDATIVE HYDROGEN PEROXIDE BLEACH BATH It is well known that typically only a small fraction of hydrogen peroxide is consumed or decomposed during an efficient and effective bleaching process. In a typical two step, two-bath oxidative/reductive process, the goods are first bleached oxidatively using hydrogen peroxide (alkaline or acidic). They are then removed from the first bath and bleached in the second bath with a reducing agent. This process is not only costly but also time-consuming, since both baths must be heated up to a suitable temperature. The principle behind this aspect of the present invention is that the active surplus hydrogen peroxide remaining after an oxidative bleaching treatment may be successfully decomposed with no adverse effect on the fiber or subsequent chemical treatment, thus allowing a reductive substance to be added to the bath directly. This is particularly sound for a single-bath process, since the bath is already in the temperature range suitable for subsequent reductive bleaching. There are many inorganic catalysts (such as, transition metals, e.g. iron, copper, manganese, cobalt, etc.) and enzymes that will decompose hydrogen peroxide. A typical set of conditions would be as follows: ______________________________________Hydrogen peroxide (30% w/w) 20 mL/L of liquorTetrasodium pyrophosphate decahydrate 10 g/L of liquorTriton X-100 1 g/L of liquor______________________________________ Wool fabric (10 g) was bleached with the above solution at a liquor to goods ratio of 30 milliliter liquor: 1 gram of wool for 60 minutes at 60° C. The pH of the bleach liquor was then adjusted to 8.8 and CoSO 4 (25 mg/L) was added to the bleach bath. Rapid evolution of oxygen was observed and the decomposition of hydrogen peroxide was complete within 10-15 minutes as the titration against acidified KMnO 4 showed. At this stage, a chelating agent such as nitrilotriacetic acid trisodium salt could be added to complex with the free Co ions and the pH of the solution could be adjusted to the desired value for the reductive bleaching part of the process. The above is a specific set of typical conditions, but in general the conditions may be varied. It is found that hydrogen peroxide may be decomposed efficiently in the pH range 7.8-9.0 and temperature range 80°-60° C. with no adverse effect on wool. Reductive bleaching is either carried out under neutral or acidic conditions. Therefore, after the decomposition of hydrogen peroxide and the pH adjustment, the temperature of the bath may be increased to the desired temperature to obtain optimum bleaching yields. EXAMPLE 6 In this example the effect of reductive bleaching (sodium hydroxymethanesulfinate [Bleachit D (BASF Chemical Division, Charlotte, N.C.)] or thiourea dioxide) is demonstrated under various conditions as an aftertreatment following an oxidative alkaline hydrogen peroxide bleaching. The results of bleaching trials are shown in Table VI and depicted graphically in FIGS. 5 and 6. TABLE VI__________________________________________________________________________The effect of reductive agent aftertreatment (Bleachit D, thioureadioxide) on theoxidative/reductive bleaching of wool flannel..sup.aBath Hydrogentemperature peroxide Bleachit D Thiourea dioxide Whiteness Yellowness Alkali(°C.) (mL/L) (g/L) (g/L) Index.sup.b Index.sup.c Solubility (%).sup.d__________________________________________________________________________60 20.sup.e -- -- 35.85 ± 0.54 12.38 ± 0.17 22.43 ± 1.0960 20.sup.f 1.0 -- 39.84 ± 0.42 10.66 ± 0.21 24.58 ± 0.4760 20.sup.f 2.0 -- 39.93 ± 0.27 10.58 ± 0.07 --60 20.sup.f 4.0 -- 40.80 ± 0.07 10.60 ± 0.03 24.59 ± 0.6970 20.sup.e -- -- 39.33 ± 0.36 10.94 ± 0.17 30.73 ± 0.7870 20.sup.g -- 1.0 35.75 ± 0.66 12.51 ± 0.24 22.65 ± 0.6770 20.sup.g -- 2.0 41.21 ± 0.13 10.26 ± 0.19 --70 20.sup.g -- 3.0 42.14 ± 0.28 9.69 ± 0.08 22.51 ± 0.3270 20.sup.g -- 5.0 43.26 ± 0.52 9.24 ± 0.19 --__________________________________________________________________________ .sup.a As per experimental; residual hydrogen peroxide quenched using CoSO.sub.4 prior to reductive bleaching. .sup.b As per Table I. .sup.c As per Table I. .sup.d As per Table I. .sup.e Alkaline hydrogen peroxide bleaching for 1 hour and 25 minutes, as per Table I, note g. .sup.f As per e, but for 50 minutes, followed by peroxide decomposition with CoSO.sub.4 for the next 10 minutes at pH 8.8 and finally reductive bleaching (Bleachit D, pH adjusted to 2.5) at the same temperature for 25 minutes. .sup.g As per `f' except for reductive bleaching agent (thiourea dioxide, pH adjusted to 6.5-7.0). In the process of the instant example, the decomposition of residual hydrogen peroxide is essential; preliminary experiments showed that large amounts of reductive agents (thiourea dioxide, sodium hydroxymethanesulfinate) were needed to consume all the residual hydrogen peroxide before a high negative oxidation potential could be attained upon addition of the reductive agent. It should also be noted that thiourea dioxide, unlike sodium hydroxymethanesulfinate, does not produce a high negative oxidation potential under acidic conditions; therefore, with thiourea dioxide it is preferred to utilize a pH of about 6.5-7.0. For reasons of economy it is preferred that all residual hydrogen peroxide after oxidative bleaching be completely decomposed so that an addition of only a relatively small amount of reductive substance creates the reduction potential that is needed for the latter part of the process. EXAMPLE 7 Comparative Example The purpose of this example is to show the increased effectiveness of the present invention as compared to the processes of German Patent DE 3433926 A1 (3/27/86) and Japanese Patent JP 51-64082 (6/3/76). The German patent discloses a single-bath process whereby a reductive bleaching with thiourea dioxide precedes an oxidative hydrogen peroxide bleaching. In that patent, two processes--one with and one without thiourea dioxide--were compared and it was concluded that the process with thiourea dioxide was favorable to the one without. The optimum bleaching conditions were said to be a reductive bleaching with a buffer mixture (pH=7.8, 4 g/L) containing thiourea dioxide (0.36 g/L) for 20 minutes at 80° C. followed by a direct addition of hydrogen peroxide (20 mL/L of 35% w/w solution) and further bleaching for 60 minutes at the same temperature. The Japanese patent mentions a process whereby thiourea and hydrogen peroxide are mixed at the start of the bleaching process (i.e., no prior oxidative bleaching) and there is no prescribed pH adjustment. Optimum bleaching conditions were said to be 2.91 g/L hydrogen peroxide (30% w/w) and 2.0 g/L thiourea at 95° C. for 20 minutes. All the above processes were repeated in the exact manner outlined in the patents and the results along with those of our invention are shown in Table VII. TABLE VII__________________________________________________________________________Comparison of different bleaching processes.ProcessTreatment Hydrogen Thiourea Thiourea Bleachit D Whiteness Yellowness AlkaliType.sup.atemperature (°C.) peroxide (g/L) (g/L) dioxide (g/L) (g/L) Index.sup.b Index.sup.c solubility__________________________________________________________________________ (%).sup.dA 60 20 5.38 -- -- 43.83 ± 0.09 9.23 ± 0.04 23.53 ± 0.37B 80 20 5.38 -- -- 42.56 ± 0.29 9.51 ± 0.28 21.72 ± 0.84C 80 20 -- 0.36 -- 35.31 ± 0.07 13.29 ± 0.02 27.40 ± 0.64C 80 20 -- -- -- 32.59 ± 0.21 14.36 ± 0.07 --D 95 2.91 2.0 -- -- 20.33 ± 0.50 18.87 ± 0.15 --E 60 20 -- -- 4.0 40.80 ± 0.07 10.60 ± 0.03 24.59 ± 0.69F 70 20 -- 5.0 -- 43.26 ± 0.52 9.24 ± 0.19 --__________________________________________________________________________ .sup. a A (Our Process): Alkaline hydrogen peroxide bleaching followed by thiourea, as per Table I, note a; B (Our Process): Acidic hydrogen peroxide bleaching followed by thiourea, as per Table V, note a; C (German Patent): Reductive bleaching with thiourea dioxide at pH 7.8 fo 25 min, followed by hydrogen peroxide bleaching for 60 min.; D (Japanese Patent): Hydrogen peroxide and thiourea mixed at start of bleaching process with no pH adjustment; E (Our Process): As per Table VI, note f; F (Our Process): As per Table VI, note g. .sup.b As per Table I. .sup.c As per Table I. .sup.d As per Table I. It is clearly seen that the present invention processes (A, B, E, F) give more effective bleaching (i.e. higher Whiteness Index, lower Yellowness Index and lower alkali solubility) than either of the other processes (C or D). Process type C (Table VII; reductive/oxidative) with thiourea dioxide is a near reverse of the present invention processes A, B, E and F (oxidative/reductive). One would therefore expect similar results. The differences that were observed must be a function of the process sequence, since high negative oxidation potentials were observed in all these processes. One may therefore conclude from this that in a single-bath bleaching process, an oxidative hydrogen peroxide bleaching must be carried out first, and only then followed by a reductive bleach. C. INITIAL TREATMENT WITH FERROUS IONS FOLLOWED BY BLEACHING IN ACCORDANCE WITH THE AFOREMENTIONED PROCESSES The wool used was a flannel fabric (Whiteness Index=-4.40, Yellowness Index=32.70, 507 g/m 2 ) heavily contaminated with black hair and urine-stained wool, kindly supplied by Forstmann and Co., Inc., Dublin, Ga. The hydrogen peroxide used was a 30% (w/w) aqueous solution. The non-ionic wetting agent Triton X-100 was provided by Rohm and Haas Co., Philadelphia, Pa. Tetrasodium pyrophosphate decahydrate was obtained from Aldrich Chemicals Co., Inc., Milwaukee, Wis. All other chemicals used were of A.C.S. grade. Mordanting and bleaching of wool fabric were performed using an Ahiba Texomat (Ahiba Inc., Charlotte, N.C.) laboratory dyeing apparatus. All laboratory mordanting and bleaching trials were carried out at a liquor/wool ratio of 30 milliliters to 1 gram of fabric. (1) Mordanting: Wool flannel fabric (10.0 grams) was introduced into the mordant bath at 40° C. and the temperature was then raised to 80° C. over a period of 20 minutes. Mordanting was further carried out at this temperature for 1 hour. Mordant Solution: FeSO 4 .7H 2 O (10.0 grams/liter). Reducing Agent: Hypophosphorous acid (0.2 gram/liter) or Sodium bisulfite (2.0 gram/liter). Triton X-100 (1.0 gram/liter). pH (initial)=2.87. pH (after mordanting)=3.45. (2) Rinsing: The flannel was then removed and thoroughly rinsed 4 times in changes of deionized water at 80° C., each rinsing being for 5 minutes under acidic conditions (pH=2.0-3.5). The flannel was then air-dried. (3) Bleaching: Bleaching was carried out under alkaline conditions for a specified time and temperature in the bleach bath of composition as listed below. Bleach Solution Hydrogen peroxide (30% w/w; 20.0 ml/liter). Tetrasodium pyrophosphate decahydrate (10.0 grams/liter). Triton X-100 (1.0 g/l). Aqueous ammonia, if necessary, to pH 8.0-8.5. pH (initial)=9.37. pH (final)=8.2-8.5. Using the aforementioned methods and materials the following processes were carried out: Process A Alkaline hydrogen peroxide bleaching for 90 minutes at 60° with no prior mordanting; Process B As per A except thiourea (5.83 grams/liter) was added, pH adjusted to 7-8 and bleaching continued over the last 30 minutes; Process C Mordanting using ferrous sulfate (10.0 grams/liter) and hypophosphorous acid (0.20 grams/liter) for 1 hour at 80° C., followed by thorough rinsing with deionized water at 80° C. and finally bleaching with alkaline hydrogen peroxide for 90 minutes at 60° C.; Process D As per C except thiourea (5.83 grams/liter) was added, pH adjusted to 7-8 and bleaching continued in the last 30 minutes; Process E Mordanting using ferrous sulfate (10.0 grams/liter) and sodium bisulfite (2.0 grams/liter) for 1 hour at 80° C., followed by thorough rinsing with deionized water at 80° C. and finally bleaching using alkaline hydrogen peroxide for 90 minutes at 60° C.; Process F As per E except thiourea (5.83 grams/liter) was added, pH adjusted to 7-8 and bleaching continued over the last 30 minutes. Results were as shown in the following Table. TABLE VIII__________________________________________________________________________ Whiteness Yellowness AlkaliPROCESS Index.sup.a Index.sup.b Solubility (%).sup.c__________________________________________________________________________A: H.sub.2 O.sub.2 15.09 ± 0.20 23.47 ± 0.07 21.50 ± 0.63B: A, then thiourea 19.33 ± 0.32 21.28 ± 0.11 18.21 ± 0.43C: Fe.sup.2+, H.sub.3 PO.sub.2, then A 14.4.7 ± 0.34 23.97 ± 0.13 22.24 ± 0.21D: Fe.sup.2+, H.sub.3 PO.sub.2, then B 19.49 ± 0.04 21.43 ± 0.03 20.13 ± 0.95E: Fe.sup.2+, NaHSO.sub.3, then A 21.73 ± 0.24 22.72 ± 0.01 26.95 ± 0.82F: Fe.sup.2+, NaHSO.sub.3, then B 26.14 ± 0.31 20.55 ± 0.12 23.11 ± 0.09__________________________________________________________________________ .sup.a As per ASTM E313; mean value of 3 samples ± standard deviation, each sample having 8 measurements. .sup.b As per ASTM D1925; xeans value of 3 samples ± standard deviation, each sample having 8 measurements. .sup.c As per IWIO 460; mean value of 3 samples ± standard deviation. It is seen from Table VIII that the differences in Whiteness and Yellowness Indices of the samples treated by processes A and C are very small, even though one would have expected to obtain a whiter sample with the mordanted wool (treatment process C). There are two possible explanations to account for this. First, the samples used in the investigations are urine-stained wool with black hair contamination. Since the conditions were selected to yield optimum selective bleaching of black hair, the bleaching of the non-pigmented areas--the majority of the wool fibers--was not expected to be higher in one case over the other. The color indices are not expected to be sensitive to changes in the relatively few pigmented fibers. The human eye, however, is more discriminatory; close examination reveals that the black hairs in the case of the bleached mordanted wool have turned into a pale light brown shade that blend well with the background color of wool. In the case of the bleached non-mordanted wool, the situation is quite different; the black hairs were only negligibly lightened and are still readily detected by the eye. Second, ferrous ions, even if present in only a small amount after the rinsing step, may cause a red-brown discoloration to the overall appearance of wool as a result of oxidation of ferrous species by hydrogen peroxide during the bleaching stage. This may well account for the small differences in the Whiteness and Yellowness Indices of the mordanted vs. non-mordanted bleached wool (process C vs. A). The effect of different reducing agents during mordanting on the bleaching efficiency of wool was also investigated, i.e. a comparison of hypophosphorous acid to sodium bisulfite (Table VIII; processes C and E, respectively). Both compounds were found to be effective reducing agents in the application of ferrous ions onto wool and thus effective for selectively bleaching black hair. When the results of the bleaching trials are closely compared, it is easily seen that bleached wool mordanted in the presence of sodium bisulfite has a higher Whiteness Index but also a higher Yellowness Index than the wool mordanted in the presence of hypophosphorous acid. This is due to the fact that the wool mordanted in the presence of sodium bisulfite absorbed more iron (much darker color appearance after mordanting) than that mordanted in the presence of hypophosphorous acid. The excess iron will lead to greater reaction of hydrogen peroxide and hence enable more efficient bleaching. The bleached wool sample, however, is yellower. Measurements of hydrogen peroxide decomposition during bleaching in the presence of wool samples that had undergone different treatments are shown in FIG. 7. Enhanced decomposition of hydrogen peroxide is seen using wool that was mordanted in the presence of sodium bisulfite. Absorption of excessive amounts of iron during mordanting and retainment after thorough rinsing may cause excessive damage to wool during bleaching. This is reflected in the alkali solubility results that are presented in Table VIII. Note the higher alkali solubility in the case of iron and sodium bisulfite treated wool. We infer from our data that bisulfite is not as good a reducing agent as hypophosphorous acid for stabilizing ferrous species on wool, that excessive amounts of ferric ion form on the wool (and are even visible as a reddish-brown discoloration), and that subsequent rinsing followed by treatment with hydrogen peroxide leads to excessive decomposition of peroxide and limited damage to the wool fiber despite good whiteness. The results of the bleaching trials in combination with thiourea are also presented in Table VIII. It is clearly seen from the results in Table VIII that any of the bleaching trials that are mentioned above, when combined with thiourea and appropriate pH adjustment, yield much superior bleaching. This is very apparent when treatment processes A and B, C and D, and E and F are compared. The increase in Whiteness Index values and the decrease in Yellowness Index values are due to further bleaching of heavily yellow stained wool and the substantial lightening of the background discoloration caused by ferric species. The effect of various agents such as oxalic acid, sodium oxalate, and EDTA-disodium salt on the lightening of background discoloration on wool were investigated and the results are presented in the following Table. TABLE IX.sup.a______________________________________After Treatment Whiteness Yellowness AIkali(conc., grams/liter) Index Index Solubility______________________________________None 20.89 ± 0.03 23.06 ± 0.13 20.65 ± 0.54Oxalic acid (3.0) 17.09 ± 0.84 24.99 ± 0.32 19.63 ± 1.36Sodium oxalate (3.0) 19.79 ± 0.24 23.60 ± 0.09 --EDTA, Na.sub.2 salt 19.34 ± 0.04 23.93 ± 0.07 --(3.0)Thiourea (5.83) 25.47 ± 0.32 20.62 ± 0.18 --pH 7-8Thiourea.sup.b (5.83) 27.78 ± 0.59 19.70 ± 0.28 16.44 ± 0.25pH 7-8______________________________________ .sup.a Mordanting using ferrous sulfate (10.0 grams/liter) and hypophosphorous acid (0.2 grams/liter) for 1 hour at 80° C., followed by thorough rinsing with deionized water at 80° C. and finally bleaching using alkaline hydrogen peroxide for 65 minutes at 65° C. Aftertreatment is done, where stated, in the last 5 minutes of the bleaching stage. .sup.b As per footnote a except alkaline hydrogen peroxide bleaching is carried out for 40 minutes at 65° C., followed by thiourea addition, pH adjustment to 7-8 and further bleaching for 25 minutes. Whiteness index, yellowness index and alkali solubility were as per Table VIII. These results, in turn, were compared to those of no aftertreatment and thiourea treatment. It was thought that the above mentioned agents would chelate with and solubilize the iron present on wool after the bleaching stage and hence lighten the background discoloration. However, no after-treatments except thiourea gave any improvement in the lightening of wool as compared to the wool not given an after-treatment. The reaction of thiourea with the residual hydrogen peroxide after the bleaching stage and the necessary pH adjustment create a highly reductive medium that reduces any ferric species that may be present on wool to the ferrous form, which is easily washed away due to its much smaller affinity to unpigmented wool. Prolonged treatment with thiourea (25 minutes as compared to 5 minutes) yielded a whiter and less yellow sample due to further bleaching of the heavily yellow-stained wool. The alkali solubilities in all cases are within acceptable limits. D. OXIDATIVE BLEACHING USING HYDROGEN PEROXIDE/PERSULFATE FOLLOWED BY THE AFOREMENTIONED PROCESSES OF REDUCTIVE BLEACHING IN THE SAME BATH EXAMPLE 8 Bleaching experiments were done in stirred bleaching vessels immersed in a stirred thermostatic bath. The substrate was a wool flannel fabric (507/g/M 2 ) heavily contaminated with black hair and urine-stained wool, kindly supplied by Forstmann and Co., Inc., Dublin, Ga. The hydrogen peroxide was a 30% (w/w) aqueous solution. The non-ionic wetting agent Triton X-100 was provided by Rohm and Haas Co., Philadelphia, Pa. Tetrasodium pyrophosphate decahydrate was obtained from Aldrich Chemical Co., Inc., Milwaukee, Wis. All other chemicals used were of A.C.S. grade. All laboratory bleaching trials were carried out at a liquor/wool ratio of 30 milliliters to 1 gram of fabric. BLEACHING Bleaching was carried out under alkaline conditions for a specified time and temperature in the bleach bath of composition as listed below: ______________________________________Bleach Solution______________________________________Hydrogen Peroxide (30% w/w; 20.0 ml/liter)Tetrasodium Pyrophosphate Decahydrate (10.0 grams/liter)Ammonium Persulfate (3.0 grams/liter) (3.0 grams/liter)Triton X-100 (1.0 gram/liter)______________________________________ Aqueous Ammonia, if necessary, to PH 8.0-8.5. On addition of ammonium persulfate, the solution pH rapidly drops from about 9.4. to under 6. Sufficient ammonia is added to adjust pH back to 8.2-8.5. pH (initial)=6.00 pH (final)=8.2-8.5 Using the formulations above, the following processes were carried out. Process A Bleaching with the above composition for 90 minutes at 60° C.; Process B As per process A for 60 minutes, then addition of thiourea (5.83 grams/liter), pH adjustment to 7-8 and continuation of bleaching for 3 minutes. The results were as follows: ______________________________________ Whiteness Index Yellowness Index (E-313) (D-1925)______________________________________Control -4.40 ± 0.30 32.70 ± 0.16Process A 11.59 ± 0.63 25.27 ± 0.24Process B 16.43 ± 0.30 22.74 ± 0.10______________________________________ The foregoing examples and detailed descriptions are given merely for purposes of illustration. Modifications and variations may be made therein without departing from the spirit and scope of the invention.
The present invention is drawn to new processes for sequential oxidative and reductive bleaching of pigmented and unpigmented fibers (e.g. natural, synthetic, or blends thereof) e.g. in a single bath, which provide superior bleaching with less physical damage. Said processes including processes comprised of: (1) adsorption of ferrous ions by pigmented and unpigmented fibers; (2) removing a portion of the ferrous ions from the fibers, with at least a portion of the ions remaining on the pigmented fibers; (3) contacting the fibers with hydrogen peroxide to provide oxidative bleaching including bleaching by interaction with the ferrous ions; (4) adding either (a) a material which combines with hydrogen peroxide to form a reductive bleaching agent, or (b) an inactivating material to inactivate unspent hydrogen peroxide with subsequent addition of a reductive bleaching agent, and; (5) reductively bleaching the already oxidatively bleached fibers. The aforementioned processes provide the advantages of preventing deposition of ferric species and producing fibers which are essentially free of iron residue. The present invention also encompasses processes employing hydrogen peroxide and at least one persulfate containing compound, rather than the aforementioned iron-mordanting. The instant invention produces fibers having surprising, highly advantageous, and desirable properties, e.g. fibers which are essentially pigment free, have a high degree of whiteness with low degree of damage.
3
This is a continuation of the application Ser. No. 834,381 filed Feb. 28, 1986 now abandoned. BACKGROUND OF THE INVENTION U.S. Pat. Nos. 3,959,974, 4,301,655 and 4,417,447 issued to L. B. Thomas, disclose several embodiments of a combination internal combustion-steam engine, the power of which is increased and the efficiency of which is improved by cyclicly injecting water through the cylinder head into the combustion space above the piston when the power cylinder is sufficiently hot to produce superheated steam. While all three of the patented engine structures achieve the enumerated objectives, the improvement herein includes an engine structure which will more completely exhaust all of the combustion gases and improve the power characteristics of a gasoline or diesel engine. Furthermore, these patents represent improvements in two-cycle engines and the water injection concept can be improved by using a four-cycle principle and utilizing two companion cylinders to complete the four-cycle operation. Accordingly, it is an object of this invention to provide a water-injection internal combustion engine which can be built to operate on either the Diesel principle of compression ignition or the Otto principle of low compression using a carburetor or fuel injection and spark ignition. Either technique will produce the heat needed by internal combustion for generating the superheated steam according to the invention. Another object of this invention is to provide a new and improved water injection, internal combustion engine of the four-cycle design, which engine is characterized by sets of at least two companion cylinders separated by at least one transfer valve, one of which cylinders initiates combustion, wherein the burning gases are forced through the transfer valve into the second power cylinder where water is injected and the power and exhaust strokes are completed. Another objecte of the invention is to provide a four-cycle, water-injection, internal combustion engine of either the compression ignition or spark ignition design, which engine is characterized by at least two companion cylinders having ceramic liners at the upper ends thereof and cooperating pistons with upper ceramic surfaces for reciprocation in the cylinders, respectively, with a pair of transfer valves located between the cylinders. Yet another object of this invention is to provide a four-cycle, water-injection engine which can be adapted for compression ignition or spark ignition operation, which engine includes at least one pair of companion compression and power cylinders served by ceramic pistons, each of the cylinders having a conventional lower portion and a ceramic upper portion for operation at high temperatures, with a pair of transfer valves located between and communicating with the compression and power cylinders, wherein a fuel and air mixture is first compressed and burned in the compression cylinder and is then routed through the transfer valves to the power cylinder, where steam is generated to enhance the power cycle. SUMMARY OF THE INVENTION These and other objects of the invention are provided in a water-injection, four-cycle, compression ignition or spark ignition engine having at least one compression cylinder and piston and a companion power cylinder and piston, wherein air or air and fuel, depending upon Diesel or Otto cycle operation, are drawn by aspiration or forced by turbocharger into the compression cylinder as the corresponding compression piston moves down on the first cycle of operation. The air or air and fuel are then compressed by the returning upward stroke of the compression piston, fuel is introduced into the compression cylinder under circumstances of Diesel operation and combustion takes place in the compression cylinder. While the fuel is burning and the compression piston is still on the upward stroke, the transfer valve or valves located between each compression cylinder and power cylinder open and allow the hot gases to pass into the power cylinder to complete the second cycle of the four-cycle operation. The power piston operating in the power cylinder is designed to operate approximately 50 degrees ahead of the compression piston in the compression cylinder and has already reached top dead center and started down on the power stroke when the transfer valve or valves closes, thus isolating the hot gases in the power cylinder. As the power piston nears the bottom of the power stroke, the exhaust valve or valves open, thus completing the third cycle of operation. All gases are expelled from the power cylinder by the power piston when it moves upwardly on the fourth cycle, the exhaust valve then closes and the first cycle of operation begins again. The power cylinder and power piston get very hot, since the burning gases are transferred to the power cylinder very soon after combustion is initiated in the compression cylinder. As a result of this, very little heat is absorbed in the compression cylinder. The pistons used in this invention are identical to those described in my U.S. Pat. No. 3,959,974. They are ceramic displacement-type pistons having a ringless top section capable of withstanding high temperatures. The ceramic pistons operate in a cylinder liner constructed of the same ceramic material as the pistons, most preferably a silicone carbide derivative, as hereinafter described. This combination of power piston and cooperating cylinder liner requires no lubrication in the hot upper section of the engine. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a typical vertical cross-sectional view taken through two cylinders of the improved engine of this invention, showing the compression piston, transfer valve and power piston constructed in accordance with the invention, using the Diesel cycle principle; FIG. 2 is a typical vertical cross-sectional view taken through the cylinders of the improved engine, showing the compression piston, transfer valve and power piston constructed in accordance with the invention, using the Otto cycle principle; FIG. 3 is a vertical cross-sectional view taken through the transfer valve assembly illustrating two transfer valves and associated elements; and FIG. 4 is a horizontal cross-sectional view taken through the upper engine block also showing the two transfer illustrated in FIG. 3. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIGS. 1, 3 and 4 of the drawings a pair of companion cylinder and piston combinations is illustrated for simplicity, although it will be appreciated that the invention can be embodied in engines having various numbers of cylinders in different engine configurations. As illustrated, a compression cylinder 12 is provided with a ceramic liner 25 at the top portion thereof and receives a compression piston 1, having a ceramic compression piston portion 22, as illustrated. A companion power cylinder 11 is also provided with a ceramic liner 25 and receives a power piston 2, having a ceramic power piston portion 20. The ceramic compression piston portion 22 and the ceramic power piston portion 20 operate in an upper cylinder block 9, which houses the ceramic liners 25. The lower compression portion 27 of the compression piston 1 and the lower power portion 13 of the power piston 2 are fabricated of metal in conventional fashion and are provided with conventional rings 14. The lower compression portion 27 and ceramic compression piston portion 22, as well as the lower power portion 13 and the ceramic power piston portion 20 of the compression piston 1 and the power piston 2, respectively, reciprocate in conventional cylinder bores 3, respectively, provided in the engine block 10. Conventional piston rods 15 drive the compression piston 1, as well as the power piston 2, respectively, from a common crankshaft (not illustrated). Since the piston and cylinder configuration illustrated in FIG. 1 is designed for Diesel operation, a fuel injector 21 is provided in the head 10a above the compression cylinder 12, along with a compression cylinder heat sensor 17 and an intake valve 30, positioned in the intake port 30a. An exhaust valve 8 is located in the exhaust port 8a of the head 10a above the power cylinder 11, along with a water injector 23, a power cylinder heat sensor 16 and an exhaust heat sensor 32, located in the exhaust port 8a. A pair of transfer valves 28, each having a valve body 29 rotatably provided in a valve cylinder 29a, are located in the head 10a between the compression cylinder 12 and the power cylinder 11. The lower segments of the transfer valves 28 are seated in the upper cylinder block 9 by means of a valve mount plate 31 and a mount bolt 33, as illustrated in FIG. 3. Referring now to FIGS. 2, 3 and 4 of the drawings a second compression cylinder 12 and power cylinder 11 configuration is disclosed, which is indentical to the configuration illustrated in FIG. 1, with the exception of a spark plug 34, located in the head 10a and extending into the cylinder bore 3 of the compression cylinder 12. The engine configuration illustrated in FIG. 2 is set up for spark ignition operation and also includes a pair of transfer valves 28 located between the compression cylinder 12 and the power cylinder 11. As illustrated in FIGS. 3 and 4 of the drawings, in a most preferred embodiment of the invention a pair of transfer valves 28 is preferably located between the respective compression cylinders 12 and power cylinders 11 in both the compression ignition and spark ignition versions of the engine of this invention which are illustrated in FIGS. 1 and 2, respectively. Each of the valve bodies 29 of the transfer valves 28 are equipped with a passage 26 and located in the lower portion thereof, and with a registering valve port 29b, located in the respective valve cylinders 29a. This mechanical arrangement facilitates the transfer of hot, compressed combustion gasses from the compression cylinder 12 to the power cylinder 11, as hereinafter described. Referring again to FIGS. 1, 3 and 4 of the drawings, the four-cycle Diesel principle begins operation in the first engine configuration modified according to this invention as the compression piston 1, located in the compression cylinder 12, starts down on the first cycle by operation of a conventional starter mechanism (not illustrated). The intake valve 30 then opens and air is drawn by aspiration or forced by a turbocharger through the intake port 30a and into the cylinder bore 3 of the compression cylinder 12. As the compression piston 1 starts upwardly to begin the second, or compression cycle, the intake valve 30 closes and the air is compressed to the compression ignition point. Fuel is then injected through the fuel injector 21 into the cylinder bore 3 of the compression cylinder 12 and starts to burn. At this point the transfer valve 28 open and the hot, burning gases pass through the respective aligned valve ports 29b and passages 26 located in the valve bodies 29 and valve cylinders 29a of the transfer valves 28, into the power cylinder 11 above the ceramic power piston portion 20 of the power piston 2. The power piston 2 has by this time reached top dead center in the power cylinder 11 and has begun the downward power stroke. The compression piston 1 continues upwardly in the compression cyclinder 12 to top dead center, forcing all hot gases through the valve ports 29b and the passages 26, into the cylinder bore 3 of the power cylinder 11 and the transfer valves 28 then close. When the power piston 2 reaches the bottom of the power stroke, the exhaust valve 8 opens and all gases are expelled through the exhaust port 8a as the power piston 2 reverses direction and moves upwardly. When the power piston 2 reaches the top of the power stroke, the exhaust valve 8 closes. When the ceramic liner 25 in the power cylinder 11 and the ceramic power piston portion 20 are sufficiently hot, a circuit through the power cylinder heat sensor 16 (not illustrated) closes and a computer (not illustrated) initiates the steam cycle. A small quantity of water is injected at high pressure through the water injector 23 into the cylinder bore of the hot cylinder bore 3 and water vapor impinges on the top of the ceramic power piston portion 20 of the power piston 2, producing super-heated steam in a few milliseconds. The pressure and expansion of the steam forces the power piston 2 downwardly in the power cylinder 11 on the power stroke. Referring now to FIG. 2 of the drawings, the four-cycle Otto engine cycle begins as the compression piston 1, located in the compression cylinder 12, starts down on the first cycle. The intake valve 30 opens and a combustible mixture of air and fuel is drawn or by aspiration forced by turbocharger through the intake port 30a into the cylinder bore 3 of the compression cylinder 12. As the compression piston 1 starts upwardly in the compression cylinder 12 to begin the second cycle, the intake cycle 30 closes and the combustible mixture is compressed and ignited by the spark plug 34. At this point, the transfer valves 28 open by operation of a cam (not illustrated) or by alternative means known to those skilled in the art, and the hot, burning gases pass through the valve ports 29b and passages 26 into the cylinder bore 3 of the power cylinder 11 above the power piston 2, which by this time has reached top dead center and has started moving downwardly on the power stroke. Meanwhile, the compression piston 1 continues upwardly to top dead center in the compression cylinder 12, forcing all hot gases into the power cylinder 11 and the transfer valve 28 then closes. When the power piston 2 reaches the bottom of the power stroke, the exhaust valve 8 opens and all gases are expelled through the exhaust port 8a as the power piston 2 reverses direction and travels upwardly; when the power piston 2 reaches the top of the exhaust stroke the exhaust valve 8 closes. When the ceramic liner 25 in the power cylinder 11 and the ceramic power piston portion 20 of the power piston 2 are sufficiently hot, a circuit through the power cylinder heat sensor 16 closes and a computer (not illustrated) begins the steam cycle as in the case of the Diesel engine configuration illustrated in FIG. 1. As heretofore described, a small amount of water is injected at high pressure into the hot cylinder bore 3 and on to the top of the ceramic power piston portion 20 of the power piston 2, producing super-heated steam. The pressure and expansion of the steam, coupled with the expanding combustion gasses, force the power piston 2 downwardly on the power stroke. In both of the variations illustrated in FIGS. 1 and 2, the engine of this invention can be operated with one or more transfer valves 28, located between each set of companion compression cylinders 12 and power cylinders 11, respectively, as heretofore noted. The transfer valve 28 configuration illustrated in FIGS. 3 and 4 illustrates the use of two transfer valves 28 which are constructed of a high temperature-resistant material, similar to silicon carbide, that requires no lubrication and is able to withstand very high temperatures. In a first operational mode, each transfer valve 28 is opened by turning the valve body 29 approximately 90 degrees to align the passage 26 with the corresponding valve port 29b located in the valve cylinder 29a and turning the valve body 29 back to the original position to close the passage 26. In a second operational mode, each transfer valve 28 can also be opened and closed by raising and lowering each valve body 29 with respect to the valve cylinder 29a as a sliding valve using cam action, as in conventional engines using overhead valves. As illustrated in FIG. 4, one of the transfer valves 28 is illustrated in the open position, while the other transfer valve 28 is shown in the closed position; however, in a preferred mode of operation, both transfer valves 28 will be opened and closed by turning the respective valve bodies 29 in concert. In a most preferred embodiment of the invention a preferred material of construction for the liners 25 of the compression cylinder 12 and power cylinder 11, respectively, the ceramic compression piston portion 22 of the compression piston 1, the ceramic power piston portion 20 of the power piston 2 and all components of the transfer valves 28, is similar to a silicon carbide ceramic. However, other ceramic materials which will retain structural integrity at high temperatures can be used in the engine of this invention according to the knowledge of those skilled in the art. In yet another preferred embodiment of the invention the ceramic compression piston portion 22 of the compression piston 1 is attached to the lower compression portion 27 by cement bonding or by methods such as bolting. Furthermore, the ceramic power piston portion 20 of the power piston 2 is similarly attached to the lower power portion 13. It will be understood that in addition to water, other vaporable liquids, including ethyl alcohol and other liquids which are miscible with water, in non-exclusive particular, can be used as the injection medium under circumstances of freezing weather. While the preferred embodiments of the invention have 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 such modifications which may fall within the spirit and scope of the invention.
A high temperature, high pressure, four-cycle piston engine having two companion cylinders or multiple pairs of companion cylinders connected by a transfer valve or valves and working together to complete the four-cycle operation. The internal combustion of fuel and air in the ceramic cylinders is utilized as a means of producing heat and this heat is used to generate superheated steam by cyclicly injecting water into the hot power cylinders, with each power cylinder serving as a steam boiler. Ceramic pistons in the power cylinders use the power of the expanding steam to do useful work and operate to exhaust all gases after each power stroke. The engine can be adapted for both compression ignition and spark ignition operation.
5
CROSS-REFERENCE TO RELATED APPLICATION This application claims priority under 35 U.S.C. §119 from Japanese Patent Application No. 2007-176317 filed on Jul. 4, 2007. The entire subject matter of the application is incorporated herein by reference. BACKGROUND 1. Technical Field The following description relates to one or more sheet feeding techniques for an image forming apparatus. 2. Related Art Among image forming apparatuses, for example, there is an apparatus provided with a loading portion configured to be loaded with a sheet, a lifting mechanism configured to lift the loading portion, and a detecting unit configured to detect whether the loading portion reaches a predetermined height. It is noted that the predetermined height represents such a height that a sheet on the loading portion can be fed to a carrying route inside a main body of the apparatus. In the meantime, a configuration has been known, in which ON/OFF control of a lifting operation by the lifting mechanism is mechanically performed with, for example, a cam (see Japanese Patent Provisional Publication No. 2006-151655). Specifically, the aforementioned configuration includes a cam and a control unit configured to control a rotational position of the cam. The control unit holds the cam in a first rotational position to set the lifting operation ON until the loading portion reaches the predetermined height, and rotates the cam to a second rotational position to set the lifting operation OFF when the loading portion reaches the predetermined height. SUMMARY In the aforementioned configuration, the lifting operation is maintained until the cam is rotated to the second rotational position from the first rotational position even after the loading portion reaches the predetermined height. A time-lag until the cam is rotated to the second rotational position from the first rotational position (hereinafter referred to as a first time-lag) cannot be avoided as far as the aforementioned configuration is applied, in which the ON/OFF control of the lifting operation by the lifting mechanism is mechanically performed with a cam mechanism. However, in the aforementioned configuration, in addition to the first time-lag mechanically caused, there is caused a time-lag until the rotation of the cam to the second rotational position is actually started after it is detected that the loading portion reaches the predetermined height (hereinafter referred to as a second time-lag). Therefore, it is unfortunate that the lifting operation might be further continued even after the loading portion reaches the predetermined height and a sheet feeding performance might be worsened. Aspects of the present invention is advantageous in that there are provided one or more improved sheet feeding devices and image forming apparatuses that make it possible to restrain worsening of sheet feeding performance even though a mechanical configuration is applied so as to control a lifting operation for a loading portion loaded with a sheet. According to aspects of the present invention, there is provided a sheet feeding device, which includes a loading portion configured to be loaded with a stack of sheets and to be movable up and down, a lifting mechanism configured to lift the loading portion in an operating state and to stop the lifting of the loading portion in an stopped state, a cam configured to be rotated alternately to a first rotational position for setting the lifting mechanism to the operating state and to a second rotational position for setting the lifting mechanism to the stopped state, a detecting unit having a contact portion configured to be movable up and down while contacting a top sheet of the stack on the loading portion, the detecting unit being configured to detect whether the top sheet reaches a first height based upon the movement of the contact portion thereof, and a control unit configured to rotate the cam before the detecting unit detects that the top sheet reaches the first height and to stop the cam in the second rotational position in response to the detecting unit detecting that the top sheet reaches the first height. In some aspects of the present invention, the cam is driven and rotated before the top sheet on the loading portion reaches the first height. Thereafter, until the top sheet reaches the first height, the lifting mechanism is repeatedly set alternately to the operating state and the stopped state, as the cam is rotated alternately to the first rotational position and the second rotational position. Thereby, the loading portion is intermittently lifted. After that, in response to the top sheet reaching the first height, an operation of stopping the cam being rotated is started, and the cam is then stopped. It is noted that, even in some aspects of the present invention, the first time-lag has to be caused that is taken for the cam to be rotated from the first rotational position to the second rotational position. However, in some aspects of the present invention, the cam has already been rotating before the sheet on the loading portion reaches the first height. Therefore, the lifting mechanism is stopped the first time-lag after the sheet reaches the first height. Thus, the second time-lag is not caused that is a time period until a start time to cause the cam rotate after it is detected that the sheet on the loading portion reaches the first height. Thereby, it is possible to prevent the worsening of sheet feeding performance better than the aforementioned conventional configuration. According to another aspect of the present invention, there is provided an image forming apparatus, which a sheet feeding unit configured to feed a sheet, and an image forming unit configured to form an image on the sheet fed by the sheet feeding unit. The sheet feeding unit includes a loading portion configured to be loaded with a stack of sheets and to be movable up and down, a lifting mechanism configured to lift the loading portion in an operating state and to stop the lifting of the loading portion in an stopped state, a cam configured to be rotated alternately to a first rotational position for setting the lifting mechanism to the operating state and to a second rotational position for setting the lifting mechanism to the stopped state, a detecting unit having a contact portion configured to be movable up and down while contacting a top sheet of the stack on the loading portion, the detecting unit being configured to detect whether the top sheet reaches a first height based upon the movement of the contact portion thereof, and a control unit configured to rotate the cam before the detecting unit detects that the top sheet reaches the first height and to stop the cam in the second rotational position in response to the detecting unit detecting that the top sheet reaches the first height. According to the image forming apparatus configured as above, the same effect as the aforementioned sheet feeding unit can be provided. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS Illustrative aspects of the invention will be described in detail with reference to the following figures in which like elements are labeled with like numbers and in which: FIG. 1 is a cross-sectional side view showing a configuration of a laser printer in an embodiment according to one or more aspects of the present invention. FIG. 2 is a perspective view of a storage cassette of the laser printer in the embodiment according to one or more aspects of the present invention. FIG. 3 is a perspective view showing a mechanism for lifting a pressing plate in a case where the pressing plate is in a sheet loading state in the embodiment according to one or more aspects of the present invention. FIG. 4 is a perspective view showing the mechanism for lifting the pressing plate in a case where the pressing plate is between the sheet loading state and a sheet feeding state in the embodiment according to one or more aspects of the present invention. FIG. 5 is a perspective view showing the mechanism for lifting the pressing plate in a case where the pressing plate is in the sheet feeding state in the embodiment according to one or more aspects of the present invention. FIG. 6 is a perspective view of a gear mechanism viewed from a left side of the laser printer in the embodiment according to one or more aspects of the present invention. FIG. 7 is a perspective view of the gear mechanism viewed from a right side of the laser printer in the embodiment according to one or more aspects of the present invention. FIG. 8A is a right side view of the gear mechanism in the case where a sheet feeding roller is in the lowest position in the embodiment according to one or more aspects of the present invention. FIG. 8B is a rear side view of the gear mechanism in the case where the sheet feeding roller is in the lowest position in the embodiment according to one or more aspects of the present invention. FIG. 8C is a left side view of the gear mechanism in the case where the sheet feeding roller is in the lowest position in the embodiment according to one or more aspects of the present invention. FIG. 9A is a right side view of the gear mechanism in a case where the sheet feeding roller is in a second release position in the embodiment according to one or more aspects of the present invention. FIG. 9B is a rear side view of the gear mechanism in the case where the sheet feeding roller is in the second release position in the embodiment according to one or more aspects of the present invention. FIG. 9C is a left side view of the gear mechanism in the case where the sheet feeding roller is in the second release position in the embodiment according to one or more aspects of the present invention. FIG. 10A is a right side view of the gear mechanism in a case where a cam gear is engaged with a differential gear in the embodiment according to one or more aspects of the present invention. FIG. 10B is a rear side view of the gear mechanism in the case where the cam gear is engaged with the differential gear in the embodiment according to one or more aspects of the present invention. FIG. 10C is a left side view of the gear mechanism in the case where the cam gear is engaged with the differential gear in the embodiment according to one or more aspects of the present invention. FIG. 11A is a right side view of the gear mechanism in a case where the sheet feeding roller is in a first release position in the embodiment according to one or more aspects of the present invention. FIG. 11B is a rear side view of the gear mechanism in the case where the sheet feeding roller is in the first release position in the embodiment according to one or more aspects of the present invention. FIG. 11C is a left side view of the gear mechanism in the case where the sheet feeding roller is in the first release position in the embodiment according to one or more aspects of the present invention. FIG. 12A is a right side view of the gear mechanism in a case where the sheet feeding roller is between the first release position and the second release position in the embodiment according to one or more aspects of the present invention. FIG. 12B is a rear side view of the gear mechanism in the case where the sheet feeding roller is between the first release position and the second release position in the embodiment according to one or more aspects of the present invention. FIG. 12C is a left side view of the gear mechanism in the case where the sheet feeding roller is between the first release position and the second release position in the embodiment according to one or more aspects of the present invention. FIG. 13 schematically shows side views of the gear mechanism in a case where a storage cassette is inserted in the embodiment according to one or more aspects of the present invention and a comparative example. FIG. 14 schematically shows side views of the gear mechanism in a case where the number of sheets is reduced through a sheet feeding operation in the embodiment according to one or more aspects of the present invention and the comparative example. FIG. 15 shows time dependency of height of the sheet feeding roller in each the embodiment according to one or more aspects of the present invention and the comparative example. DETAILED DESCRIPTION It is noted that various connections are set forth between elements in the following description. It is noted that these connections in general and, unless specified otherwise, may be direct or indirect and that this specification is not intended to be limiting in this respect. Hereinafter, an embodiment according to aspects of the present invention will be described with reference to the accompany drawings. It is noted that, in each drawing, an outline arrow denotes a direction in which a sheet feeding roller 9 or each gear is moved or rotated. (Overall Configuration in Embodiment) FIG. 1 is a cross-sectional side view showing a configuration of a laser printer 1 (hereinafter, simply referred to as a printer 1 ). FIG. 2 is a perspective view of a storage cassette 6 . FIGS. 3 to 5 are perspective views showing respective states in process of lifting a pressing plate 11 . The printer 1 is provided with a main body casing 2 , a feeder unit 4 configured to feed a sheet 3 , and an image forming unit 5 configured to form an image on the sheet 3 . 1. Feeder Unit The feeder unit 4 is provided at a bottom portion in the main body casing 2 , and provided with a storage cassette 6 set therein to be drawn. In a following description, a side to which the storage cassette 6 is drawn is defined as a front side of the printer 1 . The feeder unit 4 further includes a separation roller 7 and a separation pad 8 provided at an upper front portion of the storage cassette 6 , and a sheet feeding roller 9 provided at a rear side of the separation roller 7 (at an upstream side of the separation pad 8 in a carrying direction in which the sheet 3 is conveyed). The carrying route is fold back in a U-shape at a downstream side of the separation roller 7 and separation pad 8 in the carrying direction. At a further downstream side in the carrying direction, a pair of registration rollers 10 is provided. As shown in FIGS. 1 and 2 , a pressing plate 11 on which the sheet 3 is placed in an accumulated manner is provided inside the storage cassette 6 . The pressing plate 11 is supported at a supporting portion 11 A at a rear end thereof, swingably between a sheet loading state where a front end portion 11 B of the pressing plate 11 is disposed at a lower side and the pressing plate 11 is along a bottom plate 12 of the storage cassette 6 (as shown in FIGS. 1 to 3 ) and a sheet feeding state where the front end portion 11 B of the pressing plate 11 is disposed at an upper side and the pressing plate 11 is tilted up from the bottom plate 12 of the storage cassette 6 (namely, a state where the sheet feeding roller 9 contacts the uppermost sheet 3 placed on the pressing plate 11 as shown in FIG. 5 , and the sheet 3 is fed by the sheet feeding roller 9 being rotated). In addition, at a front end portion of the storage cassette 6 , a lever 13 is provided to lift up the front end portion 11 B of the pressing plate 11 . The lever 13 is disposed under the front end portion 11 B of the pressing plate 11 and supported such that a rear end portion 13 A of the lever 13 is swingable between a lying down state where a front end portion 13 B of the lever 13 is lying down on the bottom plate 12 of the storage cassette 6 (as shown in FIGS. 1 to 3 ) and a tilted state where the front end portion 13 B is lifting the pressing plate 11 (as shown in FIG. 5 ). When a rotational driving force is applied to the rear end portion 13 A of the lever 13 in a clockwise direction of the figure, the lever 13 is rotated around the rear end portion 13 A, and the front end portion 13 B of the lever 13 lifts the front end portion 11 B of the pressing plate 11 to set the pressing plate 11 in the sheet feeding state. At a side end of the lever 13 , a fan-shaped gear 43 is fixed as shown in FIG. 2 . The gear 43 is linked, via a gear 44 , with a linking gear 45 to which the driving force is transmitted from a driving source (not shown). When the pressing plate 11 is set in the sheet feeding state, the uppermost sheet 3 placed on the pressing plate 11 is pressed by the sheet feeding roller 9 , and sheet feeding is caused by rotation of the sheet feeding roller 9 to feed the sheet 3 toward a separation position between the separation roller 7 and separation pad 8 . Meanwhile, when the storage cassette 6 is drawn from the feeder unit 4 , the linkage of the driving source (not shown) with the linking gear 45 is released. Then, the pressing plate 11 is set into the sheet loading state where a user can place the sheet 3 on the pressing plate 11 in an accumulated manner, with the front end portion 11 B thereof moving down due to its own weight. It is noted that the separation pad 8 , pressing plate 11 , and lever 13 are disposed in the storage cassette 6 , and that the sheet feeding roller 9 , separation roller 7 , registration rollers 10 are disposed in the main body casing 2 . When the sheet 3 is fed by the sheet feeding roller 9 toward the separation position and pinched in the separation position between separation roller 7 and separation pad 8 , the sheet 3 is separated and fed on a sheet-by-sheet basis. The sheet 3 as fed is turned down along the U-shaped carrying route and conveyed to the registration rollers 10 . The registration rollers 10 are configured to adjust skewing of the sheet 3 and then convey the sheet 3 into a transfer position between a below-mentioned photoconductive drum 29 and transfer roller 32 , where a toner image on the photoconductive drum 29 is transferred onto the sheet 3 . 2. Image Forming Unit The image forming unit 5 is provided with a scanner unit 19 , a process cartridge 20 , and a fixing unit 21 . The scanner unit 19 is provided at an upper portion inside the main body casing 2 . A laser light source (not shown) emits a laser beam based upon image data. As indicated by a chain line in FIG. 1 , the laser beam is deflected by a polygon mirror 22 , transmitted through an fθ lens 23 , bent by a reflective mirror 24 , transmitted through a lens 25 , and bent downward by a reflective mirror 26 . Thereby, the laser beam is incident onto a surface of the below-mentioned photoconductive drum 29 of the process cartridge 20 . The process cartridge 20 is provided under the scanner unit 19 , and includes, in a housing thereof, the photoconductive drum 29 , a scorotron-type charger 30 , a development cartridge 31 , and the transfer roller 32 . In addition, the development cartridge 31 includes a toner container 39 , a toner supply roller 40 , and a development roller 41 . Toner provided from the toner container 39 is supplied to the development roller 41 through rotation of the toner supply roller 40 . At this time, the toner is positively friction-charged between the toner supply roller 40 and the development roller 41 . The toner supplied onto the development roller 41 is held on the development roller 41 as a thin layer with a constant thickness. First, the surface of the photoconductive drum 29 is evenly and positively charged by the charger 30 through rotation of the photoconductive drum 29 . Thereafter, the surface of the photoconductive drum 29 is exposed by fast scanning of the laser beam emitted from the scanner unit 19 , and an electrostatic latent image corresponding to an image to be formed on the sheet 3 is formed thereon. Subsequently, the toner held on the development roller 41 is supplied to the electrostatic latent image formed on the surface of the photoconductive drum 29 , namely, exposed portions on the photoconductive drum 29 as evenly and positively charged that have been exposed by the laser beam to have a lowered electric potential, when facing and contacting the photoconductive drum 29 through rotation of the development roller 41 . Thereby, the electrostatic latent image formed on the photoconductive drum 29 is visualized with the toner image due to inversion development being held on the photoconductive drum 29 . After that, as shown in FIG. 1 , the toner image held on the surface of the photoconductive drum 29 is transferred onto the sheet 3 by a transfer bias applied to the transfer roller 32 while the sheet 3 conveyed by the registration rollers 10 is passing through the transfer position between the photoconductive drum 29 and the transfer roller 32 . The sheet 3 with the toner image transferred thereon is carried to the fixing unit 21 . The fixing unit 21 thermally fixes the toner transferred onto the sheet 3 in the transfer position while the sheet 3 is passing through between a heating roller 33 and pressing roller 34 . The sheet 3 with the toner fixed thereon is conveyed to a sheet discharge path 35 extending toward the upper face of the main body casing 2 along a vertical direction. The sheet 3 carried to the sheet discharge path 35 is discharged, by a sheet discharge roller 36 provided above the sheet discharge path, onto a catch tray 37 formed on the upper face of the main body casing 2 . (Configurations of Sheet Feeding Roller and Separation Roller) FIG. 6 is a perspective view of a gear mechanism 60 viewed from a front side of the printer. FIG. 7 is a perspective view of the gear mechanism 60 viewed from a rear side of the printer. As shown in FIG. 6 , the sheet feeding roller 9 and the separation roller 7 are provided to a bearing member 50 so as to be aligned in a front-to-rear direction of the printer 1 . Specifically, the sheet feeding roller 9 and the separation roller 7 are borne by the bearing member 50 via rotational shaft bodies 51 and 52 along a right-to-left direction, respectively. One end of the rotational shaft body 52 of the separation roller 7 penetrates a side wall portion 50 A provided at a left side of the bearing member 50 . Further, a separation roller gear 53 is provided at a distal end portion of the rotational shaft body 52 so as to be rotated integrally with the rotational shaft body 52 . When the separation roller gear 53 receives a driving force from a below-mentioned gear mechanism 60 , the rotational shaft body 52 is rotated, and thereby the separation roller 7 is rotated integrally with the rotational shaft body 52 . Additionally, the bearing member 50 is configured such that a portion thereof at a side of the sheet feeding roller 9 can be swung around the rotational shaft body 52 of the separation roller 7 (along a direction indicated by an outline double-sided arrow in FIG. 1 ). While the pressing plate 11 is lifted with the lever 13 being turned, the sheet feeding roller 9 contacts a surface of the uppermost sheet 3 of sheets placed on the pressing plate 11 from a lower side of the sheet feeding roller 9 and is swung up. Additionally, gears 54 and 55 , respectively rotating integrally with the rotational shaft bodies 51 and 52 , are provided concentrically with the sheet feeding roller 9 and the separation roller 7 , respectively. The gears 54 and 55 are linked via a linking gear 56 . Thereby, the sheet feeding roller 9 is driven by the rotation of the separation roller 7 . As shown in FIG. 6 , an arm member 57 with a center portion 57 A thereof rotatably supported is provided in parallel with the rotational shaft body 52 at a rear side of the rotational shaft body 52 . A hole provided at one end portion 57 B of the arm member 57 is engaged with a protrusion 50 B provided at a swingable end side of the bearing member 50 at which the sheet feeding roller 9 is provided. Further, the other end portion 57 C of the arm member 57 is engaged with the gear mechanism 60 . (Configuration of Gear Mechanism) The gear mechanism 60 is provided with a plurality of gears configured to be rotated by a driving force transmitted by a driving motor (not shown) provided at a main body casing 2 side. The gear mechanism 60 is configured to mainly control the lifting operation of the pressing plate 11 and the rotating operation of the separation roller 7 . Specifically, the gear mechanism 60 includes the aforementioned separation roller gear 53 , a first engaging lever 61 , a second engaging lever 62 , a cam gear 63 , and differential gears 64 and 65 . The first engaging lever 61 and second engaging lever 62 are arranged side by side in the right-to-left direction, and provided swingably around the same rotational shaft 66 extending along the right-to-left direction. The first engaging lever 61 and the second engaging lever 62 are formed with locking claws 61 A and 62 A at rear sides thereof and arm portions 61 B and 62 B at front sides thereof, respectively. The arm portions 61 B and 62 B are provided so as to pinch the end portion 57 C of the arm member 57 therebetween. Thereby, when the arm portions 61 B and 62 B are moved in response to a swing motion of the end portion 57 C of the arm member 57 , respective sides of the locking claws 61 A and 62 A of the first engaging lever 61 and second engaging lever 62 are swung. The cam gear 63 is formed with a cam 67 and a tooth-lacking gear 68 being concentrically integrated. The cam 67 is formed such that a portion thereof corresponding to about one forth as long as an entire circumference of the cam 67 has a smaller radius than that of the other portion of the cam 67 (for example, see FIG. 8A ). In addition, on an outer circumferential surface of the cam 67 , there are formed a first engaged portion 71 configured to be engaged with the locking claw 61 A of the first engaging lever 61 and a second engaged portion 72 configured to be engaged with the locking claw 62 A of the second engaging lever 62 . It is noted that the first engaged portion 71 is provided in a position slightly shifted from the second engaging lever 62 in the right-to-left direction so as to comply with the positional relationship between the first engaging lever 61 and second engaging lever 62 . As illustrated in FIG. 8C , the tooth-lacking gear 68 is provided with a tooth-lacking portion 68 A with no tooth that corresponds to about one forth as long as an entire circumference of the tooth-lacking gear 68 . Additionally, a lower end 69 A of a spring 69 is fixed at a side of the main body casing 2 , and a free end 69 B of the spring 69 is hooked with a protrusion 68 B protruded at a point off a rotational center of the tooth-lacking gear 68 in an axial direction of the tooth-lacking gear 68 . The differential gear 64 , which is configured to be rotated due to a driving force transmitted from a main motor (not shown), is provided in the vicinity of the tooth-lacking gear 68 . The tooth-lacking gear 68 is rotated while teeth thereof are being engaged with the differential gear 64 . Meanwhile, the tooth-lacking gear 68 is not driven and stopped while the tooth-lacking portion 68 A thereof is facing the differential gear 64 . As shown in FIG. 8A , a switching tilting member 75 for taking ON/OFF control of the lifting operation for the pressing plate 11 is disposed behind the cam gear 63 . The switching tilting member 75 is tiltably supported at a center portion thereof by a rotational shaft 75 C extending along the right-to-left direction. The switching tilting member 75 includes a front end portion 75 A that is configured to contact the outer circumferential surface of the cam 67 , and a locking claw 75 B that is integrally provided at a distal end of a rear end portion of the switching tilting member 75 . Additionally, a spring 76 is formed with a front end 76 A thereof being fixed at a side of the main body casing 2 and a free end 76 B thereof being linked with a lower end of the switching tilting member 75 . Thereby, the switching tilting member 75 is biased by the spring 76 in a clockwise direction of FIG. 8A . The differential gear 65 is provided with a locked gear 80 , an input gear 81 , and an output gear 82 . The locked gear 80 is disposed to be latched with the locking claw 75 B of the switching tilting member 75 . The input gear 81 is always driven and rotated by the driving force received from the main motor. The output gear 82 is in an idling state until the locked gear 80 is latched with the locking claw 75 B of the switching tilting member 75 . Meanwhile, in response to the locked gear 80 being latched with the locking claw 75 B of the switching tilting member 75 , the output gear 82 is driven and rotated in conjunction with the input gear 81 . The output gear 82 is linked to a linking gear 86 via gears 83 to 85 . The linking gear 86 is provided in such a position as to be linked with the linking gear 45 at a side of the storage cassette 6 in a state where the storage cassette 6 is inserted and attached into the feeder unit 4 (in a state shown in FIG. 1 ). On the other hand, when the storage cassette 6 is drawn out from the feeder unit 4 , the linkage between the linking gears 45 and 86 is released, and thus, as described above, the pressing plate 11 is set into the sheet loading state, with the front end portion 11 B thereof moving down due to its own weight. (Operation of Gear Mechanism) Next, operation of the gear mechanism 60 will be described with reference to FIGS. 8A to 12C . Each figure indicated by a number with a suffix “A” is a right side view of a part of the gear mechanism 60 . Each figure indicated by a number with a suffix “B” is a rear side view of a part of the gear mechanism 60 . Each figure indicated by a number with a suffix “C” is a left side view of a part of the gear mechanism 60 . 1. Continuous Lifting Mode The gear mechanism 60 continuously lifts the pressing plate 11 until the sheet feeding roller 9 reaches a second release position X 2 from the lowest position O. As described above, for example, when the storage cassette 6 is drawn out from the feeder unit 4 , the pressing plate 11 is shifted in the sheet loading state due to its own weight. At this time, the sheet feeding roller 9 (the end portion 57 B of the arm member 57 , or strictly, a bottom face of the sheet feeding roller 9 ) is moved to the lowest position O as illustrated in FIG. 8B . Thereby, the arm member 57 is tilted like a seesaw, and on the contrary, the end portion 57 C thereof is moved to the highest position. Thereafter, for example, when the storage cassette 6 is inserted and re-attached into the feeder unit 4 after the sheet 3 is re-supplied (see FIG. 3 ), the gear mechanism 60 is set into a state shown in FIGS. 8A and 8C . When the end portion 57 C is moved up, the locking claw 61 A of the first engaging lever 61 is spaced from the first engaged portion 71 . Further, the locking claw 62 A of the second engaging lever 62 is engaged with the second engaged portion 72 of the cam gear 63 . Thereby, the rotation of the cam gear 63 is stopped against a biasing force of the spring 69 . At this time, the tooth-lacking gear 68 is in a state where the tooth-lacking portion 68 A faces the differential gear 64 and thus the driving force from the differential gear 64 is not transmitted to the tooth-lacking gear 68 . In addition, since the front end portion 75 A of the switching tilting member 75 is within the smaller-radius portion of the cam 67 , the locking claw 75 B is latched with the locked gear 80 owing to a biasing force of the spring 76 . Thereby, in accordance with a mechanical property of the differential gear 65 , the output gear 82 is rotated and set into an operating state for lifting the pressing plate 11 , while the locked gear 80 is stopped (a rotational position of the cam 67 shown in FIGS. 8A to 8C and 9 A to 9 C is defined as a first rotational position in the present embodiment). As illustrated in FIGS. 9A to 9C , the gear mechanism 60 maintains the operating state until the sheet feeding roller 9 reaches the second release position X 2 from the lowest position O. Namely, during the operating state, the output gear 82 of the differential gear 65 is always rotated, and the pressing plate 11 is continuously lifted. Specifically, when the pressing plate 11 is lifted to a certain height, the uppermost sheet 3 of sheets stacked on the pressing plate 11 contacts the sheet feeding roller 9 . Thereby, the sheet feeding roller 9 is lifted up from the lowest position O along with the rising of the pressing plate 11 (see FIG. 5 ). When the sheet feeding roller 9 is lifted up, the end portion 57 C of the arm member 57 is reversely moved down so as to move the first engaging lever 61 and the second engaging lever 62 , which are disposed to pinch the end portion 57 C therebetween. Then, when the sheet feeding roller 9 reaches the second release position X 2 (see FIG. 9B ), the second engaging lever 62 is disengaged from the second engaged portion 72 as shown in FIG. 9A . 2. Intermittent Lifting Mode Subsequently, when the second engaging lever 62 is disengaged from the second engaged portion 72 , the operation of the gear mechanism 60 shifts to an intermittent lifting mode from the continuous lifting mode. Specifically, the cam gear 63 is enforcedly rotated by the biasing force of the spring 69 in a counterclockwise of FIG. 9C . Then, as shown in FIG. 10C , the teeth of the tooth-lacking gear 68 of the cam gear 63 are engaged with the differential gear 64 . Thereby, the cam gear 63 is driven by a driving force from the differential gear 64 in a counterclockwise direction of FIG. 10C . It is noted that, at this time, since the front end portion 75 A of the switching tilting member 75 is still within the smaller-radius portion of the cam 67 , the aforementioned operating state is maintained (see FIG. 10A ), and the sheet feeding roller 9 is further lifted up (see FIG. 10B ). Thereafter, when the cam gear 63 is further rotated, the front end portion 75 A of the switching tilting member 75 runs upon the larger-radius portion of the cam 67 . Therefore, the switching tilting member 75 is rotated against the biasing force of the spring 76 , in the counterclockwise of FIG. 10A , and the locking claw 75 B is disengaged from the locked gear 80 . Thereby, in accordance with a mechanical property of the differential gear 65 , power transmission to the output gear 82 is stopped even while the locked gear 80 keeps its rotation. Thus, the gear mechanism 60 is set into a stopped state for stopping the rising of the pressing plate 11 from the aforementioned operating state. The second engaging lever 62 is in a position away from the cam 67 and never engaged with the second engaged portion 72 whenever the sheet feeding roller 9 is positioned higher than the second release position X 2 . Accordingly, when the sheet feeding roller 9 is positioned higher than the second release position X 2 , the cam gear 63 alternately receives the driving force from the differential gear 64 and the biasing force of the spring 69 and keeps the rotation thereof as far as the first engaging lever 61 is not engaged with the first engaged portion 71 . Thus, since the gear mechanism 60 alternately repeats the operating state and the stopped state, the pressing plate 11 is intermittently lifted up. As illustrated in FIG. 11B , when the sheet feeding roller 9 reaches the first release position X 1 , the first engaging lever 61 contacts the cam 67 and waits for the first engaged portion 71 to come. Therefore, as shown in FIG. 11A , the first engaging lever 61 is engaged with the first engaged portion 71 , and the cam gear 63 is stopped against the biasing force of the spring 69 (a rotational position of the cam 67 shown in FIGS. 11A to 11C is defined as a second rotational position in the present embodiment). At this time, since the front end portion 75 A of the switching tilting member 75 runs upon the larger-radius portion of the cam 67 , the pressing plate 11 is not lifted. In addition, as illustrated in FIG. 11C , the tooth-lacking gear 68 , of which the tooth-lacking portion 68 A is facing the differential gear 64 , does not receive the driving force from the differential gear 64 . It is noted that there is caused even in the present embodiment, a first time-lag until the cam 67 takes the second rotational position after the sheet feeding roller 9 reaches the first release position X 1 . When the gear mechanism 60 is set into a state shown in FIG. 11B , the pressing plate 11 is set into the sheet feeding state, in which a sheet feeding operation is permitted. Then, based upon a sheet feeding command issued by a CPU (not shown), the sheet feeding roller 9 is rotated, the sheet 3 is fed to the image forming unit 5 , and a printing operation is performed. After that, the sheet feeding operation is repeated, and when the number of sheets placed on the pressing plate 11 is reduced, for example, by about 10 sheets, the sheet feeding roller 9 is moved down to a position between the first release position X 1 and the second release position X 2 as shown in FIG. 12B . Then, as illustrated in FIG. 12A , the locking claw 61 A of the first engaging lever 61 and the locking claw 62 A of the second engaging lever 62 are slightly rotated in a clockwise direction of the figure, and the first engaging lever 61 is disengaged from the first engaged portion 71 . It is noted that, at this time, the second engaging lever 62 is still in the position away from the cam 67 and is not engaged with the second engaged portion 72 . Accordingly, the gear mechanism 60 again begins the operation of alternately repeating the operating state and stopped state in the intermittent lifting mode (in the state shown in FIGS. 10A to 10C ). Thereafter, the gear mechanism 60 repeatedly performs operations of shifting to the state shown in FIGS. 12A to 12C from the state shown in FIGS. 10A to 10C (in the intermittent lifting mode). Further, it is noted that when the storage cassette 6 is drawn out from the feeder unit 4 and then re-attached thereinto, the gear mechanism 60 is set into the state shown in FIG. 9 and the continuous lifting mode is restarted. (Summary of Operations) Positions of the sheet feeding roller 9 depending on time will be described with reference to FIGS. 13 to 15 . FIGS. 13 and 14 are schematic side views of the gear mechanism 60 for explaining operations of the cam gear 63 , the first engaging lever 61 , and the second engaging lever 62 when the storage cassette 6 is inserted and when the number of the sheets 3 on the pressing plate 11 is reduced through the sheet feeding operation, respectively. In FIGS. 13 and 14 , operations in the present embodiment are shown on left sides of the figures, while operations in a comparative example are shown on right sides of the figures. FIG. 15 shows time dependency of height of the sheet feeding roller 9 , where a solid line denotes the present embodiment, and a chain line denotes the comparative example. 1. Regarding when the Storage Cassette is Inserted (1) Operations in Embodiment In the present embodiment, as shown in FIG. 13 , when the storage cassette 6 is inserted, in the same manner as the comparative example, the second engaging lever 62 is engaged with the second engaged portion 72 of the cam gear 63 (see “pressing plate is being lifted up” of the present embodiment in FIG. 13 ). Thereby, the gear mechanism 60 is set in the operating state for lifting the pressing plate 11 as shown in FIG. 8A . The sheet feeding roller 9 is in the lowest position O ( FIG. 8B ) at a time t 0 ( FIG. 15 ), and therefrom shifted up to the second release position X 2 ( FIG. 9B ) at a time t 1 , where the engagement of the second engaging lever 62 with the second engaged portion 72 is released, and the cam gear 63 is rotated in a clockwise direction of FIG. 13 (see “sheet feeding roller reaches second release position X 2 ” of the present embodiment in FIG. 13 ). At this time, the first engaging lever 61 does not contact the cam gear 63 , yet gradually approaches the cam gear 63 . Then, when the sheet feeding roller 9 reaches the second release position X 1 ( FIG. 11B ) (at a time t 2 in FIG. 15 at when an instruction for stopping lifting the pressing plate 11 is instructed), the first engaging lever 61 contacts the cam gear 63 (see “sheet feeding roller reaches first release position X 1 ” of the present embodiment in FIG. 13 ). After that, when the cam gear 63 takes the second rotational position, as shown in FIG. 13 , the first engaging lever 61 is engaged with the first engaged portion 71 (see “pressing plate is stopped” of the present embodiment in FIG. 13 ). At this time, as illustrated in FIG. 15 , the sheet feeding roller 9 is lifted up to a height X 3 and stopped at a time t 3 . Here, a time period between t 2 and t 3 taken for the sheet feeding roller 9 to be lifted from the first release position X 1 to the height X 3 corresponds to the first time-lag in the present embodiment. (2) Operations in Comparative Example Unlike the present embodiment, in the comparative example, at the time (t 1 in FIG. 15 ) when the sheet feeding roller 9 reaches the second release position X 2 , the engagement of the second engaging lever 62 with the second engaged portion 72 is not released (see “sheet feeding roller reaches second release position X 2 ” of the comparative example in FIG. 13 ). Namely, the cam gear 63 is maintained in the first rotational position. Thereafter, when the sheet feeding roller 9 is further lifted up to the first release position X 1 (at t 2 in FIG. 15 ), as shown in “sheet feeding roller reaches first release position X 1 ” of the comparative example in FIG. 13 , firstly the first engaging lever 61 contacts the cam gear 63 , and then the engagement of the second engaging lever 62 with the second engaged portion 72 is released around a time t 2 ′. Thereby, finally the cam gear 63 is rotated in the clockwise direction of FIG. 13 toward the second rotational position. A time period between t 2 ′ and t 3 corresponds to the second time-lag. Thus, in the comparative example, when the sheet feeding roller 9 reaches the first release position X 1 , the first engaging lever 61 contacts the cam gear 63 , and thereafter the engagement of the second engaging lever 62 with the second engaged portion 72 is released. This is because in the comparative example, unlike the present embodiment, when the sheet feeding roller 9 reaches the first release position X 1 , the cam gear 63 is still latched in the first rotational position by the second engaging lever 62 . Therefore, in order to stop the rising of the pressing plate 11 , firstly the engagement of the second engaging lever 62 with the second engaged portion 72 has to be released. Here, supposing that the comparative example is configured such that the engagement of the second engaging lever 62 with the second engaged portion 72 is released before the first engaging lever 61 contacts the cam gear 63 , the first engaged portion 71 of the cam gear 63 may pass without being engaged with the first engaging lever 61 as still spaced from the cam gear 63 . Thus, an undesired situation may be caused that it is delayed to stop the cam gear 63 in the second rotational position. To avoid such a situation, in the comparative example, when the sheet feeding roller 9 reaches the first release position X 1 , firstly the first engaging lever 61 is brought into contact with the cam gear 63 , and then the engagement of the second engaging lever 62 with the second engaged portion 72 is released. The second time-lag is set in view of dimensional tolerances of the cam gear 63 , the first engaging lever 61 , and the second engaging lever 62 . Then the first time-lag is caused after the second time-lag has elapsed. Consequently, the sheet feeding roller 9 is lifted up to a height X 4 at a time t 4 as shown in FIG. 15 , and the pressing plate 11 is shifted up to a higher position than that in the present embodiment. Hereinabove, in the comparative example, the second time-lag is caused as well as the first time-lag until the rising of the pressing plate 11 is actually stopped after the sheet feeding roller 9 reaches the first release position X 1 . On the contrary, in the present embodiment, before the sheet feeding roller 9 reaches the first release position X 1 , the engagement of the second engaging lever 62 with the second engaged portion 72 has already been released, and the cam gear 63 has been driven and rotated. Accordingly, in the present embodiment, the second time-lag is not caused at the time when the pressing plate 11 reaches the first release position X 1 . Furthermore, in the present embodiment, the engagement of the second engaging lever 62 with the second engaged portion 72 is released earlier than in the comparative example. Hence, a rising height amount of the pressing plate 11 is more constrained in the present embodiment than in the comparative example. Thus sheet feeding performance can be improved. 2. Regarding when Sheet Count is Reduced through Sheet Feeding Operation (1) Operations in Embodiment As shown in “while pressing plate is stopped in sheet feeding operation” of the present embodiment in FIG. 14 , while the sheet feeding operation is performed with the sheet feeding roller 9 , the first engaging lever 61 is engaged with the first engaged portion 71 of the cam gear 63 . The sheet feeding roller 9 is moved lower along with decrease of the number of the sheets 3 , as shown between a time t 5 and a time t 6 in FIG. 15 . At the time t 6 when the sheet feeding roller 9 is shifted down to the height X 5 , as shown in “pressing plate is caused to be lifted up” of the present embodiment in FIG. 14 , the engagement of the first engaging lever 61 with the first engaged portion 71 is released (see FIGS. 12A to 12C ), and the cam gear 63 is rotated in a clockwise direction of FIG. 14 . Thereby, the pressing plate 11 begins to intermittently rise, and when the sheet feeding roller 9 reaches the first release position X 1 (at a time t 7 in FIG. 15 ), the first engaging lever 61 contacts the cam gear 63 (see “sheet feeding roller reaches first release position X 1 ” of the present embodiment in FIG. 14 ). Thereafter, when the cam gear 63 reaches the second rotational position, as illustrated in “pressing plate is stopped” of the present embodiment in FIG. 14 , the first engaging lever 61 is engaged with the first engaged portion 71 . At this time, as shown in FIG. 15 , the sheet feeding roller 9 is lifted up to the height X 3 and stopped at a time t 8 . Here, a time period between t 7 and t 8 taken for the sheet feeding roller 9 to be lifted from the first release position X 1 to the height X 3 corresponds to the first time-lag in the present embodiment. (2) Operations in Comparative Example In the comparative example, at a time t 9 when the sheet feeding roller 9 is moved down to the height X 5 , as shown in “pressing plate is caused to be lifted up” of the comparative example in FIG. 14 , the second engaging lever 62 contacts the cam gear 63 , and the engagement of the first engaging lever 61 with the first engaged portion 71 is released. Thereby, the cam gear 63 is held in the first rotational position, and the pressing plate 11 begins to rise. After that, in the same manner as from “sheet feeding roller reaches first release position X 1 ” to “pressing plate is stopped” of the comparative example in FIG. 13 , the second time-lag is caused as well as the first time-lag until the rising of the pressing plate 11 is actually stopped after the sheet feeding roller 9 reaches the first release position X 1 (see “sheet feeding roller reaches first release position” to “pressing plate is stopped” of the comparative example in FIG. 14 , and a time period from t 10 to t 12 in FIG. 15 ). Hereinabove, according to the present embodiment, the second time-lag is not caused as well when the number of the sheets 3 is reduced through the sheet feeding operation. Thus, the rising height amount of the pressing plate 11 is more constrained in the present embodiment than in the comparative example. Therefore the sheet feeding performance can be improved. (Effects of Embodiment) In the comparative example, even though a loading portion (which corresponds to the pressing plate 11 of the present embodiment) reaches a predetermined height (which corresponds to the first release position X 1 of the present embodiment), a continuous lifting operation is maintained while a cam (which corresponds to the cam gear 63 of the present embodiment) is rotated from the first rotational position (a rotational position where a lifting mechanism is set to an operating state) to the second rotational position (a rotational position where a lifting mechanism is set to a stopped state). Further, since the height of the loading portion is mechanically detected, the second time-lag is caused until the cam is actually rotated after it is detected that the loading portion reaches the predetermined height. Accordingly, even though the loading portion reaches the predetermined height, the lifting operation is further maintained. Hence, an undesired situation might be caused in which a contact pressure between the sheet feeding roller and a sheet is increased too much and thus sheet feeding performance is deteriorated such that two or more sheets are fed together or that no sheet is fed. On the contrary, in the present embodiment, the gear mechanism 60 alternately repeats the operating state and stopped state until the pressing plate 11 reaches the first release position X 1 . Thereby, the pressing plate 11 intermittently rises (intermittent lifting mode). Then, when the pressing plate 11 reaches the first release position X 1 , the cam 67 is stopped in a rotational position where the gear mechanism 60 is set to the stopped state (see FIGS. 11A to 11C ). Even in the gear mechanism 60 of the present embodiment, it may be delayed that the cam 67 is rotated to the rotational position (see FIGS. 11A to 11C ) where the gear mechanism 60 is set in the stopped state, with respect to the time when the sheet feeding roller 9 reaches the first release position X 1 (the first time-lag). However, when the sheet feeding roller 9 reaches the first release position X 1 , and the engagement of the first engaging lever 61 with the first engaged portion 71 is released, the second engaging lever 62 is still in the position away from the cam 67 , and is not engaged with the second engaged portion 72 . Accordingly, the second time-lag as caused in the comparative example is not caused in the present embodiment. Namely, the cam 67 is driven and rotated immediately after the sheet feeding roller 9 reaches the first release position X 1 , and it can be avoided to lift the pressing plate 11 too high. Further, the pressing plate 11 is intermittently lifted. Therefore, it can be prevented that the sheet feeding roller 9 is lifted too far from the first release position X 1 . Further, a rising speed of the pressing plate 11 in the intermittent lifting mode is lower than that in the continuous lifting mode. In addition, a sound is emitted in the intermittent lifting mode when the engagement of the first engaging lever 61 with the first engaged portion 71 is established and released. On the contrary, in the continuous lifting mode, engagement of any lever 61 or 62 is not established or released. In the present embodiment, the continuous lifting mode is implemented until the pressing plate 11 reaches the second release position X 2 , and the mode is switched to the intermittent lifting mode when the pressing plate 11 is lifted in or higher than the second release position X 2 . Thereby, it is possible to increase the rising speed of the pressing plate 11 and reduce noises until the pressing plate 11 reaches the second release position X 2 . Hereinabove, the embodiments according to aspects of the present invention have been described. The present invention can be practiced by employing conventional materials, methodology and equipment. Accordingly, the details of such materials, equipment and methodology are not set forth herein in detail. In the previous descriptions, numerous specific details are set forth, such as specific materials, structures, chemicals, processes, etc., in order to provide a thorough understanding of the present invention. However, it should be recognized that the present invention can be practiced without reapportioning to the details specifically set forth. In other instances, well known processing structures have not been described in detail, in order not to unnecessarily obscure the present invention. Only exemplary embodiments of the present invention and but a few examples of its versatility are shown and described in the present disclosure. It is to be understood that the present invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein. (Modifications) In the aforementioned embodiment, the first engaging lever 61 and the second engaging lever 62 are configured as different members, respectively. However, they may be configured to be swung as a single integrated member. The aforementioned “sheet” may include an OHP sheet and a banknote as well as a recording medium. The aforementioned “feeder unit” may be a unit configured to be detachably attached or a unit configured to be un-detachably attached to a main body of an image forming apparatus (e.g., printer, facsimile machine, and multi function peripheral with a printer function and a scanner function). Further, the aforementioned “feeder unit” is not limited to a unit configured to feed a sheet to the main body of the image forming apparatus. The aforementioned “feeder unit” may be incorporated in an apparatus configured to count the number of sheets such as banknotes. In the aforementioned embodiment, the feeder unit according to aspects of the present invention is applied to the laser printer. However, the feeder unit may be applied to various image forming apparatuses such as a printer having an LED as an exposure unit and an inkjet printer. Furthermore, the feeder unit may be applied to a sheet feeding apparatus configured to feed a sheet such as a banknote.
A sheet feeding device includes a loading portion configured to be loaded with a sheet, a lifting mechanism that lifts the loading portion in an operating state and stops the loading portion in an stopped state, a cam configured to be rotated alternately to a first rotational position for setting the lifting mechanism to the operating state and to a second rotational position for setting the lifting mechanism to the stopped state, a detecting unit having a contact portion movable up and down while contacting the sheet on the loading portion, which detects whether the sheet reaches a first height based upon the movement of the contact portion thereof, and a control unit configured to rotate the cam before the detecting unit detects that the sheet reaches the first height and to stop the cam in the second rotational position in response to the detection by the detecting unit.
1
This is a continuation of copending PCT application No. PCT/US971/17442 filed Sep. 30, 1997 (now PCT Publication WO 98/14754), which claims priority from U.S. application Ser. No. 60/027,392, filed Sep. 30, 1996. FIELD OF THE INVENTION This invention relates to methods and apparatus for measuring turgor pressure of a cell or cells by determining the area of contact between a probe and a specimen, and more particularly to an instrument including a transparent mechanical probe and its use to view the area of its contact with a specimen. BACKGROUND OF THE INVENTION A characteristic of a deformable specimen that can be related to area of contact between a mechanical probe and the specimen is the turgor pressure of a cell. Growing plants are hydrostatic structures. Plant form is maintained by turgor pressure. In most of the biomechanics of plant growth, an understanding requires some knowledge of turgor pressure changes to determine the physical properties of the plant, such as yield threshold and wall modulus. However, turgor pressure is not readily measured in a nondestructive, noninvasive way. Traditional approaches for determining turgor pressure in plant cells were conducted using either an incipient plasmolysis method, a pressure bomb method, or a micropipette-pressure-probe or “micropressure probe” method (see Park S. Nobel, Physicochemical and Environmental Plant Physiology, 103, 176-180, Academic Press Inc., New York, 1991). These traditional methods are laborious and subject to artefactual error. For example, the incipient plasmolysis method is highly subjective, and it radically alters the environment of the cells being measured. The “micropressure probe” method, in contrast, is potentially precise and accurate, but inherently difficult to perform. The micropressure method necessarily destroys the cells whose turgor is being measured. Finally, other techniques, such as the pressure-bomb method, are only suitable for whole organs and are generally characterized as single use, one-shot methods. Thus, the traditional ways of determining turgor pressure are invasive or disruptive to the cellular specimen, thereby interfering with the normal dynamics of the cell, including cellular behavior. In contrast, the present invention relates to a method and an apparatus for measuring the contact area or contact patch between a specimen and a mechanical probe, and this can be used to determine, virtually instantaneously and repeatably, the turgor pressure in a cellular specimen. The method and apparatus can be non-invasive and non-destructive to the specimen. In cellular specimens the present invention's method can be repeated from point to point, for example, along a growing axis. SUMMARY OF THE INVENTION In accordance with this invention a method and an apparatus for determining the area of contact between a convex probe surface and a cellular specimen uses a transparent probe and an optical viewing path through the probe to the area of contact. The area of contact can be described as the contact area or contact patch between the objective and the specimen. In one embodiment, the specimen is located at the working distance of a microscope objective, and the probe is introduced between the objective and the specimen. A known force is applied by the probe to a deformable specimen. The amount of deformation of the specimen will depend on the force. If the probe's contact surface is of known geometry, for example spherical, and of known dimensions, the contact area between the probe's contact surface and the cellular specimen will be a function of the turgor pressure. Contact area image information, i.e. the optical image or data descriptive of the optical image, is conveyed to an image analysis system. This calculates the contact area and consequently, permits calculation of the specimen characteristic affecting contact area. By applying a series of known forces via the probe and measuring respective contact areas it is possible to derive data representing a plot of area versus force. This enables extrapolation of the specimen characteristic at zero force. As discussed in more detail below, when method and apparatus of the invention is used to determine turgor pressure in a cell, an extrapolation of this kind permits determination of the turgor pressure when no force is applied by the probe. The turgor pressure of a cell is the hydrostatic pressure contained in a constraining membrane of each individual cell. Given a constant force and a spherical probe contact surface, the greater the internal pressure of the cell, the smaller will be the contact area or patch between probe and cell. In measuring this pressure in a cellular specimen, composed of one or more cells, the method and apparatus of the invention have the capability of making such measurement without invasion or destruction of the cellular specimen or any cell of the cellular specimen. The method of nondestructively and noninvasively calculating the turgor pressure in the cellular specimen uses an appropriate proportionality relationship between the turgor pressure in a supported cell that has a substantially smooth upper surface, and the contact area between the transparent mechanical probe, having a known geometry. The contact area is viewed by a microscope, which will have a suitable support for the specimen and may have associated with it an appropriate means for illuminating the contact area, either by a substage light source and condenser, by a fiber optic light guides brought in at substantially the level of the microscope stage and providing oblique illumination at approximately ninety degrees to the optical axis of the microscope, or by epi-illumination through the objective lens itself The light source is manipulated until a clear image of the outline bordering the contact area is observed. The term view or observe as used here is meant to include both observation by an individual using the method and apparatus of the invention and retrieving of image information optically, electrically or otherwise. For example, the apparatus for determining the contact area may include an image capturing system using a CCD camera to which the image is exported. A video frame grabber and image analysis station can be used to arrive at the actual contact area. A force controllable mechanical probe support provides an accurately determined contact force between the probe and the specimen. The probe is an optically neutral element. In a preferred embodiment the probe's contact surface was spherical, formed by a sphere of glass, diamond, or quartz and affixed to a strip of cover glass by a drop of ultraviolet cured optical adhesive. This arrangement avoids distortion at the spherical ball surface remote from the specimen. Essentially, the contact area is being viewed through a flat window to the far surface of the ball. The force controllable mechanical probe may employ a jewel bearing system for reducing friction, e.g. one employing a sapphire or like-bearing material. A field instrument used to measure the turgor pressure of leaves of crop plants is one application of the turgor pressure measuring embodiment of the invention. Such a device can be employed to quantify water stress on plants quickly in the field to serve as a “go-no go” gauge for irrigation, that is to say, to indicate whether or not irrigation is required. DESCRIPTION OF THE DRAWINGS The invention will be more readily understood from the description of a preferred embodiment that follows and from the diagrammatic figures of the drawings. In the drawings: FIG. 1 is a cross-sectional view of a spherical force controllable transparent mechanical probe contacting a cellular specimen; FIG. 2 is a schematic view partially in section and partially in block diagram form and illustrates a transparent mechanical probe in a system to determine the contact area between the probe and a specimen; FIG. 3 is a schematic view like that of FIG. 2 and diagrammatically illustrates an alternative means of illumination of the probe-specimen contact area; and FIG. 4 is a graphical illustration plotting a relationship between contact area derived turgor pressure (Bars) and medium osmotic pressure (Bars). DESCRIPTION OF THE PREFERRED EMBODIMENTS I. Theoretical Background for a Proportionality Relationship between the Turgor Pressure and the Contact Area of a Spherical Force Controllable Transparent Mechanical Probe Contacting a Cellular Specimen In a preferred embodiment of this invention a cellular specimen 10 , shown as an individual cell, is contacted by a spherical surface of a transparent optical probe 20 , as shown in FIG. 1 . The individual cell is treated as a thin-walled pressure vessel to which an external load W is applied for a theoretical understanding of the invention. The cell has a substantially smooth upper surface 12 . By “substantially smooth upper surface” is meant a surface not having features, such as epidermal hairs, that would interfere with a force controllable transparent optical probe's contacting that surface of the specimen. For the general case of a thin-walled pressure vessel to which an external load is applied by means of a rigid probe, the area of the contact patch is related to the internal pressure, turgor pressure, of the individual cell by: W=Ap;   (1) wherein: W is the force applied to the cell through the force controllable transparent mechanical probe (measured in Newtons or other units of force); A is a contact area (measured in square meters or other units of area); and p is a turgor pressure (measured in Bars, Pascals or other units of pressure). Referring to FIG. 1, where the contact surface of the probe 20 is spherical, the probe causes an indentation in the surface 12 of the pressure vessel or cell 10 . There is an additional supporting force which results from the stress in the skin acting to lift the load, as shown in FIG. 1 . Thus, the force acting on an indentor of this nature will be balanced by the internal pressure, turgor pressure, of the individual cell according to the relationship: W=pπr 2 +2 πrσt sin(θ);  (2) wherein: W is the force applied to the cell through the force controllable transparent mechanical probe causing the indentation (measured in Newtons or other units of force); t is the cell wall thickness (measured in meters or other units of length); p is a turgor pressure (measured in Bars, Pascals or other units of pressure); σ is a stress in the cell wall (measured in Bars, Pascals or other units of pressure); R is a radius of the spherical, force-controllable transparent, mechanical probe (measured in meters or other units of length); r is a radius of the contact patch (measured in meters or other units of length); and θ is a contact angle with respect to the center of the sphere and the outline of the contact area (measured in degrees). If one keeps the indentation of the force controllable transparent mechanical probe into the individual cell small, sin(θ) is approximated by r/R; such that equation (2) reduces to: W=pπr 2 +2 πr 2 σt/R.   (3) Moreover, the wall stress, σ, is related to internal pressure according to the following relationship: σ= pD/ 4 t;   ( 4 ) where D is the approximate cell size (measured in meters or other units of length). Substitution of equation (4) into equation (3) produces the following relationship: W=pπr 2 (1+½ D/R )= pA (1+½ D/R ).  (5) Because D generally has a dimension near 50 μm and R in this case is 1000 μm, equation (5) can be reduced for these specific dimensions to the following relationship: W=pA ×1.05.  (6) If a spherical probe is applied to a surface of a cellular specimen that comprises a multicellular tissue, and the probe contact area spans more that one cell, the additional support offered by the anticlinal walls may be considered. The internal support of the anticlinal walls could cause a decrease in the contact area and an apparent increase in the measured turgor pressures. However, if the additional support of the anticlinal walls within the contact area is negligible with respect to the turgor pressure, then the contact area is related to the average turgor pressure of the cells in contact with the probe. Considering the delicate nature of the cell walls and the fact that the experimentally measured pressures were consistently lower than would otherwise be predicted it is presently believed that the anticlinal walls may at this time be safely ignored. Additionally, there is the possibility of compartmentalization in a cellular specimen composed of a multicellular tissue resulting in a lack of fluid mobility. under the probe. This lack of fluid mobility could result in higher pressures at the center of the probe producing an apparent increase in the cell pressure. The thin-walled model discussed above for the embodiment described here does not incorporate any correction for either subsurface support or fluid compartmentalization, but corrections for these effects may be included where necessary. II. Method and Apparatus for the Measurement of Turgor Pressure To determine specimen turgor pressure, an accurate measurement is made of the contact area between the cell 10 and the force-controllable, transparent mechanical probe 20 , of known geometry. Such probe may have, but is not limited to, a contacting surface that is spherical, hemispherical, or cylindrical. A calibrated load is applied to the specimen via the probe by a suitable accurate force producing mechanism. The specimen 10 is supported from below by support 11 . The transparent probe 20 may be made of any light transparent material, such as, but not limited to, glass, diamond, and quartz. The cellular specimen may be composed of a plurality of eukaryotic, either plant or animal, cells; a plurality of procaryotic cells; a plurality of organic micelles; a plurality of inorganic ricelles; or a single cell or micelle, provided that the cellular specimen includes a constraining membrane 14 . The probe 20 is small enough to be inserted directly beneath an objective lens 32 of a standard compound microscope 30 as shown in FIG. 2 . The particular probe of this embodiment includes a strip 22 of No. 2 cover glass, acting as a support beam, and a 1 millimeter diameter ball lens 24 cemented to the strip 22 with a drop of ultraviolet cured optical adhesive 26 . The probe is thus inserted into the optical path of the microscope 30 . There it is manipulated into the working distance of the objective 32 , and carefully lowered onto the cellular specimen 10 , supported by the microscope stage 11 . The adhesive prevents distortion at the spherical surface remote from the specimen. The ball lens 24 serves as a spherical mechanical indentor, while at the same time it provides an optically neutral, flat window at the upper surface through which the contact area can be observed directly. Because the image formed by the microscope is of the tissue in contact with the lower surface of ball lens itself, the optical properties of the ball lens do not contribute to total magnification of the system. This results in a reasonably clear observable image of the cell or cells of specimen 10 on which the ball lens is resting. In an actual embodiment, the total mass of the ball lens 24 and its support 22 was 150 milligrams. The actual controlled force applied to the cellular specimen 10 was 45 milligrams times gravity. For the purpose of applying the controlled force, any accurate force producing mechanism 35 may be coupled to the probe. As shown in part in FIG. 2, the cellular specimen 10 and the contact patch formed with the probe 20 are transilluminated by a standard substage condenser 41 , and light source 40 . Alternatively, as illustrated in FIG. 3, illumination may be by fiber-optic light guides 42 brought in at the substantially the level of the microscope stage, providing oblique illumination at approximately ninety degrees to the optical axis of the microscope. In still another alternative, illumination may be by epiillumination through the objective lens itself These means for illumination are manipulated to provide sufficient contrast to reveal the contact area. In the preferred embodiment, as shown in FIG. 2, the image of the contact area is exported to an image capturing system, via, for example, a CCD camera 44 , thence to a video frame grabber 46 and finally to an image analysis station 48 where the contact area is determined directly. The image analysis station is suitably a computer running OPTIMAS™ or another commercially available image analysis program. The area may also be determined directly by the use of an eye piece incorporating a measuring reticle. Measurements of neighboring cells in the cellular specimen 10 can be rapidly assessed using a translation device 50 as shown in FIG. 2 . The translation device is movable in either one, two, or three dimensions. The translation device allows the probe 10 to slide over the surface of the specimen 20 . Multiple measurements can be taken as fast as the probe can be moved to another cell and the image captured using the image analysis system. The capturing of the image is generally accomplished by clicking the “Freeze” button on the image analysis system. The turgor pressure is then directly calculated from the observed and measured contact area using the relationships described in Equations (1) through (6). By repeating the measurement of the contact area at a variety of different forces of indention, data representing a plot of turgor pressure versus force are developed. The turgor pressure at zero force thus may be extrapolated. The method and apparatus described above was used to determine if the measured areas and the calculated turgor pressures varied linearly with cellular osmotic pressure. In this test, peeled patches of onion leaf-base adaxial epidermis were incubated in mannitol solutions of varying osmolality, where one osmole equals one mole of nonpermeating molecules plus ions per liter. These solutions corresponded to 1 Bar increments in osmotic pressure from distilled water to −6 Bars. A slight meniscus of liquid around the contact patch facilitated observation of the contact patch outline. FIG. 4 shows a plot of the turgor pressure, calculated by the contact area method, against the ambient osmotic pressure of the incubating medium. This plot shows a basically linear relationship between the calculated turgor pressure of the target cells, and the osmolarity (water potential) of the incubating medium. Sources of scatter in the graph may include: inaccuracies in the method employed, real differences in turgor pressure from cell to cell in the cellular specimen, and the presence of the contact meniscus which inflates the area and consequently lowers the apparent turgor pressure. It should be noted that several factors can contribute to real differences in turgor pressure from cell to cell in cellular specimen. These factors include: deformations of the cellular specimen resulting from constraining a spherical layer of cells onto a flat microscope slide which can result in local strains that could either act to raise or lower the turgor pressure in the cells, and the geometry of individual cells comprising the cellular specimen can also give rise to different measured turgor pressures. A hand held version of the turgor pressure measuring apparatus may be fabricated. This would include the same elements as the described embodiment. The addition of a portable power supply to power the means for illumination is envisioned. In certain applications natural light may suffice to illuminate the contact patch. Whereas a specific preferred embodiment of this invention has been described it will be understood that variations and modifications may be made without departure from the spirit and scope of the invention as set forth in the appended claims.
Turgor pressure is measured in a cellular sample by contacting the sample with a convex probe, measuring the area of contact and using a formula to convert the area into turgor pressure.
6
CROSS REFERENCE TO RELATED APPLICATION [0001] This application claims the benefits of the Taiwan Patent Application Serial Number 103140763, filed on Nov. 25, 2014, the subject matter of which is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a method for treating abnormal β-amyloid mediated diseases with a pharmaceutical composition, wherein a compound contained in the pharmaceutical composition is served as a chemical chaperone and enhances heat shock protein HSPB1 activity to facilitate the β-amyloid folding; therefore, the purposes of inhibiting β-amyloid aggregation, decreasing reactive oxygen species level in cells, and promoting neurite outgrowth can be achieved. [0004] 2. Description of Related Art [0005] Alzheimer's disease (AD) is the most prevalent form of dementia in elderly patients causing neurodegeneration. The progressive cognitive decline and memory loss are usually observed in AD patients, and health expenditures and costs of care are high and expensive for AD patients. Significant neurological symptoms are not observed in the early stage of AD, and can be revealed in the middle and late stages thereof. The most observed symptoms are extrapyramidal symptoms, including increased muscle tone, and increased deep tendon reflex or myoclonus. Sometimes, epilepsy may also occur. [0006] Although the drugs used nowadays cannot completely cure AD, some drugs are proved having efficacy of improving cognitive impairment. Currently, two kinds of drugs have been proved by the U.S. Food and Drug Administration, one is cholinesterase inhibitors including rivastigmine, donepezil and galantamine, and the other one is N-methyl-D-aspartate (NMDA) receptor antagonist such as memantine. Except for the administration of drugs for improving cognitive impairment, other suitable drugs also have to be administered to AD patients with other symptoms derived from AD such as depression and sleeplessness. [0007] The worldwide populations with AD are gradually increased. Therefore, it is desirable to provide a method or a pharmaceutical composition for treating β-amyloid mediated diseases, which can be used to treat neurodegenerative diseases such as AD to further delay disease progression and improve patients' quality of life. SUMMARY OF THE INVENTION [0008] The object of the present invention is to provide a pharmaceutical composition for treating β-amyloid mediated diseases, to treat neurodegenerative diseases such as Alzheimer's disease. [0009] Another object of the present invention is to provide a method for treating β-amyloid mediated diseases with the pharmaceutical composition of the present invention. [0010] Another object of the present invention is to provide a use of the pharmaceutical composition of the present invention for manufacturing a drug of β-amyloid mediated diseases. [0011] In addition, another object of the present invention is to provide a pharmaceutical composition for inhibiting β-amyloid aggregation, wherein the active component contained therein can be served as chemical chaperone or activate chaperone activity to inhibit β-amyloid aggregation and decrease reactive oxygen species (ROS) level. [0012] Another object of the present invention is to provide a method for inhibiting β-amyloid aggregation in a subject with the pharmaceutical composition of the present invention. [0013] A further another object of the present invention is to provide a use of the pharmaceutical composition of the present invention for manufacturing a drug for inhibiting β-amyloid aggregation. [0014] To achieve the object, the pharmaceutical composition of the present invention comprises: a compound represented by the following formula 1, [0000] [0000] wherein R1 and R3 are independently H or an alkyl group, in which the alkyl group is a C 1 -C 10 linear or branched monovalent hydrocarbon group; and R2 is [0000] [0015] In addition, the method for treating an abnormal β-amyloid mediated diseases of the present invention comprises: administering the aforementioned pharmaceutical composition to a subject in need. Furthermore, the method for inhibiting β-amyloid aggregation in a subject of the present invention comprises: administering the aforementioned pharmaceutical composition to a subject. [0016] In the present invention, the term “alkyl group” refers to a C 1 -C 10 linear or branched monovalent hydrocarbon group; and the examples thereof comprise, but not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl and tert-butyl. [0017] In the present invention, the compound represented by the formula 1 preferably is a compound represented by the following formulas 2 to 5: [0000] [0018] The pharmaceutical composition of the present invention may comprise one or more compounds represented by the formula 1. For example, the pharmaceutical composition of the present invention may comprise one or more compounds selected from the group consisting of compounds represented by the formulas 2 to 5. [0019] In the pharmaceutical composition of the present invention, the compound contained therein itself has chemical chaperone activity or activates chaperone activity, to achieve the purpose of inhibiting β-amyloid aggregation and decreasing reactive oxygen species (ROS) level. Herein, in the chaperone pathway, the activity of heat shock 27 kDa protein 1 (HSPB1) can be enhanced, and the present invention is not limited thereto. [0020] Abnormal protein aggregations are usually observed in brains of patients having neurodegenerative disorders. Among the known neurodegenerative disorders, Alzheimer's disease (AD) is the most prevalent form of dementia associated with progressive cognitive decline and memory loss. Extracellular β-amyloid (Aβ) is a major constituent of senile plaques, one of the hallmarks of AD. Aβ deposition causes neuronal death via a number of possible mechanisms including oxidative stress (increased ROS level). As Aβ aggregates show good correlation with neurotoxic effect, therapeutic approaches to identify novel Aβ aggregate reducers will be effective for the disease treatment. In addition, chaperone can identify and inhibit abnormal protein aggregation to protect neurons. [0021] Herein, the types of the abnormal β-amyloid mediated disease of the present invention are not particularly limited, and can be Alzheimer's disease. [0022] In the pharmaceutical composition of the present invention, the concentration of the compound of the formula 1 is not particularly limited, and can be adjusted according to disorder severity or complementary medicines. In one example of the present invention, the concentration of the compound of the formula 1 is in a range from 1 μM to 50 μM, and preferably from 1 μM to 30 μM, based on a total weight of the pharmaceutical composition. The pharmaceutical composition may further comprise: at least one pharmaceutically acceptable carrier, a diluent, or an excipient. For example, the compound can be encapsulated into liposome to facilitate delivery and absorption. Alternatively, the compound can be diluted with aqueous suspension, dispersion or solution to facilitate injection. Or, the compound can be prepared in a form of a capsule or tablet for storage and carrying. In addition, an effective concentration of the compound of the formula 1 may be changed according to administration, use of excipient, or co-use with other active agents; and a person skilled in the art can adjust the concentration of the compound of the formula 1 in the pharmaceutical composition or the dose of the pharmaceutical composition to achieve the purpose of obtaining desired curative effect. [0023] More specifically, the compound of the formula 1 of the present invention can be formulated in a solid or liquid form. The solid formulation form may include, but is not limited to, powders, granules, tablets, capsules and suppositories. The solid formulation may comprise, but is not limited to, excipients, flavoring agents, binders, preservatives, disintegrants, glidants and fillers. The liquid formation form may include, but is not limited to, water, solutions such as propylene glycol solution, suspensions and emulsions, which may be prepared by mixing with suitable coloring agents, flavoring agents, stabilizers and viscosity-increasing agent. [0024] For example, a powder formulation may be prepared by simply mixing the compound of the formula 1 of the present invention with suitable pharmaceutically acceptable excipients such as sucrose, starch and microcrystalline cellulose. A granule formulation may be prepared by mixing the compound of the formula 1 of the present invention with suitable pharmaceutically acceptable excipients and/or suitable pharmaceutically acceptable binders such as polyvinyl pyrrolidone and hydroxypropyl cellulose, followed by wet granulation method using a solvent such as water, ethanol and isopropanol, or dry granulation method using compression force. Also, a tablet formulation may be prepared by mixing the granule formulation with suitable pharmaceutically acceptable glidants such as magnesium stearate, followed by tableting using a tablet machine. Hence, a person skilled in the art can appropriately choose suitable formulation according to his/her needs. [0025] In the present invention, the term “treat” refer to the case that the pharmaceutical composition of the present invention is applied to a subject suffering from abnormal β-amyloid mediated disease such as Alzheimer's disease, having symptoms of disease, or having a tendency of development of disease, in order to achieve the mitigation, slowing, therapy, improvement, or recovery of the tendency of the disease and symptoms. [0026] To implement the method according to the present invention, the above pharmaceutical composition can be administered via oral administering, parenteral administering, inhalation spray administering, topical administering, rectal administering, nasal administering, sublingual administering, vaginal administering, or implanted reservoir, and so on. The term “parenteral” used here refers to subcutaneous injection, intradermal injection, intravenous injection, intramuscular injection, intra-articular injection, intraarterial injection, joint fluid injection, intrathoracic injection, intrathecal injection, injection at morbid site, and intracranial injection or injection technique. [0027] Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0028] FIG. 1 shows chemical structures of 11 indolylquinoline derivatives used in examples of the present invention. [0029] FIG. 2 shows quantitative result of Trx-His-Aβ biochemical assay after purified Trx-His-Aβ protein was treated with indolylquinoline derivatives and stained with thioflavin T in one preferred example of the present invention. [0030] FIG. 3 shows quantitative result of GFP fluorescence in Tet-On Aβ-GFP HEK-293 cells treated with indolylquinoline derivatives in one preferred example of the present invention. [0031] FIG. 4 shows quantitative result of ROS level in Tet-On Aβ-GFP HEK-293 cells treated with indolylquinoline derivatives in one preferred example of the present invention. [0032] FIG. 5 shows quantitative result of neurite outgrowth of Tet-On Aβ SH-SY5Y cells treated with indolylquinoline derivatives in one preferred example of the present invention. [0033] FIG. 6 shows quantitative result of HSPB1 expression in Aβ-GFP SH-SY5Y cells treated with indolylquinoline derivatives in one preferred example of the present invention. [0034] FIG. 7 (A) to (F) respectively show quantitative results of total cell number, mature neuron number, neurite process, neurite branch, neurite length and synaptophysin expression level in Aβ-induced mouse hippocampal primary culture treated with indolylquinoline derivatives in one preferred example of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [Indolylquinoline Derivatives] [0035] In the following examples, the used indolylquinoline derivatives are available from Prof. Ching-Fa Yao in National Taiwan Normal University. FIG. 1 shows 11 kinds of indolylquinoline derivatives used herein, which are named as compound 1 to compound 11. [Trx-His-Aβ Biochemical Assay] [0036] Aggregation of β-amyloid (Aβ) was considered as target for intervention. For the biochemical assay, the inventors overexpressed Trx-His tagged Aβ construct in E. coli . After metal-affinity chromatography purification, the misfolded Trx-His-Aβ proteins can be identified by thioflavin T staining assay. The fluorescent intensity is increased after thioflavin T binds misfolded Trx-His-Aβ protein, and thus the misfolding level of Trx-His-Aβ protein can be measured. The purified Trx-His-Aβ protein (10 μM) was incubated at 37° C. with the tested compounds 1-11 (5˜20 μM) for 48 hr. Then thioflavin T (10 μM) was added for 5 min and fluorescence analyzed on a microplate reader (excitation: 420 nm, emission: 485 nm). The obtained quantitative result is shown in FIG. 2 . To normalize, the relative thioflavin T fluorescence of Trx-His-Aβ protein with 2 days' incubation at 37° C. is set as 100%. *, P<0.05 (n=3). [0037] When aggregate formation was measured with fluorescence generated by thioflavin T binding, significantly more Trx-His-Aβ aggregate formed after 2 days' incubation at 37° C. (100% vs. 85%, P=0.009), as shown in FIG. 2 . As a positive control, curcumin in 5˜20 μM significantly reduced the misfolded Aβ to 76˜54% (P=0.006˜<0.001). Significantly reduced Aβ aggregation was also observed with synthetic indolylquinoline compound 1 (79% in 20 μM, P=0.010), compound 2 (74˜70% in 10˜20 μM, P=0.009˜0.011), compound 6 (90˜71% in 5˜20 μM, P=0.006˜<0.001) and compound 7 (84% in 20 μM, P=0.035). In addition, Trx-His-Aβ protein aggregations were not significant decreased after treating with compounds 3-5 and 8-11 (not shown in the figure). [Tet-On Aβ-GFP HEK-293 Cell Assay] [0038] For cell assay, we used a HEK-293 cell clone (human embryonic kidney cells) with Tet-On Aβ-GFP expression as a screening platform. GFP fluorescence was used to reflect Aβ aggregation status as Aβ aggregated rapidly to cause the fused GFP misfolded. Inhibition of Aβ aggregation may improve GFP misfolding, leading to increasing fluorescence on Aβ-GFP expressing cells. Tet-On Aβ-GFP HEK-293 cells were pretreated with different concentrations of compounds 1, 2, 6, 7 and curcumin for 8 hr before inducing Aβ-GFP expression. Then doxycycline (Dox) (10 μM) was added to the medium for 64 hr to induce Aβ-GFP expression, and GFP fluorescence was assessed by a high-content analysis (HCA) system (ImageXpressMICRO, available from Molecular Devices). [0039] The quantitative result of GFP fluorescence in the present assay is shown in FIG. 3 . To normalize, the relative GFP fluorescence of untreated cells (untreated with compounds 1, 2, 6 and 7, and curcumin) is set as 100%. *, P<0.05 as compared to the untreated cells; #, P<0.05 as compared to the same concentration curcumin-treated cells (n=3). As shown in FIG. 3 , curcumin increased the Aβ-GFP fluorescence to 111˜122% (2.5˜5.0 μM, P=0.003˜<0.001) as compared to untreated cells (100%). With above 80% of viable cells, significantly increased GFP fluorescence was observed with synthetic indolylquinoline compound 1 (112˜129%), compound 6 (107˜130%) (1.2˜5.0 μM, P=0.010˜<0.001), compound 2 (107˜120%) (1.2˜2.5 μM, P=0.025˜0.002) and compound 7 (105%) (1.2 μM, P<0.001), as compared to the same concentration curcumin-treated cells. [0040] Given that Aβ deposition causes cell death via a number of potential mechanisms including oxidative stress, the inventor also performed ROS assay with curcumin or synthetic indolylquinoline compounds 1, 2, 6 and 7 treatment (5 μM). FIG. 4 shows the relative ROS level, wherein the relative ROS of uninduced cells is set as 100%. *, P<0.05 between induced vs. uninduced cells or compound-treated vs. untreated cells (n=3). Induced expression of Aβ-GFP significantly increased ROS level as compared to uninduced cells (128% vs. 100%, P<0.001). Treatment with curcumin significantly reduced ROS level as compared to the untreated cells (86% vs. 128%, P<0.001). Treatment with synthetic indolylquinoline compounds 1, 2, 6 and 7 (5 μM) significantly reduced ROS level induced by Aβ deposition (99˜123% vs. 128%, P=0.001˜<0.001). [Tet-On Aβ-GFP SH-SY5Y Cell Assay] [0041] Tet-On Aβ human neuroblastoma SH-SY5Y cells were used to examine the neuroprotective potential of the compounds of the present invention. Tet-On Aβ-GFP SH-SY5Y cells were plated into 24-well plates with 10 μM retinoic acid (RA), grown for 24 hr and treated with tested indolylquinoline compounds 1, 2, 6 and 7 (5 μM) for 8 hr. Then doxycycline (10 μM) was added to the medium to for 6 days. Neurite outgrowth was assessed after TUBB3 immunostaining, and examined with the HCA system. The result is shown in FIG. 5 , wherein the relative neurite outgrowth of uninduced cells (untreated with Dox) is set as 100%. *, P<0.05 between induced vs. uninduced cells or compound-treated vs. untreated cells (n=3). [0042] As shown in FIG. 5 , induced expression of Aβ-GFP significantly reduced neurite outgrowth as compared to uninduced cells (87% vs. 100%, P<0.001). Treatment of curcumin significantly improved neurite outgrowth as compared to the untreated cells (untreated with compounds 1, 2, 6 and 7 and curcumin) (105% vs. 87%, P<0.001). Examination of neurite features of Aβ-GFP SH-SY5Y cells revealed that synthetic indolylquinoline compounds 1, 2, 6 and 7 (5 μM) significantly improved neurite outgrowth (101˜108% vs. 87%, P<0.001). [0043] To examine if the indolylquinoline compounds of the present invention up-regulated HSPB1 expression in Aβ-GFP SH-SY5Y cells, the Western blot analysis was performed to examine the expression level of HSPB1. The result is shown in FIG. 6 , wherein the relative HSPB1 level of uninduced cells is set as 100%. *, P<0.05 between induced vs uninduced cells or compound-treated vs. untreated cells (n=3). [0044] As shown in FIG. 6 , induced expression of Aβ-GFP attenuated the expression of HSPB1 as compared to uninduced cells (90% vs. 100%, P=0.006). Addition of curcumin, compounds 1, 2, 6 and 7 of the present invention (5 μM) led to significantly increased HSPB1 expression (curcumin: 123%; compound 1: 126%; compound 2: 112%; compound 6: 116%; and compound 7: 117%; P=0.044˜0.001) as compared to untreated cells (90%). [Mouse Hippocampal Primary Culture] [0045] Postnatal day 0-1 mouse hippocampus was isolated for primary culture, and used to confirm the neuroprotective potential of the compounds of the present invention. Oligomeric Aβ (1 μM) was applied to the primary culture after the indolylquinoline compound (compounds 1, 2, 6 and 7) administration (1, 10, or 30 μM) at day 9. Cells were harvested 1 hr later for immunocytochemical analysis and quantitated the total cell number (as shown in FIG. 7(A) , by DAPI staining), mature neuron number (as shown in FIG. 7(B) , by NeuN antibody staining), neurite process (as shown in FIG. 7(C) , by MAP2 antibody staining), neurite branch (as shown in FIG. 7(D) , by MAP2 antibody staining), neurite length (as shown in FIG. 7 (E), by MAP2 antibody staining), and synaptophysin expression level (as shown in FIG. 7(F) , by synaptophysin antibody staining) In FIG. 7(A) to (F), the relative amount of cells treated with vesicle (hexafluoroisopropanol) is set as 100%. ###, P<0.001 between cells treated with Aβ and vehicle (n=3). *, P<0.05; **, P<0.01; ***, P<0.001 between cells treated with Aβ combined the compound of the present invention and Aβ alone (n=3). Oligomeric Aβ significantly reduced total cells, mature neurons, neurite outgrowth and synaptophysin expression level as compared to vehicle-treated cells. Synthetic indolylquinoline compounds 1, 2, 6 and 7 (1, 10 or 30 μM) significantly improved total cells ( FIG. 7(A) ), mature neurons ( FIG. 7(B) ), neurite outgrowth ( FIG. 7(C) -(E)) and synaptophysin level ( FIG. 7(F) ) against the oligomeric Aβ toxicity in the hippocampal primary culture. [0046] In the present invention, Trx-His-Aβ cell-free and Aβ-GFP 293/SH-SY5Y cell models with Aβ aggregation were used to screen synthetic indolylquinoline compounds potentially inhibiting Aβ aggregation. In Trx-His-Aβ biochemical assay, thioflavin T was used as a diagnostic of amyloid structure, as thioflavin T exhibiting enhanced fluorescence upon binding to amyloid fibrils. Among several tested synthetic indolylquinoline compounds (compounds 1-11 of the present invention), compounds 1, 2, 6 and 7 displayed good potential to inhibit Aβ aggregation. In Aβ-GFP cell assays, Tet-On HEK-293 cells with inducible Aβ-GFP expression were used as a cellular screening platform. Inhibitors that retard or block Aβ aggregation can be distinguished by increasing GFP fluorescence on Tet-On HEK-293 cells. Good aggregation-inhibitory effects were seen in Tet-On Aβ-GFP HEK-293 cells treated with tested synthetic indolylquinoline compounds 1, 2, 6 and 7, accompanying with reduced reactive oxygen species and enhanced HSPB1 chaperone expression. These tested compounds also promoted neurite outgrowth in Tet-On Aβ-GFP SH-SY5Y cells. The effect in promoting neuronal cell viability, neurite outgrowth, and synaptophysin expression level were also confirmed with mouse hippocampal primary culture under oligomeric Aβ-induced cytotoxicity. The results demonstrate how synthetic indolylquinoline compounds of the present invention are likely to work in Aβ-aggregation reduction, and provide insight into the possible working mechanism of indolylquinoline compounds in AD patients. These findings may have therapeutic applications in AD. [0047] Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.
A method for treating abnormal β-amyloid mediated diseases is disclosed, comprising administering a pharmaceutical composition to a subject in need, wherein the pharmaceutical composition comprises an indolylquinoline derivative represented by the following formula 1:
0
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation of U.S. patent application Ser. No. 13/297,788, filed Nov. 16, 2011, entitled “Phosphonate Polymers, Copolymers, and Their Respective Oligomers as Flame Retardants for Polyester Fibers,” which claims benefit of and priority to U.S. Provisional Application No. 61/414,569 entitled “Phosphonate Polymers, Copolymers, and Their Respective Oligomers as Flame Retardants For Polyester Fibers,” filed Nov. 17, 2010. The contents of each of these applications are incorporated herein by reference in their entireties. BACKGROUND [0002] A number of approaches have been investigated to impart fire resistance to polyester fibers with varying degrees of success. In general, it has been extremely challenging to impart fire resistance into polyester fibers without detracting from other important properties such as processability (i.e., melt viscosity increase), ability to melt spin fibers, and mechanical properties. Thus, there is a recognized need to provide fire resistance to polyester fibers without detracting from melt processability, strength, modulus, dyeing and heat-setting characteristics as compared to the unmodified polyester. SUMMARY OF THE INVENTION [0003] Embodiments are generally directed to a polymer fiber that includes a thermoplastic polyester and at least one phosphorous containing polymer or oligomer. In various embodiments, the phosphorous containing polymer may be a phosphonate containing polymer, phosphonate containing copolymer, phosphonate containing oligomer, phosphorous containing polyester, a phosphorous containing oligoester, a phosphorous containing polyester-co-carbonate, a phosphorous containing oligoester-co-carbonate, or combinations thereof, and in some embodiments, the at least one phosphorous containing polymer or oligomer may be a polyester or oligoester including at least one phosphinate. In certain embodiments, the polymeric fibers may include a polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate), and/or their respective oligomers and a polyester. [0004] Other embodiments of the invention are directed to polymer compositions including a polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate), and/or their respective oligomers and a polyester that maintains acceptable melt processing characteristics as compared to the unmodified polyester. [0005] Still other embodiments of the invention are directed to polymeric fibers including a polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate), and/or their respective oligomers and a polyester that meets the UL or similar standardized fire resistance ratings required for a variety of consumer products without detracting from other important safety, environmental, manufacturing and consumer use requirements. DETAILED DESCRIPTION [0006] Before the present compositions and methods are described, it is to be understood that this invention is not limited to the particular processes, compositions, or methodologies described, as these may vary. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present invention, which will be limited only by the appended claims. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred methods, devices, and materials are now described. All publications mentioned herein are incorporated by reference in their entirety. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention. [0007] It must also be noted that, as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a combustion chamber” is a reference to “one or more combustion chambers” and equivalents thereof known to those skilled in the art, and so forth. [0008] As used herein, the term “about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50% means in the range of 45%-55%. [0009] The terms “flame retardant,” “flame resistant,” “fire resistant,” or “fire resistance,” as used herein, means that the composition exhibits a limiting oxygen index (LOI) of at least 27. “Flame retardant,” “flame resistant,” “fire resistant,” or “fire resistance,” may also refer to the flame reference standard ASTM D6413-99 for textile compositions, flame persistent test NF P 92-504, and similar standards for flame resistant fibers and textiles. Fire resistance may also be tested by measuring the after-burning time in accordance with the UL test (Subject 94). In this test, the tested materials are given classifications of UL-94 V-0, UL-94 V-1 and UL-94 V-2 on the basis of the results obtained with the ten test specimens. Briefly, the criteria for each of these UL-94-V-classifications are as follows: [0010] UL-94 V-0 the average burning and/or glowing time after removal of the ignition flame should not exceed 5 seconds and none of the test specimens should release and drips which ignite absorbent cotton wool. [0011] UL-94 V-1: the average burning and/or glowing time after removal of the ignition flame should not exceed 25 seconds and none of the test specimens should release any drips which ignite absorbent cotton wool. [0012] UL-94 V-2: the average burning and/or glowing time after removal of the ignition flame should not exceed 25 seconds and the test specimens release flaming particles, which ignite absorbent cotton wool. [0013] Fire resistance may also be tested by measuring after-burning time. These test methods provide a laboratory test procedure for measuring and comparing the surface flammability of materials when exposed to a prescribed level of radiant heat energy to measure the surface flammability of materials when exposed to fire. The test is conducted using small specimens that are representative, to the extent possible, of the material or assembly being evaluated. The rate at which flames travel along surfaces depends upon the physical and thermal properties of the material, product or assembly under test, the specimen mounting method and orientation, the type and level of fire or heat exposure, the availability of air, and properties of the surrounding enclosure. If different test conditions are substituted or the end-use conditions are changed, it may not always be possible by or from this test to predict changes in the fire-test-response characteristics measured. Therefore, the results are valid only for the fire test exposure conditions described in this procedure. The state-of-the-art approach to rendering polyesters flame retardant is to use additives such as brominated compounds or compounds containing aluminum and/or phosphorus. Use of the additives with polyesters has a deleterious effect on the processing characteristics and/or the mechanical performance of fibers produced from them. In addition, some of these compounds are toxic, and can leach into the environment over time making their use less desirable. In some countries certain brominated additives and aluminum and/or phosphorus containing additives are being phased-out of use because of environmental concerns. [0014] The requirements for flame retarding polyesters are stringent in part because of the high processing temperatures and sensitivity of the polyesters' melt viscosity and consequently melt-spinnability into fibers. Moreover, flame retardant polyesters must be resistant to degradation by residual acidic groups in the polyester, exhibit long-term dimensional stability, have good dyeing characteristics in the final fiber, and exhibit good mechanical properties. These challenges combined with environmental regulations for toxicity and mitigation of leaching of the flame retardant into the environment over time have made it extremely difficult to meet all of these requirements. [0015] Embodiments of the invention are directed to polymer fibers and flame retardant polyesters that include a thermoplastic polyester and one or more phosphonate containing polymer, copolymer, or oligomer. Embodiments of the invention are not limited by the type of phosphonate containing polymer, copolymer, or oligomer. For example, in various embodiments, the phosphonate containing polymer, copolymer, or oligomer may be derived from diaryl alkylphosphonates, diaryl arylphosphonates, or combinations thereof and an aromatic dihydroxy compound such as dihydric phenols, bisphenols, or combinations thereof. Such phosphonate containing polymers, copolymers, or oligomers may be block copolymers having discrete phosphonate and carbonate blocks that are covalently attached to one another, or the phosphonate containing polymer, copolymer, or oligomer may be random copolymers in which individual phosphonate and carbonate monomers or small phosphonate or carbonate segments, for example, 1 to 10 monomeric units, are covalently attached. [0016] In certain embodiments, phosphonate containing polymer, copolymer, or oligomer may be the polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate) as described and claimed in U.S. Pat. Nos. 6,861,499, 7,816,486, 7,645,850, and 7,838,604 and U.S. Publication No. 2009/0032770, each of which are hereby incorporated by reference in their entireties, or their respective oligomers. Briefly, such polymers and oligomers may include repeating units derived from diaryl alkyl- or diaryl arylphosphonates. For example, in some embodiments, such polyphosphonates or phosphonate oligomers may have a structure including: [0000] [0017] where Ar is an aromatic group and —O—Ar—O— may be derived from a compound having one or more, optionally substituted, aryl rings such as, but not limited to, resorcinols, hydroquinones, and bisphenols, such as bisphenol A, bisphenol F, and 4,4′-biphenol, phenolphthalein, 4,4′-thiodiphenol, 4,4′-sulfonyldiphenol, or combinations of these, X is a C 1-20 alkyl, C 2-20 alkene, C 2-20 alkyne, C 5-20 cycloalkyl, or C 6-20 aryl, and n is an integer from 1 to about 100, 1 to about 75, or 2 to about 50, or any integer between these ranges [0018] In other embodiments, the copoly(phosphonate ester), copoly(phosphonate carbonate) and their respective oligomers may have structures such as, but not limited to: [0000] [0019] and combinations thereof, where Ar, Ar 1 , and Ar 2 are each, independently, an aromatic group and —O—Ar—O— may be derived from a compound having one or more, optionally substituted aryl rings such as, but not limited to, resorcinols, hydroquinones, and bisphenols, such as bisphenol A, bisphenol F, and 4,4′-biphenol, phenolphthalein, 4,4′-thiodiphenol, 4,4′-sulfonyldiphenol, or combinations of these, X is a C 1-20 alkyl, C 2-20 alkene, C 2-20 alkyne, C 5-20 cycloalkyl, or C 6-20 aryl, R 1 and R 2 are aliphatic or aromatic hydrocarbons, and each m, n, and p can be the same or different and can, independently, be an integer from 1 to about 100, 1 to about 75, 2 to about 50, or any integer between these ranges. In certain embodiments, each m, n and p are about equal and generally greater than 5 or greater than 10. [0020] In particular embodiments, the Ar, Ar 1 , and Ar 2 may be bisphenol A and X may be a methyl group providing polyphosphonates, copoly(phosphonate carbonate), copoly(phosphonate ester), and their respective oligomers. Such compounds may have structures such as, but not limited to: [0000] [0021] and combinations thereof, where each of m, n, p, and R 1 and R 2 are defined as described above. Such copoly(phosphonate ester), copoly(phosphonate carbonate) and their respective oligomers may be block copoly(phosphonate ester), copoly(phosphonate carbonate) or oligomers thereof in which each m and n is greater than about 1, and the copolymers contain distinct repeating phosphonate and carbonate blocks. In other embodiments, the copoly(phosphonate ester), copoly(phosphonate carbonate) or their respective oligomers can be random copolymers in which each n can vary and may be from 1 to about 10. [0022] The weight average molecular weight (Mw) of each of the one or more phosphonate containing polymers and copolymers, and in particular embodiments, the polyphosphonate, copoly(phosphonate ester), and/or copoly(phosphonate carbonate), in the polymer fibers and flame retardant polyesters of the invention can range from about 10,000 g/mole to about 120,000 g/mole measured against polystyrene (PS) standards. The Mw of the oligomeric phosphonates and cophosphonate oligomers can range from about 1,000 g/mole to about 10,000 g/mole measured against PS standards, and in some embodiments, the Mw can range from about 2,000 g/mole to about 6,000 g/mole measured against PS standards. [0023] “Molecular weight,” as used herein, is, generally, determined by relative viscosity (η rel ) and/or gel permeation chromatography (GPC). “Relative viscosity” of a polymer is measured by dissolving a known quantity of polymer in a solvent and comparing the time it takes for this solution and the neat solvent to travel through a specially designed capillary (viscometer) at a constant temperature. Relative viscosity is a measurement that is indicative of the molecular weight of a polymer. It is also well known that a reduction in relative viscosity is indicative of a reduction in molecular weight, and reduction in molecular weight causes loss of mechanical properties such as strength and toughness. GPC provides information about the molecular weight and molecular weight distribution of a polymer. It is known that the molecular weight distribution of a polymer is important to properties such as thermo-oxidative stability (due to different amount of end groups), toughness, melt flow, and fire resistance, for example, low molecular weight polymers drip more when burned. [0024] The thermoplastic polyester used in various embodiments is not limited and can vary. For example, in some embodiments, the thermoplastic polyester can be poly(butylene terephthalate) (PBT), poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(ethylene naphthalate) (PEN), or any combination of these. Other polyesters not specifically described are also encompassed by these embodiments and can be combined with the phosphonate containing polymers, copolymers, and oligomers described above to create polymer fibers or flame retardant polyesters of the invention. [0025] The amount of the phosphonate containing polymer, copolymer, or oligomer mixed can vary among embodiments and may be modified based on the desired properties of the flame retardant polyester. For example, in some embodiments, the amount of polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate) or their respective oligomer can be up to about 25% by weight relative to the host thermoplastic polyester. In other embodiments, the amount of polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate) or their respective oligomer can be from about 1 wt. % to about 25 wt. %, about 2 wt. % to about 20 wt. % or about 5 wt. % to about 15 wt. % relative to the host thermoplastic polyester. [0026] In some embodiments, the polymer fibers and flame retardant polyesters may include additional additives that can be incorporated to improve one or more properties exhibited by the fiber or flame retardant polyester or provide, for example, color. Non-limiting examples of such additional additives include fire resistant additives, fillers, dyes, antioxidants, pigments, anti-dripping agents, wetting agents, lubricating agents, and other additives typically used with polyester fibers. In particular embodiments, the polyester fibers or flame retardant polyesters may include a dye and/or pigment. The fire resistant additives of such embodiments may include, but are not limited to, metal hydroxides, nitrogen containing flame retardants such as melamine cyanurate, phosphinate salts, organic phosphates, other phosphonates, organic sulfonate salts, siloxanes, and the like. [0027] In particular embodiments, the polymer compositions of the invention can be used, incorporated into, or spun into fibers that can be used in woven and non-woven products. For example, the polymer compositions of various embodiments may be used in woven products such as clothing, carpet, flooring materials, wigs, and non-woven articles used in consumer products that must meet fire resistance standards. More particular exemplary embodiments include fabrics that are woven or knitted from polyester thread or yarn that are used in apparel and home furnishings, such as shirts, pants, jackets, hats, bed sheets, blankets, upholstered furniture and the like. Non-woven fibers prepared from the polymer compositions of the invention can be used in other applications cushioning and insulating material in pillows, blankets, quilts, comforters, and upholstery padding. Other embodiments include industrial polyester fibers, yarns, and ropes that are used, for example, in tire reinforcements, fabrics for conveyor belts, safety belts, coated fabrics, and plastic reinforcements with high-energy absorption. [0028] The fibers of various embodiments may have any thickness or diameter, and the diameter of fibers may vary by their intended use. For example, in embodiments in which the fibers are used in textiles for clothing, the fiber diameter may be less than fibers used for carpeting or upholstery, which may have a smaller diameter than fibers used for industrial yarns and ropes. In some embodiments, the fiber diameter may be from about 2.0 μm to about 50 μm, about 5 μm to about 40 μm, about 10 μm to about 30 μm, or from about 12 μm to about 25 μm. In other embodiments, the density of the fiber may be from about 0.9 denier to about 30 denier, about 2 denier to about 25 denier, or 10 denier to about 15 denier. A “denier” is a well-known unit of linear density in the textile arts and is defined herein as the weight in grams of 9000 meters of a linear material. [0029] Some embodiments of the invention are directed to other articles of manufacture incorporating the polymer compositions described above. For example, certain embodiments are directed to articles of manufacture such as, but not limited to, “plastic” bottles, films, tarpaulin, canoes, liquid crystal displays, holograms, filters, dielectric films, insulation for wires, insulating tapes, and other films, moldings, and other articles including the polymer compositions. In other embodiments, fibers including the polymer compositions of the invention can be incorporated into fiber reinforced composites that include a matrix material that is compatible with the polymer compositions described above. Such fiber reinforced composites may be incorporated into any of the articles described above. In still other embodiments, the polymer compositions described herein may be incorporated into wood finishes that can be applied to wood products as a liquid or gel. [0030] Further embodiments of the invention are directed to methods for making the polymer compositions of the invention and methods for preparing articles of manufacture or fibers from the blended material. For example, some embodiments include methods for preparing a polymer composition including the steps of blending in a melt a thermoplastic polyester and a phosphonate containing polymer, copolymer, or oligomer. The melt blending may be carried out by any mixing technique, for example, melt mixing may be carried out in a brabender mixer or extruder. In some embodiments, the methods may include the steps of extruding the mixture after melt mixing and pelleting the resulting material. In other embodiments, the methods may include compressing the melt mixed material in rollers to create a film, spincasting a film, or blowmolding a film. In still other embodiments, the methods may include molding the melt mixed material into an article of manufacture. [0031] In particular embodiments, the melt mixed polymer composition of the invention may be spun into fibers by fiber spinning. In such embodiments, the solution viscosity of the melt mixed material may be modified to improve the processability of material during fiber spinning. In particular, the solution viscosities of the melt mixed material during fiber spinning may be from about 0.04 dL/g to about 3.0 dL/g, about 0.1 dL/g to about 2.5 dL/g, or about 0.5 dL/g to about 2.0 dL/g, or any value between these ranges. In some embodiments, the solution viscosities may depend on the end application. For example, textile grade fibers may be prepared from a polymer composition having a solution viscosity of from about 0.04 dL/g to about 0.70 dL/g, and fibers for industrial applications such as tire cord may have a solution viscosity of from about 0.7 dL/g to about 1.0 dL/g. Monofilament fibers may be prepared from a polymer composition having a solution viscosity of from about 1.0 dL/g to about 2.0 dL/g. “Solution viscosity” as defined herein is the difference in time it takes for a polymer solution to pass through a capillary of specified length at a specific temperature versus the time it takes the pure solvent and can be measured according ASTM method D5225. [0032] In certain embodiments, methods for the preparation of polymer fibers may include the step of heat setting the spun fibers. The term “heat setting” as used herein refers to thermal processing of the fibers in either a steam atmosphere or a dry heat environment. Heat setting gives fibers, yarns, or fabric dimensional stability and can provide other desirable properties such as higher volume, wrinkle resistance, and/or temperature resistance. [0033] The polymer compositions, polymer fibers, articles of manufacture, and such described herein exhibit excellent flame resistance and a superior combination of properties including processing characteristics, mechanical properties, heat-setting characteristics, and ability to dye as compared to fiber compositions containing conventional brominated or phosphorus-containing flame retardants. Because the additives are polymeric or oligomeric, and form compatible mixtures with the host polyesters, they do not leach out and will generally not produce environmental concerns. Therefore, polymer compositions described herein including a thermoplastic polyester and one or more polyphosphonates, copoly(phosphonate ester)s, copoly(phosphonate carbonate)s, and/or their respective oligomers meet all of the processing and performance requirements specified for polyester fibers, and also overcome the environmental and toxicity considerations. Moreover, formulations containing these flame retardant materials were spun into high quality fibers, woven into test articles and tested for flame resistant properties. [0034] Without wishing to be bound by theory, one plausible explanation for the unexpected behavior is that the polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate) or their respective oligomer may become incorporated into the polyester chemically via transesterification that can occur during high temperature processing. They may also become incorporated chemically via reaction of end groups present on the polyester or polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate) or their respective oligomer. Such end groups may be ester, phosphonate, carbonate, or hydroxyl. Due to chemical incorporation, the chance of leaching is negated. Yet another possible explanation is that the polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate) or their respective oligomer may become entangled in the polyester matrix. At the same time, the flame retardant materials satisfy the UL or similar standardized fire resistance requirements without detracting from important mechanical and processing properties. This is achieved by formulating a composition comprising a polyphosphonate, copoly(phosphonate ester), copoly(phosphonate carbonate) or their respective oligomer, and a polyester which is subsequently melt spun into a fiber. EXAMPLES [0035] Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, other versions are possible. Therefore the spirit and scope of the appended claims should not be limited to the description and the preferred versions contained within this specification. Various aspects of the present invention will be illustrated with reference to the following non-limiting examples. Example 1 Preparation of Polyester Mixtures [0036] Poly(ethylene terephthalate) (PET, solution viscosity 0.62 dL/g) was melt mixed with polyphosphonate having a molecular weight of 100,000 g/mole (PS standards) to produce PET/phosphonate blends having phosphonate polymer loading levels ranging from 2.5% to 15% by weight. These blends where then spun into fibers. Each of the PET/polyphosphonate blends exhibited excellent processability and melt spinning produced 5 to 8 denier fibers and 18 to 22 denier fibers using the same production equipment used for pure PET fibers. Fibers then underwent heat setting and exhibited excellent heat-setting characteristics. Table 1 gives a description of each of the samples tested. [0000] TABLE 1 Composition of textile samples Sample Description Control #1 Commercial PET with fire retardant (FR) Control #2 PET, No FR Control #3 PET, No FR FRX-100@ 2.5% in PET 2.5% phosphonate polymer FRX-100@ 5% in PET 5% phosphonate polymer FRX-100@ 10% in PET 10% phosphonate polymer FRX-100@ 15% in PET 15% phosphonate polymer Example 2 Flame Resistance Testing [0037] The fibers described in Table 1 were tested according to ASTM 701 and exhibited good fire resistant behavior. Fabric samples woven from these compositions were tested according to ASTM D6413-99 “Standard Test Method for Flame Resistance of Textiles” with a slight modification in the procedure in that the samples were not conditioned before testing. Specifically, test samples were cut into 3 inches by 12 inches samples that were vertically mounted 0.75 inches above the flame burner. The flame had a height of 1.5 inches, and the sample was exposed to a flame for 12 seconds. The char length was determined after a weight of 200 g (tearing force) was attached to one edge of the burnt sample, and the opposite end was raised in a smooth continuous motion until the tearing force was supported by the sample. A minimum of three repeats were performed on each sample composition. The results are presented in Table 2. [0000] TABLE 2 Flame Resistance Testing of Textile Compositions Time to self ext, After Glow Char Sample (after flame time), Time, Length, Melting/ and Trial sec sec (mm) Dripping Control 1-1 0 0 69 None Control 1-2 0 0 79 None Control 1-3 0 0 81 None Control 2-1 57 0 120 flaming drips Control 2-2 37 0 90 flaming drips Control 2-3 30 0 98 flaming drips Control 2-4 43 0 99 flaming drips Control 3-1 73 0 100 flaming drips Control 3-2 43 0 88 flaming drips Control 3-3 49 0 92 flaming drips FRX 2.5%-1 0 0 86 None FRX 2.5%-2 0 0 84 None FRX 2.5%-3 0 0 81 None FRX 2.5%-4 0 0 84 None FRX 2.5%-5 0 0 61 None FRX 5%-1 0 0 88 None FRX 5%-2 0 0 81 None FRX 5%-3 0 0 81 None FRX 5%-4 0 0 76 None FRX 5%-5 0 0 — None FRX 10%-1 0 0 74 None FRX 10%-2 0 0 74 None FRX 10%-3 0 0 74 None FRX 15%-1 0 0 61 None FRX 15%-2 0 0 76 None FRX 15%-3 0 0 52 None FRX 15%-4 0 0 73 None FRX 15%-5 0 0 65 None [0038] The results in Table 2 show that the control test #1, blank test #1, and all the samples containing the polyphosphonate self-extinguished before the flame was removed. Control samples 2 and 3 continued to burn after the flame was removed and produced flaming drips. Increasing the amount of polyphosphonate in the PET samples decreased the char length. In particular, FRX 2.5% exhibited an average char length of 80 mm, and FRX 15% exhibited an average char length of 65 mm. Samples including 5%, 10%, and 15% polyphosphonate did not show any blackening along the burned edges. Example 3 Flame Persistence Testing [0039] PET/polyphosphonate fibers were prepared as described in Example 1 were fabricated into circular knitted fabric specimens. The fabric specimens were fabricated from a false-twisted PET yarn (130, dtex (225), f 38 bright-3.5 dtex/filament). Washing, drying and conditioning of all specimens was conducted according to ISO 6330 (2000-2008), using washing procedure 5A. The flame persistence test was conducted according to NF P 92-504 (1995) with some deviations from the standard due to the small sample size. The results from this test on several formulations are provided in Table 3. [0000] TABLE 3 Flame Persistence Test Results After Flame Time, seconds Control (Virgin FRX FRX Test Number PET) FRX 2.5% FRX 5.0% 7.5% 10.0% 1 40 * * * * 2 * * * * * 3 21 5 * * * 4 20 * 3 * * 5 N/T * * * * 6 N/T * * * * 7 N/T 5 * * * 8 N/T * * * * 9 N/T * * * * 10  N/T 3 * 3 * Flaming Debris Yes No No No No Non-Flaming No Yes Yes No Yes Debris N/T = not tested * = afterflame time was less than 2 seconds [0040] The test results in Table 3 show the superior fire resistant behavior of the samples comprised of PET/phosphonate blends with phosphonate polymer or oligomer loading levels from 2.5 to 10.0% by weight.
The invention relates to the use of polyphosphonates, copoly(phosphonate ester)s, copoly(phosphonate carbonate)s, and their respective oligomers, as flame retardant additives for polyester fibers to impart fire resistance while maintaining or improving processing characteristics for melt spinning fibers.
3
FIELD [0001] The present disclosure relates generally to a meat substitute product. Aspects of the disclosure are particularly directed to a meat substitute product consisting of a meat substitute, starch(es), hydrocolloid(s), and oil(s) from a vegetable source(s). BACKGROUND [0002] Many people are choosing to limit the amount of meat in their diet. Specifically, people are looking to reduce the amount of animal fat in their diets. Animal fat is a primary source of saturated fat, which raises blood cholesterol. [0003] Despite the desire to limit meat in the diet, people nonetheless want to eat products that were traditionally meat-based products, such as burgers. Non-meat burgers can he made, for example, from vegetables, legumes, nut, dairy products, mushrooms, grain or textured vegetable protein. [0004] Fat in a non-meat burger, and other meat substitutes, plays a vital role in a variety of sensory attributes, including juiciness, mouth feel and flavor. When a meat substitute product has lower amounts of fat, there is a tendency for the cooked product to be less desirable in regards to juiciness, mouth feel and flavor. On the contrary, when a meat substitute product has an optimal amount of fat, it is more desirable in terms of juiciness, mouth feel and flavor. [0005] Meat substitute products also are an appropriate system for the application of functional fats. A functional food ingredient is defined as an ingredient or food that provides potential health benefits beyond basic nutrition. These functional components can be naturally occurring or may he added to certain foods. Such ingredients include but arc not limited to Omega-3 fatty acids, antioxidants, phytosterols and dietary fibers. The functional fat system would serve as a delivery medium to deliver functional ingredients into processed meat products. SUMMARY [0006] This invention allows for the production of a meat substitute product without sacrificing sensory attributes. There is a nutritional/sensory interaction which allows for the addition of a modifying agent to textured soy protein meat substitute which increases the sensory attributes of the product. [0007] One embodiment of this invention is directed toward a meat substitute composition comprising a meat substitute, a starch, a gum and an oil from a non-animal source. DETAILED DESCRIPTION [0008] The present invention will now be described in more detail. [0009] The meat composition of the present invention comprises (A) meat substitute, (B) starch(es), (C) hydrocolloid(s), and (D) oil(s) from a vegetable source(s). [0010] Component A: Meat Substitute. The meat substitute composition can be vegetables, legumes, nuts, dairy products, eggs, mushrooms, grains or vegetable protein. [0011] Component B: Starch. Starch is a carbohydrate polymer. Starches are comprised of amylose and amylopectin and arc typically in the form of granules. Amylopectin is the major component (about 70-80%) of most starches. It is found in the outer portion of starch granules and is a branched polymer of several thousand to several hundred thousand glucose units. Amylose is the minor component (about 20-30%) of most starches (there are high amylose starches with 50 to 70% amylose). It is found in the inner portion of starch granules and is a linear glucose polymer of several hundred to several thousand glucose units. [0012] Sources of starch include but are not limited to fruits, seeds, and rhizomes or tubers of plants. Common sources of starch include but are not limited to rice, wheat, corn, potatoes, tapioca, arrowroot, buckwheat, banana, barley, cassava, kudzu, oca, sago, sorghum, sweet potatoes, taro and yams. Edible beans, such as favas, lentils and peas, are also rich in starch. [0013] Some starches are classified as waxy starches. A waxy starch contains high amounts of amylopectin with very little amylose. Common waxy starches include waxy maize starch, waxy rice starch, and waxy wheat starch. [0014] A modified starch is one that has been altered from its native state, resulting in modification of one or more of its chemical or physical properties. Starches may be modified, for example, by enzymes, oxidation or, substitution with various compounds. Starches can be modified to increase stability against heat, acids, or freezing, improved texture, increase or decrease viscosity, increase or decrease gelatinization times, and increase or decrease solubility, among others. Modified starches may be partially or completely degraded into shorter chains or glucose molecules. Amylopectin may be debranched. Starches that are modified by substitution have a different chemical composition. A nOSA starch is a modified starch that has been partially substituted with n-octenyl succinic anhydride. [0015] Component C: Hydrocolloid. Hydrocolloids are a family of long chain water soluble polysaccharides and are generally carbohydrate based which affect the viscosity/gelling of aqueous solutions. Common examples are locust bean gum, carrageenan (seaweed extract), guar gum, xanthan gum, gellan gum, scleroglucan, agar, pectin, alginate, cellulose derivatives, and gum acacia. These are broadly classified as gums. Starches and gelatin are sometimes characterized as hydrocolloids. One skilled in the art can use combinations of starches, gelatin, and gums to achieve desired texture and melt properties. [0016] Component D: Oil from vegetable source(s): A lipid material composed of a mixture of generally triacylglycerides from non-animal sources such as soya, olive, rapeseed, avocado, palm, palm kernel, coconut, cocoa, peanut, corn, flax, sunflower, safflower, and cottonseed. These lipids may be solid or liquid at room temperature depending on the chain lengths of the fatty acids, degree of saturation, and method of hydrogenation. Oils from multiple sources may he combined or certain fractions removed by processing such as winterization. [0017] One significant benefit of this invention is to replace the animal oils with oils that have a dietary functional use. Examples [0018] Various products have been manufactured. Each comprises a fat mimetic and a meat substitute. The examples below are merely illustrative and not limiting. Vegan Fat Mimetic [0019] [0000] Ingredient Percentage Water 40-60%  Vegetable Shortening 15-35%  Acid Thinned Starch 7-15%  Acid thinned nOSA starch, (EmCap ™ 06375) 5-12%  Viscosifying nOSA starch, (DeliTex ™ 75320) 3-8% Kappa Carrageenan, (Satiagel ™ ME4) 1-3% Salt 0-4% Guar gum/xanthan gum 0-3% [0020] All ingredients are compiled and then heated with agitation to 165 to 170° F. using a Blentech model CC-10 at low speed. Direct steam injection is quickest method, but other methods are possible. Product is hot filled and cooled. After refrigeration for a minimum of 24 hours the product can be ground, diced, grated, or shredded to desired size. Veggy Burger [0021] [0000] Ingredient Percentage Water 45.6% Textured soy flour 20.0% Vegan fat mimetic 20.0% Flavors, seasonings, salt, and colors 5.4% Soy Flour 3.0% Methylcellulose 2.0% Autolyzed yeast extract 2.0% Modified wheat gluten 2.0% [0022] Add dry textured soy flour to mixer with ⅔ water and mix for five minutes. Add wheat gluten, fat mimetic, soy flour and methylcellulose to mixer and start mixing. Add remaining ⅓ water and mix for ten minutes until tacky. Add remaining dry ingredients and mix for five to ten minutes. Form patties and cook to internal of 165° F.
A meat substitute product is disclosed. A meal substitute, such as vegetable protein, is blended with a starch, hydrocolloid, and an oil from a vegetable source.
0
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation application of U.S. patent application Ser. No. 10/525,110 filed on Feb. 18, 2005 which is the U.S. national stage of International Application Number PCT/CA2002/001284 filed on Aug. 20, 2002, the disclosures of which are expressly incorporated herein in their entireties by reference. FIELD OF THE INVENTION [0002] The invention relates generally to the field of disinfectants and in particular to wide spectrum disinfectants. BACKGROUND OF THE INVENTION [0003] It is known in that art that there are many compounds which can act as a disinfecting agent. For example, solutions of 70-85% (volume/volume) ethanol are commonly used as disinfectants. As is known in the art, there are two forms of ethanol generally available in North America: denatured ethanol, and potable alcohol. Both denatured and potable ethanols are used in the preparation of the solutions noted above. Denatured ethanol contains additives for the purpose of preventing or reducing abuse or consumption of the alcohol. Such additives may include aviation fuel, emetics, various organic solvents, mercury salts. Bitrex is an example of an additive that is commonly present in ethanol in varying amounts. For instance, bitrex is present in specially denatured alcohol grade-3 (SDAG-3) at 700 mg per 100 litres, and is present in specially denatured alcohol grade-6 (SDAG-6) at 1 g per 100 litres. Solutions of 70-85% ethanol are effective in inactivating most vegetative bacteria, fungi, and lipid containing viruses. However, ethanol is not effective against bacterial spores. [0004] As noted above, disinfecting agents vary in their ability to kill different microorganisms. For example, some compounds may act as a bactericide only, other as a virucide only, and yet others as a fungicide only. Some compounds are known which may kill gram-positive bacteria, yet not be effective in killing gram-negative bacteria. Accordingly, a disinfectant that can effectively kill most if not all microorganisms may require a combination of known disinfecting agents with complementary activity in order to provide a wide spectrum disinfectant. [0005] Combinations of disinfecting agents can compound the risks associated with the use of any of those agents individually. Due to interactions between disinfecting agents, the combination may introduce new hazards in use, such as reduced efficacy of the disinfecting agents, irritation to the user, environmental risks such as flammability, and reduced residual effects of the disinfecting agents. [0006] U.S. Reissue Pat. No. 32,300 describes the use of anti-microbial agents in combination with polyethylene glycol as a skin cleansing composition. The polyethylene glycol is used as a sudsing agent and lacks any anti-microbial properties. The anti-microbial agents suggested in that reissue patent have limited efficacy. In particular the combination described lacks tuberculocidal activity and has limited anti-viral activity. Further, the anti-microbial agents described in that reissue patent lose anti-microbial activity unless they are maintained in a non-ionic environment. [0007] Canadian Patent No. 1,290,250 relates to an antiseptic fluid which, upon drying forms a skin protective film with residual anti-bacterial properties. The residual activity of the fluid described is dependent on a disposable film forming a polymer carrying specified bactericides. Due to its limited spectral efficiency the film is limited in the scope of its application and is not suitable for use in high infection risk environments. [0008] Canadian Patent No. 1,332,136 describes the use of relatively high concentrations of a chlorhexidine salt complexed with a non-ionic surfactant in order to maintain a bactericidal activity, particularly against Staphylococcus aureus . However, chlorhexidine salts, such as chlorhexidine gluconate, in the relatively high concentrations described in Canadian Patent No. 1,332,136 irreversibly stains. [0009] U.S. Pat. No. 5,030,659 describes an aqueous disinfectant using a combination of microbicidal compounds in specified ratios to broaden the spectrum of the anti-microbial activity. However, that disinfectant uses relatively high relative concentrations of benzalkonium chloride. The disinfectant described also lacks a denaturant or a cleanser resulting in a loss of potential disinfecting capacity. Further, at some concentrations of ethanol proposed in this patent, the disinfectant described is also combustible. [0010] Canadian Patent No. 1,335,352 describes an oral bactericidal solution intended to prevent or inhibit growth of bacteria on tooth surfaces. The solution described includes at least one polymer which has one or more pendant polyalkylene oxide groups. It is stated that this solution enhances the anti-adhesive and antibacterial properties of tooth surfaces with a reduced risk of staining with chlorhexidine. However, it is not suggested that the solution has a broad spectrum of activity, or that it can act as a virucide or fungicide. Accordingly, the solution may be limited in its application to tooth surfaces. [0011] U.S. Pat. No. 5,985,931 describes the use of a combination of antimicrobial agents in an aqueous solution to achieve a synergistic effect of the component anti-microbial agents. This solution suffers from a numbers of limitations. First, since the solution is about 70% water it will have some corrosive properties. Second, and notwithstanding any synergistic effects, the spectrum of organisms which the component anti-microbial agents can kill is not suggested to be broader. Accordingly, the solution will not be suitable for many uses required in a hospital grade product as it will not significantly reduce or kill Mycobacterium tuberculosis , and is of only limited utility in killing gram-negative bacteria and fungi. [0012] Canadian Patent Application No. 2,132,688 describes a formulation that can act as a spermicide and virucide using a combination of benzalkonium chloride and nonoxynol. The purpose of the described formulation is as a vaginal application to protect against transmission of sexually transmitted viruses and other infections and to protect against conception. There is no suggestion in the description that this formulation has a broad spectrum of activity as a fungicide or bactericide. Further, there are some health concerns regarding the use of relatively high concentrations of nonoxynol and the possibility that nonoxynol when applied vaginally, may cause vaginal ulcerations. [0013] Canadian Patent Application No. 2,309,353 describes an aqueous solution containing up to 20% by weight of a surfactant, and an anti-microbial quaternary ammonium compound. The anti-microbial activity of this solution is limited by the efficacy of the quaternary ammonium compound sued. In addition, the high aqueous level can render the product corrosive and thus limit its use to skin, nail, mouth and mucous membrane applications. [0014] U.S. Pat. No. 4,870,108 describes a liquid antiseptic containing ethanol, acetone, glycerin, water, and a quaternary ammonium compound. This antiseptic is said to be rapid acting and non-irritating to skin after repeated use. However, there are problems with the use of the components of this liquid. Glycerin in the antiseptic prohibits the use of the solution on hard surfaces, instruments, and in high-risk areas. This antiseptic has limited residual anti-microbial activity, and for example, is not tuberculocidal. Further, the combination of acetone with ethanol is extremely flammable, and thus may present a safety risk in use. [0015] Canadian Patent No. 2,023,287 describes the use of a combination of alcohols including benzyl alcohol to provide a broad spectrum antimicrobial composition. The specific combination of alcohols is said to have a lowered flash point when compared to previously available mixtures while providing synergistic effects on antimicrobial activity. However, the formulation suffers from the disadvantage that it is quite toxic and is not suitable for hospital grade disinfection. Further, the combination described is also water and moisture sensitive. [0016] U.S. Pat. No. 5,800,827 describes compositions using an organic acid, with chlorhexidine in ethanol in concentrations greater than 50% by weight. The organic acid is believed to stabilize the chlorhexidine in the ethanol while maintaining the germicidal activity of the chlorhexidine. The organic acids described to stabilize the chlorhexidine are lactic acid and citric acid. However, while the chlorhexidine is stabilized, its spectrum of activity is unchanged. Thus, the compositions described are limited to the spectrum of activity of the chlorhexidine. SUMMARY OF THE INVENTION [0017] It is now an object of the present invention to provide a wide spectrum disinfectant wherein the disinfectant kills microorganisms quickly, and yet is safe for the user and is not environmentally harmful. [0018] Accordingly the invention provides a wide spectrum disinfectant comprising SDAG-3 ethanol (95%), bitrex, O-phenylphenol, benzalkonium chloride, chlorhexidine gluconate, nonoxynol-9, and deionized, double distilled water. The disinfectant can also optionally include a fragrance. [0019] The invention further provides a process of manufacture of a wide spectrum disinfectant including the step of slowly bleeding deionized, double distilled water into an ethanol solution to avoid points of nucleation in the ethanol. [0020] The invention further provides for the use of the disinfectant in medical and cosmetic applications. [0021] The invention provides an environmentally friendly wide spectrum disinfectant, a method of manufacture of that disinfectant, and use of the disinfectant in medical and cosmetic applications. [0022] In accordance with one aspect of the invention, there is provided wide spectrum disinfectant including as components an alcohol, O-phenylphenol, chlorhexidine gluconate, nonoxynol-9, benzalkonium chloride, and deionized double distilled water wherein on a weight/volume ratio the alcohol comprises from 50 to 80%, the O-phenylphenol comprises from 0.1 to 0.8%, the chlorhexidine gluconate comprises from 0.01 to 1%, the nonoxynol-9 comprises from 0.02 to 1%, and the benzalkonium chloride comprises from 0.15 to 1%. [0023] In accordance with one embodiment of the invention, there is provided a wide spectrum disinfectant wherein the alcohol is selected from the group consisting of methanol, ethanol, propanol and butanol. In accordance with another embodiment of the invention, there is provided a wide spectrum disinfectant, wherein on a weight/volume ratio the alcohol comprises from 60 to 75%. In accordance with another embodiment of the invention, there is provided a wide spectrum disinfectant, wherein on a weight/volume ratio the alcohol comprises 70%. In accordance with another embodiment of the invention, there is provided a wide spectrum disinfectant, wherein on a weight/volume ratio the O-phenylphenol comprises from 0.2 to 0.5%. In accordance with another embodiment of the invention, wherein on a weight/volume ratio the nonoxynol-9 comprises from 0.04 to 0.1%. [0024] In accordance with another aspect of the invention, there is provided a method of making the wide spectrum disinfectant of the invention including the steps of dissolving in alcohol at least one antimicrobial agent and continuing to stir the solution; dissolving in deionized, double distilled water at least a second antimicrobial agent; adding to the alcohol solution while continuing to stir, a detergent; adding to the alcohol solution while continuing to stir, the deionized, double distilled water solution at a sufficiently slow rate to prevent points of nucleation. [0025] In accordance with another aspect of the invention, there is provided a method of making the wide spectrum disinfectant of the invention including the steps of dissolving in alcohol O-phenylphenol and continuing to stir the solution; dissolving in deionized, double distilled water benzalkonium chloride; adding to the alcohol solution while continuing to stir, nonoxynol-9 and chlorhexidine gluconate; adding to the alcohol solution while continuing to stir, the deionized, double distilled water solution at a sufficiently slow rate to prevent points of nucleation. [0026] In accordance with another aspect of the invention, there is provided a method of making a wide spectrum disinfectant of the invention including the steps of dissolving in alcohol containing a denaturant O-phenylphenol and continuing to stir the solution; dissolving in deionized, double distilled water benzalkonium chloride; adding to the alcohol solution while continuing to stir, nonoxynol-9 and chlorhexidine gluconate; adding to the alcohol solution while continuing to stir, the deionized, double distilled water solution at a sufficiently slow rate to prevent points of nucleation. [0027] In accordance with another aspect of the invention, there is provided a method of making a wide spectrum disinfectant of the invention including the steps of dissolving in alcohol containing a denaturant O-phenylphenol and continuing to stir the solution; dissolving in deionized, double distilled water benzalkonium chloride; adding to the alcohol solution while continuing to stir, nonoxynol-9, chlorhexidine gluconate and a fragrance; adding to the alcohol solution while continuing to stir, the deionized, double distilled water solution at a sufficiently slow rate to prevent points of nucleation. DETAILED DESCRIPTION OF THE INVENTION [0028] In one embodiment of the invention a fast acting disinfectant is described including the following (w/v): at least 50% alcohol; 0.1 to 0.8% O-phenylphenol; 0.01 to 1% chlorhexidine gluconate; 0.02 to 1% nonoxynol-9; 0.15 to 1% benzalkonium chloride; and deionized, double distilled water. One embodiment of the invention also includes bitrex (as an emetic, fire-retardant denaturant) and a fragrance such as lemon fragrance No. 431. The formulation for this embodiment is: Ingredient Content (v/v) SDAG-3 Ethanol 95% 70.0% Bitrex 3.68% O-phenylphenol 0.28% Benzalkonium chloride 0.20% Chlorhexidine gluconate 0.01% Nonoxynol-9 0.05% Lemon fragrance No. 431 0.10% Deionized/double distilled water 25.68%  [0029] The ability to kill mycobacterium is a key consideration in selecting a hospital grade product. The ability of formulations within the scope of the invention to kill mycobacterium have been tested using the following protocol. 55×13 mm diameter sterile coverslips were coated with approximately 10 5 Mycobacterium tuberculosis strain Erdman ATCC#35801. This was achieved by adding 10 7 /ml of a suspension of mycobacteria at 10 7 /ml to the coverslip, spreading evenly with the tip of the applicator and allowing to air dry. A positive control group to assess the number of viable bacteria on the coverslip were processed by placing 5 coated coverslips into 500 ul broth, sonicated for 10 seconds with a probe sonicator to disperse the bacteria and serial dilutions plated onto agar growth media (Middlebrook 7H10). A negative control group was also prepared using 5 coverslips with no bacterial inoculation but otherwise processed as above. Test samples were prepared by coating coverslips by spraying the test disinfectant 3 times from a distance of 12 inches. The coverslips were then drained after either 1 minute or 5 minutes using Whatman filter paper and placed into 500 ul broth and processed as described above for the controls. Additional controls were also prepared using previously known disinfectants. These studies of the disinfectants effect on mycobacterium show that the above formulation falling within the scope of the invention has the highest log 10 6.54 reduction scores presently known. [0030] Residual mycobacterial disinfectant capacity was also tested by spraying test coverslips with the formulation forming the subject matter of the test three times from a distance of 12 inches and draining the coverslips as described above after either 1 minute or 5 minutes. One control group comprised coverslips which had not been inoculated with mycobacteria and a second control group comprised coverslips which while inoculated had not been treated with the test disinfectant formulation. The testing shows that embodiments of the invention have residual disinfecting activity suitable for rapidly killing mycobacterium. [0031] Further, the formulation described is a powerful wide spectrum disinfectant. Spectrum studies confirm that the above formulation is 100% batericidal, fungicidal, virucidal, and tuberculocidal. Three minute exposure of various bacterial, fungal and viral cultures to disinfectants falling within the scope of the invention established the broad spectrum nature of these disinfectants including the ability to kill microorganisms including Staphylococcus aureus (ATCC 6538), Salmonella cholerawsuis (ATCC 10708), Pseudomonas aeruginosa (ATCC 15442), Trichophyton mentagrophytes , and Poliovirus type 1. [0032] Further, tests to measure antiviral activity indicated the embodiments of the present invention were highly effective in preventing viral replication. Using a laboratory isolate of HIV-1 (HTLV-III B , NIAID AIDS Reference Reagent Program, Rockville Md.) viral stocks were initially grown up to high titre in H9 lymphocytes suspended in RPMI viral culture medium supplemented with 10% fetal calf serum. After an appropriate number of passages, culture supernatants were harvested and stored at −70° C. in 1 mL aliquots for further use. Prior to the experiments being conducted, the viral stocks were titrated and diluted to yield 103 infectious particles/culture. The diluted viral stocks were added to a pellet 2×10 6 PHA-stimulated peripheral blood mononuclear cells that had been maintained in RPMI with 10% fetal calf serum, and supplemental penicillin, streptomycin, glutamine, rhIL-2 and PHA-P (1 ug/mL) for a period of three days. After incubation of the virus and the cell pellet for two hours at 37° C., the pellet was washed (to remove any adherent virus), then resuspended in fresh viral culture medium in the presence or absence of dilutions of the disinfectant formulation described above and the cultures were maintained to day 7. The supernatants were then harvested and stored at −70° C., for subsequent evaluation of p24 antigen levels (Organon Telcnika, Mississauga ON), as a measure of HIV replication in a given culture. The reduction in p24 antigen levels in the presence of a given dilution of the compound was taken as a measure of its antiretroviral activity. An uninfected culture and a positive control culture were included in the experiment. All experiments were conducted in triplicate, with the results presented as the mean of the three identical cultures. These studies showed that the embodiment of the present invention described above was 100% effective as a disinfectant on Human Immunodeficiency Virus (HIV) and related retroviruses upon contact. [0033] As a further optional ingredient additional denaturants can also be added. These denaturants provide additional disinfecting properties since they denature genetic material, i.e. DNA and RNA. In denaturing the DNA and RNA, and having a broad spectrum of activity, disinfectants falling within the scope of the invention provide a more effective means of infection control than those previously known. In the preferred embodiment of the invention described above bitrex is used as a denaturant. However, bitrex also acts as an emetic to prevent or reduce the possibility of abuse of the solvent. Bitrex also acts as a fire retardant to prevent spontaneous combustion of the disinfectant. [0034] The disinfectants of the present invention are also rapid acting in their disinfecting ability. Studies indicate that the embodiment of the invention described above provides maximal disinfection within 3 minutes. [0035] In addition, toxicology studies confirm that the above formulation is both safe to the user and the environment. Toxicity studies were performed on the disinfectant formulation described above show, in accordance with Health Effects Test Guidelines: Test Result Protocol Used Acute Oral Toxicity LD 50 > 5,000 mg/kg OPPTS 870.1100 (1998) Acute Dermal Toxicity LD 50 > 2,000 mg/kg OPPTS 870.1200 (1998) Acute Inhalation LC 50 > 2.02 mg/L OPPTS 870.1300 (1998) Toxicity Ocular Irritation Average irritation OPPTS 870.2400 (1998) score Unrinsed 29.0 Rinsed 27.3 Dermal Irritation PDII 0.0 OPPTS 870.2500 (1998) Dermal Sensitization Not a contact OPPTS 870.2600 (1998) sensitizer [0036] Finally, given the broad spectrum of activity of disinfectants falling within the scope of the invention, the existence of denaturants, the rapid action of the disinfectant, and their user and environmentally friendly nature the disinfectants of the present invention are particularly useful in medical situations such as hospitals and for paramedics. [0037] The properties of the disinfectants of the present invention are desirable in a broad field of applications. They are suitable for use in the medical field, particularly where there is a high risk of contamination and infection. In addition to first responders such as ambulance, law enforcement and fire personnel, this invention can have application in the dental profession. Disinfectants of the present invention can also be used to prevent, or reduce the likelihood of transmission of sexually transmitted diseases. For example they can be used as components in a personal lubricant to reduce and prevent transmission of herpes, HIV and chlamydia. [0038] In addition to being a powerful disinfectant, embodiments of this invention also act as a sanitizer, a cleanser and particularly where a fragrance is used in the formulation as a deodorizer. The detergent contained in the product (nonoxynol-9) is highly regarded as a powerful detergent, in addition to its anti-microbial properties. These additional properties of the invention make the formulations of this invention particularly attractive to the public health industry where disinfection is particularly important in public areas such as spas, hotels, restaurants, nursing homes and institutions such as penal institutions. [0039] The invention has application to the beauty industry, particularly as an additive to some cosmetics. Some formulations of the invention be used as a percentage addition to creams and ointments as an anti-microbial component or as a component for single or multiple-use wipes. [0040] The present invention also includes methods for making wide spectrum disinfectant formulations. In one embodiment, the method includes the steps of: 1. dissolving in ethanol at least one antimicrobial agent and continuing to stir the solution; 2. dissolving in deionized, double distilled water at least a second antimicrobial agent; 3. adding to the ethanol solution while continuing to stir, a detergent; 4. adding to the ethanol solution while continuing to stir, the deionized, double distilled water solution at a sufficiently slow rate to prevent points of nucleation. [0045] The method of making disinfectants of the present invention can be more clearly illustrated using the specific example of the formulation described above. That formulation is manufactured by: 1. adding ethanol containing Bitrex to a grounded mixing tank; 2. adding O-phenylphenol to the mixing tank containing ethanol slowly until the O-phenylphenol is fully dissolved. Once fully dissolved, continued mixing is preferred for an additional 15 minutes; 3. adding and continually mixing the fragrance, chlorhexidine gluconate and nonoxynol-9 to the grounded mixing tank; 4. bleeding double distilled deionized water into the mixing tank at a sufficiently slow rate to prevent shock to the solution in the tank and avoid points of nucleation. 5. adding and mixing benzalkonium chloride to the mixing tank, with continued mixing for an additional 30 minutes being preferred. [0051] The mixture can then be filtered using a 0.20 micron filter and stored in sterilized bottles. [0052] The sequence of addition of ingredients is important to the creation of the desired disinfectant. In the example described above, the OPP should be dissolved in the ethanol first. Other alcohols such can be used instead of ethanol, including methanol or 1-propanol. Further, the advantages of the present invention can also be realized using alcohol concentrations from about 50-80% (w/v). The addition of the OPP slowly to the ethanol ensures complete miscibility in solution. A complex compound is thus formed, allowing the OPP to remain a free radical, not bound to ethanol. Effectively the OPP dissolves in the ethanol to form a complex. [0053] The nonoxynol-9, fragrance (if desired) and chlorhexidine gluconate are added before the addition of the water. [0054] When manufacturing the disinfectant of the present invention care must be taken when adding the double distilled deionized water to the ethanol to avoid shocking the mixture in that the O-phenylphenol (“OPP”) and possibly the added ingredients will separate from the solution, and precipitate, rendering the solution a failure. [0055] Further, it is important that double distilled deionized water be used so as to avoid points of nucleation that would cause the O-phenylphenol to leave solution. Regular water will allow the OPP to leave the solution, (‘points of nucleation’). OPP has a natural tendency to want to leave or form a guam thus separating from the alcohol when exposed to regular water. Additionally, the double distilled deionized water provides an environment whereby the micro-voltage and electrical field supports complete adhesion of the final disinfectant product to the targeted micro organism for proteolysis, cytolysis and ultimately cell death, as well as total destruction of the DNA and RNA. [0056] The optional but desirable step of filtration of the disinfectant through a 0.20 micron filter ensures the disinfectant is free of any vegetative growth which could potentially compromise the quality and efficacy of the disinfectant. This step renders a final product free of any impurities. This step, coupled with the foil heat-induction seal of bottles for storage of the disinfectant creates a high quality, spore free, disinfectant. [0057] Various embodiments of the present invention having been thus described in detail by way of example, it will be apparent to those skilled in the art that variations and modifications may be made without departing from the invention. The invention includes all such variations and modifications as fall within the scope of the appended claims.
The invention discloses methods of making and uses for wide spectrum disinfectants including as components an alcohol, O-phenylphenol, chlorhexidine gluconate, nonoxynol-9, benzalkonium chloride, and deionized double distilled water wherein on a weight/volume ratio the alcohol comprises from 50% to 80%, the O-phenylphenol comprises from 0.1% to 0.8%, the chlorhexidine gluconate comprises from 0.1% to 1%, the nonoxynol-9 comprises from 0.02% to 1%, and the benzalkonium chloride comprises from 0.15% to 1%.
0
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to the manufacture of high quality optical films, and in particular to a method of depositing an optical quality silica film by PECVD. The invention can be applied to the manufacture of photonic devices, for example, Mux/Demux devices for use fiber optic communications. 2. Description of Related Art The manufacture of integrated optical devices, such as optical Multiplexers (Mux) and Demultiplexers (Dmux) requires the fabrication of optical quality elements, such as waveguides and gratings highly transparent in the 1.30 μm and 1.55 μm optical bands. These silica-based optical elements are basically composed of three layers: buffer, core and cladding. For reasons of simplicity, the buffer and cladding layers are typically of the same composition and refractive index. In order to confine the 1.55 μm (and/or 1.30 μm) wavelength laser beam, the core must have a higher refractive index than the buffer and cladding layers. The required refractive index difference is referred to as the ‘delta-n’ and is one of the most important characteristics of these silica-based optical elements. It is very difficult to fabricate transparent silica-based optical elements in the 1.55 μm wavelength (and/or 1.30 wavelength) optical region while maintaining a suitable difference delta-n and preventing stress-induced mechanical and problems. Our co-pending U.S. patent application Ser. No. 09/799,491 filed on Mar. 7, 2000 entitled ‘Method of Making a Functional Device with Deposited Layers subject to High Temperature Anneal” describes an improved Plasma Enhanced Chemical Vapour Deposition technique for these silica-based elements which allows the attainment of the required ‘delta-n’ while eliminating the undesirable residual Si:N—H oscillators (observed as a FTIR peak centered at 3380 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm), SiN—H oscillators (centered at 3420 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) and SiO—H oscillators (centered at 3510 cm −1 and whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) after a high temperature thermal treatment in a nitrogen ambient, typically at 800° C. With such a high temperature thermal treatment are associated some residual stress-induced mechanical problems of deep-etched optical elements (mechanical movement of the side-walls) and some residual stress-induced mechanical problems at the buffer/core interface or at the core/cladding interface (micro-structural defects, micro-voiding and separation). Recently published literature reveals various PECVD approaches to obtain these high performance optically transparent silica-based optical elements: Valette S., New integrated optical multiplexer-demultiplexer realized on silicon substrate, ECIO '87, 145, 1987; Grand G., Low-loss PECVD silica channel waveguides for optical communications, Electron. Lett., 26 (25), 2135, 1990; Bruno F., Plasma-enhanced chemical vapor deposition of low-loss SiON optical waveguides at 1.5-μm wavelength, Applied Optics, 30 (31), 4560, 1991; Kapser K., Rapid deposition of high-quality silicon-oxinitride waveguides, IEEE Trans. Photonics Tech. Lett., 5 (12), 1991; Lai Q., Simple technologies for fabrication of low-loss silica waveguides, Elec. Lett., 28 (11), 1000, 1992; Lai Q., Formation of optical slab waveguides using thermal oxidation of SiOx, Elec. Lett., 29 (8), 714, 1993; Liu K., Hybrid optoelectronic digitally tunable receiver, SPIE, Vol 2402, 104, 1995; Tu Y., Single-mode SiON/SiO2/Si optical waveguides prepared by plasma-enhanced Chemical vapor deposition, Fiber and integrated optics, 14, 133, 1995; Hoffmann M., Low temperature, nitrogen doped waveguides on silicon with small core dimensions fabricated by PECVD/RIE, ECIO'95, 299, 1995; Bazylenko M., Pure and fluorine-doped silica films deposited in a hollow cathode reactor for integrated optic applications, J. Vac. Sci. Technol. A 14 (2), 336, 1996; Poenar D., Optical properties of thin film silicon-compatible materials, Appl. Opt. 36 (21), 5112, 1997; Hoffmann M., Low-loss fiber-matched low-temperature PECVD waveguides with small-core dimensions for optical communication systems, IEEE Photonics Tech. Lett., 9 (9), 1238, 1997; Pereyra I., High quality low temperature DPECVD silicon dioxide, J. Non-Crystalline Solids, 212, 225, 1997; Kenyon T., A luminescence study of silicon-rich silica and rare-earth doped silicon-rich silica, Fourth Int. Symp. Quantum Confinement Electrochemical Society, 97-11, 304, 1997; Alayo M., Thick SiOxNy and SiO2 films obtained by PECVD technique at low temperatures, Thin Solid Films, 332, 40, 1998; Bulla D., Deposition of thick TEOS PECVD silicon oxide layers for integrated optical waveguide applications, Thin Solid Films, 334, 60, 1998; Valette S., State of the art of integrated optics technology at LETI for achieving passive optical components, J. of Modern Optics, 35 (6), 993, 1988; Ojha S., Simple method of fabricating polarization-insensitive and very low crosstalk AWG grating devices, Electron. Lett., 34 (1), 78, 1998; Johnson C., Thermal annealing of waveguides formed by ion implantation of silica-on-Si, Nuclear Instruments and Methods in Physics Research, B141, 670, 1998; Ridder R., Silicon oxynitride planar waveguiding structures for application in optical communication, IEEE J. of Sel. Top. In Quantum Electron., 4 (6), 930, 1998; Germann R., Silicon-oxynitride layers for optical waveguide applications, 195 th meeting of the Electrochemical Society, 99-1, May 1999, Abstract 137, 1999; Worhoff K., Plasma enhanced cyhemical vapor deposition silicon oxynitride optimized for application in integrated optics, Sensors and Actuators, 74, 9, 1999; and Offrein B., Wavelength tunable optical add-after-drop filter with flat passband for WDM networks, IEEE Photonics Tech. Lett., 11 (2), 239, 1999. A comparison of these various PECVD techniques is summarised in FIG. 1 which shows the approaches and methods used to modify the ‘delta-n’ between buffer (clad) and core with post-deposition thermal treatment. The various techniques can be grouped into main categories: PECVD using unknown chemicals, unknown chemical reactions and unknown boron (B) and/or phosphorus (P) chemicals and unknown chemical reactions to adjust the ‘delta-n’ (When specified, the post-deposition thermal treatments range from 400 to 1000° C.); PECVD using TEOS and unknown means of adjusting the ‘delta-n’ (The post-deposition thermal treatments are not specified); PECVD using oxidation of SiH 4 with O 2 coupled with silicon ion implantation or adjustment of silicon oxide stoichiometry as means of adjusting the ‘delta-n’ (The post-deposition thermal treatments range from 400 to 1000° C.); PECVD using oxidation of SiH 4 with O 2 coupled with the incorporation of CF 4 (SiH 4 /O 2 /CF 4 flow ratio) as means of adjusting the ‘delta-n’ (When specified, the post-deposition thermal treatments range from 100 to 1000° C.); PECVD using oxidation of SiH 4 with N 2 O coupled with variations of N 2 O concentration (SiH 4 /N 2 O flow ratio) as means of adjusting the silicon oxide stoechiometry and the ‘delta-n’ (The post-deposition thermal treatments range from 400 to 1100° C.); PECVD using oxidation of SiH 4 with N 2 O coupled with variations of N 2 O concentration and with the incorporation of Ar (SiH 4 /N 2 O/Ar flow ratio) as means of adjusting the silicon oxide stoechiometry and the ‘delta-n’ (The post-deposition thermal treatments is 1000° C.); PECVD using oxidation of SiH 4 with N 2 O coupled with the incorporation of NH 3 (SiH 4 /N 2 O/NH 3 flow ratio) to form silicon oxynitrides with various ‘delta-n’ (When specified, the post-deposition thermal treatments range from 700 to 1100° C.); PECVD using oxidation of SiH 4 with N 2 O coupled with the incorporation of NH 3 and Ar (SiH 4 /N 2 O/NH 3 /Ar flow ratio) as to form silicon oxynitrides with various ‘delta-n’ (The post-deposition thermal treatments are not specified); PECVD using oxidation of SiH 4 with N 2 O coupled with the incorporation of NH 3 and N 2 chemicals variation (SiH 4 /N 2 O/NH 3 /N 2 flow ratio) as to form silicon oxynitrides with various ‘delta-n’ (The post-deposition thermal treatments range from 850 to 1150° C.); PECVD using oxidation of SiH 4 with N 2 O and O 2 coupled with the incorporation of CF 4 , N 2 and He (SiH 4 /(N 2 O/N 2 )/O 2 /CF 4 flow ratio) as to form complex mixtures of carbon and fluorine containing silicon oxide as means of adjusting the ‘delta-n’ (The post-deposition thermal treatments is 425° C.). Our co-pending U.S. patent application Ser. No. 09/833,711 entitled ‘Optical Quality Silica Films’ describes an improved Plasma Enhanced Chemical Vapour Deposition technique for silica films which shows that the independent control of the SiH 4 , N 2 O and N 2 gases as well as of the total deposition pressure via an automatic control of the pumping speed of the vacuum pump in a five-dimensional space consisting of a first independent variable, the SiH 4 flow; a second independent variable, the N 2 O flow; a third independent variable, the N 2 flow; a fourth independent variable; the total deposition pressure (controlled by an automatic adjustment of the pumping speed); and the observed film characteristics; permits the elimination of the undesirable residual Si:N—H oscillators (observed as a FTIR peak centered at 3380 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm), SiN—H oscillators (centered at 3420 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) and SiO—H oscillators (centered at 3510 cm −1 and whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) after thermal treatment at a low post-deposition temperature of 800° C. to provide improved silica films with reduced optical absorption in the 1.55 μm wavelength (and/or 1.30 μm wavelength) optical region. Another co-pending U.S. patent application Ser. No. 09/867,662 entitled ‘Method of Depositing Optical Films” describes a new improved Plasma Enhanced Chemical Vapour Deposition technique of silica waveguides which shows that the independent control of the SiH 4 , N 2 O, N 2 and PH 3 gases as well as of the total deposition pressure via an automatic control of the pumping speed of the vacuum pump in a six-dimensional space, namely a first independent variable, the SiH 4 flow; a second independent variable, the N 2 O flow; a third independent variable, the N 2 flow; a fourth independent variable, the PH 3 flow; a fifth independent variable; the total deposition pressure (controlled by an automatic adjustment of the pumping speed); and the observed waveguides characteristics, is key to achieving the required ‘delta-n’ while still eliminating the undesirable residual Si:N—H oscillators (observed as a FTIR peak centered at 3380 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm), SiN—H oscillators (centered at 3420 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) and SiO—H oscillators (centered at 3510 cm −1 and whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) after thermal treatment at a low post-deposition temperature of 800° C. as to provide improved silica waveguides with reduced optical absorption in the 1.55 μm wavelength (and/or 1.30 wavelength) optical region. While these techniques are capable of producing optical quality films, they can result in stress-induced mechanical problems for deep-etched optical components. SUMMARY OF THE INVENTION According to the present invention there is provided a method of depositing an optical quality silica film by PECVD (Plasma Enhanced Chemical Vapor Deposition), comprising independently setting a predetermined flow rate for a raw material gas; independently setting a predetermined flow rate for an oxidation gas; independently setting a predetermined flow rate for a carrier gas; independently setting a predetermined total deposition pressure; and applying a post deposition heat treatment to the deposited film at a temperature selected to optimize the mechanical properties without affecting the optical properties of the deposited film. In a preferred embodiment flow rate for a dopant gas is also independently set. The observed FTIR characteristics of the deposited film are monitored to determine the optimum post deposition heat treatment temperature. This technique permits the required ‘delta-n’ to be achieved while eliminating the undesirable residual Si:N—H oscillators (observed as a FTIR peak centered at 3380 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm), SiN—H oscillators (centered at 3420 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) and SiO—H oscillators (centered at 3510 cm −1 and whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) after an optimised thermal treatment in a nitrogen. The technique can provide improved silica-based optical elements with reduced optical absorption in the 1.55 μm wavelength (and/or 1.30 μm wavelength) optical region without the residual stress-induced mechanical problems of deep-etched optical elements (mechanical movement of side-walls), without the residual stress-induced mechanical problems at the buffer/core or core/cladding interfaces (micro-structural defects, micro-voiding and separation) and without the residual stress-induced optical problems (polarisation dependant power loss). BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which: FIG. 1 is a comparison table showing various PECVD approaches for controlling the refractive index and reducing the optical absorption of silica films; FIG. 2 shows the FTIR fundamental infrared absorption peaks and their corresponding higher harmonics peaks associated with the residual compounds resulting from high temperature thermal treatments of PECVD silica-based optical components in a nitrogen ambient; FIG. 3 a shows the basic FTIR spectra of various buffers (claddings) obtained with a typical PECVD process after a 180 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 3 b shows the basic FTIR spectra of various buffers (claddings) obtained with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/833,711 and after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 3 c shows the basic FTIR spectra of various cores obtained at 2.60 Torr with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/799,4091 and after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 3 d shows the basic FTIR spectra of various cores obtained with the PECVD deposition technique in accordance with the principles of the invention and after a 30 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 4 a shows the in-depth FTIR spectra from 810 to 1000 cm −1 of various buffers (clads) obtained with a typical PECVD process after a 180 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 4 b shows the in-depth FTIR spectra from 810 to 1000 cm −1 of various buffers (clads) obtained with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/833,711 titled after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 4 c shows the in-depth FTIR spectra from 810 to 1000 cm −1 of various cores obtained at 2.60 Torr with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/799,491 after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 4 d shows the in-depth FTIR spectra from 810 to 1000 cm −1 of various cores obtained with the new PECVD deposition technique after a 30 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 5 c shows the in-depth FTIR spectra from 1260 to 1500 cm −1 of various cores obtained at 2.60 Torr with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/799,491 after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 5 d shows the in-depth FTIR spectra from 1260 to 1500 cm −1 of various cores obtained with the new PECVD deposition technique after a 30 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 6 a shows the in-depth FTIR spectra from 1500 to 1600 cm −1 of various buffers (claddings) obtained with a typical PECVD process after a 180 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 6 b shows the in-depth FTIR spectra from 1500 to 1600 cm −1 of various buffers (claddings) obtained with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/833,711 after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 6 c shows the in-depth FTIR spectra from 1500 to 1600 cm −1 of various cores obtained at 2.60 Torr with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/799,491 after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 6 d shows the in-depth FTIR spectra from 1500 to 1600 cm −1 of various cores obtained with the new PECVD deposition technique after a 30 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 7 a shows the in-depth FTIR spectra from 1700 to 2200 cm −1 of various buffers (claddings) obtained with a typical PECVD process after a 180 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 7 b shows the in-depth FTIR spectra from 1700 to 2200 cm −1 of various buffers (claddings) obtained with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/833,711 after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 7 c shows the in-depth FTIR spectra from 1700 to 2200 cm −1 of various cores obtained at 2.60 Torr with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/799,491 after a thermal treatment in a nitrogen ambient at 800° C; FIG. 7 d shows the in-depth FTIR spectra from 1700 to 2200 cm −1 of various cores obtained with the new PECVD deposition technique after a 30 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 8 a shows the in-depth FTIR spectra from 2200 to 2400 cm −1 of various buffers (cladding) obtained with a typical PECVD process after a 180 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 8 b shows the in-depth FTIR spectra from 2200 to 2400 cm −1 of various buffers (claddings) obtained with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/833,711 after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 8 c shows the in-depth FTIR spectra from 2200 to 2400 cm −1 of various cores obtained at 2.60 Torr with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/799,491 after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 8 d shows the in-depth FTIR spectra from 2200 to 2400 cm −1 of various cores obtained with the new PECVD deposition technique after a 30 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 9 a shows the in-depth FTIR spectra from 3200 to 3900 cm −1 of various buffers (claddings) obtained with a typical PECVD process after a 180 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 9 b shows the in-depth FTIR spectra from 3200 to 3900 cm −1 of various buffers (claddings) obtained with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/833,711 after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 9 c shows the in-depth FTIR spectra from 3200 to 3900 cm −1 of various cores obtained at 2.60 Torr with the PECVD deposition technique described in our co-pending U.S. patent application Ser. No. 09/799,491 after a thermal treatment in a nitrogen ambient at 800° C.; FIG. 9 d shows the in-depth FTIR spectra from 3200 to 3900 cm −1 of various cores obtained with the new PECVD deposition technique after a 30 minutes thermal treatment in a nitrogen ambient at various temperatures; FIG. 10 shows the stress hysteresis of buffer (cladding) and core in a nitrogen ambient using a 180 minutes stabilization at 800° C.; FIG. 11 is SEM pictures of a grating and of a waveguide with quasi-vertical side-walls deep-etched through buffer and core; FIG. 12 shows the gradually sloped side-wall formation from the elastic strain of deep-etched buffer/core optical elements resulting from the (compressive stress buffer)/(tensile stress core) combination; FIG. 13 shows side-wall angle measurements of neighboring 5.0 μm wide deep-etched waveguide and a 1150 μm wide deep-etched grating; FIGS. 13 a and 13 b show the relative position between an isolated 5.0 μm wide deep-etched waveguide and its neighboring 1150 μm wide deep-etched grating at two different magnifications; FIG. 13 c shows the sidewall of the 5.0 μm wide deep-etched waveguide facing the neighboring grating has a slope of about 90°; FIG. 13 d shows the side-wall of the 1150 μm wide deep-etched grating facing the neighboring deep-etched waveguide has a much smaller slope of about 84°; FIG. 14 shows how the interfacial stress relief of the shear stress building at the buffer/core or core/clading interfaces results in a noticeable modification of the micro-structure of these interfaces; FIG. 15 shows how the interfacial stress relief of the shear stress building at the buffer/core or core/cladding interfaces results in an important modification of the micro-structure and in the formation of micro-voids in the core and near these interfaces; FIG. 16 shows the stress relief contraction of the tensile stress core during SEM preparation; FIG. 17 shows the effect of the incidence angle of infrared light at the air/core interface on the reflection and transmission of infrared optical power (case where the infrared light is incoming from the air side of the side-wall of core a waveguide, a grating or of an another optical element); and FIG. 18 shows the effect of the incidence angle of infrared light at the air/core interface on the reflection and transmission of infrared optical power (case where the infrared light is incoming from the core side of the side-wall of core a waveguide, a grating or of an another optical element). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention can be implemented to create PECVD optical quality silica-based optical elements using a commercially available PECVD system, the “Concept One” system manufactured by Novellus Systems in California, USA, and a standard diffusion tube. FIG. 2 lists some FTIR fundamental infrared absorption peaks and their corresponding higher harmonics peaks associated with the various residual compounds resulting the Plasma Enhanced Chemical Vapour Deposition (PECVD) of buffer (cladding) from a silane (SiH 4 ) and nitrous oxide (N 2 O) gas mixture at a relatively low temperature of 400° C. using the following reaction: SiH 4 ( g )+2N 2 O( g )→SiO 2 +2N 2 ( g )+2H 2 ( g ) and following high temperature thermal treatments in a nitrogen ambient. It will be seen that the FTIR fundamental infrared absorption peaks and their corresponding higher harmonics peaks associated of the residual compounds resulting from high temperature thermal treatments of PECVD silica films in a nitrogen ambient will contribute to the optical absorption in the 1.30 to 1.55 μm optical bands. The second vibration harmonics of the HO—H oscillators in trapped water vapour in the micro-pores of the silica films (3550 to 3750 cm −1 ) increase the optical absorption near 1.333 to 1.408 μm. The second vibration harmonics of the SiO—H oscillators in the silica films (3470 to 3550 cm −1 ) increases the optical absorption near 1.408 to 1.441 μm. The second vibration harmonics of the Si:N—H oscillators in the silica films (3300 to 3460 cm −1 ) increases the optical absorption near 1.445 to 1.515 μm. The second vibration harmonics of the SiN—H oscillators in the silica films (3380 to 3460 cm −1 ) increases the optical absorption near 1.445 to 1.479 μm. The third vibration harmonics of the Si—H oscillators in the silica films (2210 to 2310 cm −1 ) increases the optical absorption near 1.443 to 1.505 μm. The fourth vibration harmonics of the Si═O oscillators in the silica films (1800 to 1950 cm −1 ) increases the optical absorption near 1.282 to 1.389 μm. The fifth vibration harmonics of the N═N oscillators in the silica films (1530 to 1580 cm −1 ) increases the optical absorption near 1.266 to 1.307 μm. The negative effects of these the oscillators on the optical properties of silica-based optical components are reported in the literature. See, for example, Grand G., Low-loss PECVD silica channel waveguides for optical communications, Electron. Lett., 26 (25), 2135, 1990; Bruno F., Plasma-enhanced chemical vapor deposition of low-loss SiON optical waveguides at 1.5-μm wavelength, Applied Optics, 30 (31), 4560, 1991; Imoto K., High refractive index difference and low loss optical waveguide fabricated by low temperature processes, Electronic Letters, 29 (12), 1993; Hoffmann M., Low temperature, nitrogen doped waveguides on silicon with small core dimensions fabricated by PECVD/RIE, ECIO'95, 299, 1995; Bazylenko M., Pure and fluorine-doped silica films deposited in a hollow cathode reactor for integrated optic applications, J. Vac. Sci. Technol. A 14 (2), 336, 1996; Pereyra I., High quality low temperature DPECVD silicon dioxide, J. Non-Crystalline Solids, 212, 225, 1997; Kenyon T., A luminescence study of silicon-rich silica and rare-earth doped silicon-rich silica, Electrochem. Soc. Proc. Vol. 97-11, 304, 1997; Alayo M., Thick SiOxNy and SiO2 films obtained by PECVD technique at low temperatures, Thin Solid Films, 332, 40, 1998. Germann R., Silicon-oxynitride layers for optical waveguide applications, 195 th meeting of the Electrochemical Society, 99-1, May 1999, Abstract 137, 1999; Worhoff K., Plasma enhanced chemical vapor deposition silicon oxynitride optimized for application in integrated optics, Sensors and Actuators, 74, 9, 1999. This literature describes the tentative elimination of optical absorption (i.e. of the six residual oscillators) using thermal decomposition reactions during thermal treatments under a nitrogen ambient at a maximum temperature lower than 1350° C., the fusion point of the silicon wafer. Comparative Examples Optical absorption of typical PECVD buffer (cladding) following a 180 minutes thermal treatment in a nitrogen ambient at various high temperatures FIG. 3 a , FIG. 4 a , FIG. 6 a , FIG. 7 a , FIG. 8 a and FIG. 9 a show the FTIR spectra of typically deposited PECVD silica films before and after a 180 minutes long high temperature thermal treatment in a nitrogen ambient at a temperature of either 600, 700, 800, 900, 1000 or 1100° C. It can be seen that the higher the thermal decomposition temperature of the high temperature thermal treatment in a nitrogen ambient, the better the basic FTIR spectra of the treated silica films. FIG. 3 a shows the expected gradually more intense and smaller FWHM Si—O—Si “rocking mode” absorption peak (centred at 460 cm −1 ) and Si—O—Si “in-phase-stretching mode” absorption peak (centred at 1080 cm −1 ) as the temperature of the 180 minutes long thermal treatment in a nitrogen ambient is increased from 600° C. to 1100° C. FIG. 4 a shows that the elimination of the Si—OH oscillators (centered at 885 cm −1 ) is easy and already complete after the 180 minutes long thermal treatment in a nitrogen ambient at 600° C. FIG. 4 a also shows that the elimination of the Si—ON oscillators (centred at 950 cm −1 ) is much more difficult and that the higher the temperature of the 180 minutes long thermal treatment in a nitrogen ambient, the more nitrogen incorporation as Si—ON oscillators (i.e. as SiONH and/or SiON 2 compounds). FIG. 6 a shows that the elimination of the N═N oscillators (centered at 1555 cm −1 ) is also very difficult and does require the temperature of the high temperature thermal treatment in a nitrogen ambient to reach 1000° C. FIG. 7 a shows that there is very little influence of the temperature of the high temperature thermal treatment in a nitrogen ambient on the Si═O oscillators (centered at 1875 cm −1 ) and on the unknown oscillator (centered at 2010 cm −1 ). FIG. 8 a shows that the elimination of the Si-H oscillators (centered at 2260 cm −1 and whose 3 rd harmonics could cause an optical absorption between 1.443 and 1.508 μm) is easy and already complete after the 180 minutes long thermal treatment in a nitrogen ambient at 600° C. FIG. 9 a shows that the elimination of the Si:N—H oscillators (centered at 3380 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm) is also very difficult and does require the temperature of the high temperature thermal treatment in a nitrogen ambient to reach 1100° C. The complete elimination of the Si:N—H oscillators is extremely difficult because the nitrogen atoms of these oscillators are bonded to the silicon atoms of the SiO 2 network via two covalent bonds. FIG. 9 a also shows that the elimination of the SiN—H oscillators (centered at 3420 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) is almost as difficult and does require the temperature of the high temperature thermal treatment in a nitrogen ambient to reach 1000° C. FIG. 9 a also shows that the elimination of the SiO—H oscillators (centered at 3510 cm −1 and whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) is slightly easier and does require the temperature of the high temperature thermal treatment in a nitrogen ambient to reach 900° C. Finally, FIG. 9 a also shows that the elimination of the HO—H oscillators (centered at 3650 cm −1 and whose 2 nd harmonics could cause an optical absorption between 1.333 and 1.408 μm) is very easy since already complete after the high temperature thermal treatment in a nitrogen ambient of only 600° C. It is apparent from the various FTIR spectra that it is necessary to use extremely high temperature thermal treatments in a nitrogen ambient in order to eliminate the residual optical absorption of typically deposited PECVD silica films. In particular, it is demonstrated that the elimination of the residual nitrogen and hydrogen of typically deposited PECVD silica films is very difficult since the residual Si:N—H oscillators (whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm) requires a temperature of 1100° C. because the nitrogen atoms of these oscillators are bonded to the silicon atoms of the SiO 2 network via two covalent bonds, the elimination of the SiN—H oscillators (whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) requires a temperature of 1000° C., and the elimination of the SiO—H oscillators (whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) requires a temperature of 900° C. It is very difficult to achieve high optical quality silica-based optical components from typically deposited PECVD silica films using thermal treatments in nitrogen ambient at temperatures lower than 1100° C. Our co-pending U.S. patent application Ser. No. 09/833,711 describes an improved Plasma Enhanced Chemical Vapour Deposition technique for silica films which involves the independent control of the SiH 4 , N 2 O and N 2 gases as well as of the total deposition pressure via an automatic control of the pumping speed of the vacuum pump in a five-dimensional space. The first independent variable, the SiH 4 gas flow, is fixed at 0.20 std liter/min. The second independent variable, the N 2 O gas flow, is fixed at 6.00 std liter/min. The third independent variable, the N 2 gas flow, being fixed at 3.15 std liter/min. The fourth independent variable, the total deposition pressure, being varied between of 2.00 Torr, 2.10 Torr, 2.20 Torr, 2.30 Torr, 2.40 Torr, 2.50 Torr, and 2.60 Torr. The fifth dimension is the observed FTIR characteristics of various buffers (claddings), as reported in FIG. 3 b , FIG. 4 b , FIG. 6 b , FIG. 7 b , FIG. 8 b and FIG. 9 b. The five-dimensional space permits the elimination of these residual nitrogen and hydrogen atoms as to achieve high optical quality silica-based optical components from typically deposited PECVD silica films a 180 minutes thermal treatment in a nitrogen ambient at a reduced temperature of 800° C. FIG. 3 b , FIG. 4 b , FIG. 6 b , FIG. 7 b , FIG. 8 b and FIG. 9 b show the FTIR spectra of PECVD silica films deposited using a commercially available PECVD system, the “Concept One” system manufactured by Novellus Systems in California, USA, using the fixed flow rates of silane (SiH 4 ), of nitrous oxide (N 2 O) and of nitrogen (N 2 O), as described in this co-pending U.S. patent application Ser. No. 09/833,711. These spectra are obtained before and after a 180 minutes thermal treatment in a nitrogen ambient at a reduced temperature of 800° C. in a standard diffusion tube. It is clear that the technique described in our co-pending application allows the attainment of high optical quality silica films after a 180 minutes thermal treatment in a nitrogen ambient at a reduced temperature of 800° C. and that the independent control of the downstream pressure of this improved PECVD deposition technique has a major effect on the FTIR spectra of the treated silica films: FIG. 3 b shows a more intense and smaller FWHM Si—O—Si “rocking mode” absorption peak (centred at 460 cm −1 ) and Si—O—Si “in-phase-stretching mode” absorption peak (centred at 1080 cm −1 ) as the total deposition pressure is increased from 2.00 Torr to 2.40 Torr followed by a slight degradation as the pressure is increased further more up to 2.60 Torr; FIG. 4 b shows the gradual elimination of the Si—OH oscillators (centered at 885 cm −1 ) as the total deposition pressure is increased from 2.00 Torr up to the optimum pressure of 2.40 Torr followed by a slight degradation as the pressure is increased further more up to 2.60 Torr. FIG. 4 b also shows the gradual elimination of the Si—ON oscillators (centred at 950 cm −1 ) as the total deposition pressure is increased from 2.00 Torr to 2.40 Torr followed by a slight degradation as the pressure is increased further more up to 2.60 Torr. The optimum separation and deep valley observed at 2.40 Torr is an indication that the silica films resulting from this optimum deposition pressure are composed of high quality SiO 2 material. This contrasts with the upper-mentioned results of typical PECVD silica films which still incorporate a lot of Si—ON oscillators even after much higher temperature thermal treatments in a nitrogen ambient; FIG. 6 b shows the gradual and total elimination of the N═N oscillators (centered at 1555 cm −1 ) as the total deposition pressure is increased from 2.00 Torr to 2.60 Torr. This also contrasts with the upper-mentioned results of typical PECVD silica films which require a 180 minutes thermal treatment in a nitrogen ambient at a temperature of 1000° C. in order to achieve similar results; FIG. 7 b shows the gradual elimination of the Si═O oscillators (centered at 1875 cm −1 ) and on the unknown oscillator (centered at 2010 cm −1 ) as the total deposition pressure is increased from 2.00 Torr to 2.40 Torr followed by a slight degradation as the pressure is increased further more up to 2.60 Torr. These effects are not that important since only the fourth harmonics of the Si═O oscillators could absorb in the 1.30 to 1.55 μm optical bands; FIG. 8 b shows that the Si—H oscillators (centered at 2260 cm −1 which 3 rd harmonics could cause an optical absorption between 1.443 and 1.508 μm) are completely eliminated for all deposition pressures; FIG. 9 b shows the spectacular gradual elimination of the Si:N—H oscillators (centered at 3380 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm) as the total deposition pressure is increased from 2.00 Torr to 2.60 Torr. This contrasts with the upper-mentioned results of typical PECVD silica films which require a thermal treatment in a nitrogen ambient at a temperature of 1100° C. in order to achieve similar results. FIG. 9 b also shows a spectacular gradual elimination of the SiN—H oscillators (centered at 3420 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) as the total deposition pressure is increased from 2.00 Torr to 2.60 Torr. This also contrasts with the upper-mentioned results of typical PECVD silica films which require a thermal treatment in a nitrogen ambient at a temperature of 1000° C. in order to achieve similar results. FIG. 9 b also shows that the SiO—H oscillators (centered at 3510 cm −1 and whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) are completely eliminated for all deposition pressures. This also contrasts with the upper-mentioned results of typical PECVD silica films which require a thermal treatment in a nitrogen ambient at a temperature of 900° C. in order to achieve similar results. Finally, FIG. 9 b also shows that the elimination of the HO—H oscillators (centered at 3650 cm −1 and whose 2 nd harmonics could cause an optical absorption between 1.333 and 1.408 μm) are completely eliminated for all deposition pressures. It is apparent from the various FTIR spectra that our co-pending U.S. patent application Ser. No. 09/833,711 prohibits the use of extremely high temperature thermal treatments in a nitrogen ambient in order to eliminate the residual optical absorption of typically deposited PECVD silica films. In particular, it is demonstrated that the elimination of the residual nitrogen and hydrogen of typically deposited PECVD silica films is completely achieved after a 180 minutes thermal treatment in a nitrogen ambient at a reduced temperature of 800° C. The residual Si:N—H oscillators (whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm) are completely eliminated as the total deposition pressure is increased from 2.00 Torr to 2.60 Torr. The residual SiN—H oscillators (whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) are also completely eliminated as the total deposition pressure is increased from 2.00 Torr to 2.60 Torr. The residual SiO—H oscillators (whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) are also completely eliminated as the total deposition pressure is increased from 2.00 Torr to 2.60 Torr. It is then very easy to achieve high optical quality silica films after a 180 minutes thermal treatment in a nitrogen ambient at a reduced temperature of 800° C. using the technique described in our co-pending U.S. patent application Ser. No. 09/833,711. Our co-pending U.S. patent application Ser. No. 09/799,491 shows the spectacular effect of a fifth independent variable, the phosphine, PH 3 gas flow, on the optimization of the optical properties of the various buffer (cladding) and core waveguides in a six-dimensional space. The first independent variable, the SiH 4 gas flow, is fixed at 0.20 std liter/mi. The second independent variable, the N 2 O gas flow, is fixed at 6.00 std liter/min. The third independent variable, the N 2 gas flow, is fixed at 3.15 std liter/min. The fourth independent variable, the PH 3 gas flow, is varied between 0.00 std liter/min, 0.12 std liter/min; 0.25 std liter/min; 0.35 std liter/min; 0.50 std liter/min; and 0.65 std liter/min. The fifth independent variable, the total deposition pressure, is fixed at 2.60 Torr The sixth dimension is the observed FTIR characteristics of various buffer (cladding) and core waveguides, as reported in: FIG. 3 c , FIG. 4 c , FIG. 5 c , FIG. 6 c , FIG. 7 c , FIG. 8 c , & FIG. 9 c. FIG. 3 c , FIG. 4 c , FIG. 5 c , FIG. 6 c , FIG. 7 c , FIG. 8 c and FIG. 9 c show the FTIR spectra of PECVD silica films deposited using a commercially available PECVD system, the “Concept One” system manufactured by Novellus Systems in California, USA, using the fixed optimum total deposition pressure and the fixed flow rates of silane (SiH 4 ), of nitrous oxide (N 2 O) and of nitrogen (N 2 O), as described in our co-pending U.S. patent application Ser. No. 09/799,491. These spectra are obtained after a high temperature thermal treatment for 180 minutes in a nitrogen ambient at a fixed temperature of only 800° C in a standard diffusion tube. It is clear that the technique described in our co-pending patent application allows the achievement of high optical quality silica waveguides after a 180 minutes thermal treatment in a nitrogen ambient at a reduced temperature of 800° C.: FIG. 3 c shows that the intense and small FWHM Si—O—Si “rocking mode” absorption peak (centred at 460 cm −1 ) and Si—O—Si “in-phase-stretching mode” absorption peak (centred at 1080 cm −1 ) of the fixed deposition pressure of 2.60 Torr of FIG. 3 b is maintained in FIG. 3 c as the PH 3 flow rate is gradually increased from 0.00 std liter/min to 0.65 std liter/min. This means that at a fixed deposition pressure of 2.60 Torr, the control of the PH 3 gas flow independently of the SiH 4 gas flow, of the N 2 O gas flow and of the N 2 gas flow has no effect on the basic FTIR spectra of the treated silica films; FIG. 4 c shows that an even more gradual elimination of the Si—OH oscillators (centered at 885 cm −1 ) is observed at the total deposition pressure of 2.60 Torr as the PH 3 flow rate is increased from 0.00 std liter/min to 0.65 std liter/min. FIG. 4 c also shows that a gradual elimination of the Si—ON oscillators (centred at 950 cm −1 ) is also observed at the total deposition pressure of 2.60 Torr as the PH 3 flow rate is increased from 0.00 std liter/min up to the optimum 0.25 std liter/min followed by a very slight degradation as the PH 3 flow rate is increased further more up to 0.65 std liter/min. This spectacular improved elimination of the residual Si—ON oscillators after a 180 minutes thermal treatment of only 800° C. contrasts with the upper-mentioned results of typical PECVD silica films of FIG. 4 a which still incorporate a lot of Si—ON oscillators even after a thermal treatment in a nitrogen ambient at a much higher temperature of 1100° C. This also contrasts with the upper-mentioned results of PECVD buffer (cladding) deposited at a non-optimized pressure of less than 2.40 Torr as described in our co-pending U.S. patent application Ser. No. 09/833,711 of FIG. 4 b which still incorporate a large number of Si—ON oscillators even after a 180 minutes thermal treatment in a nitrogen ambient at a much higher temperature of 800° C. The optimum separation and deep valley between the Si—O—Si “in-phase-stretching mode” absorption peak (1080 cm −1 ) and the Si—O—Si “bending mode” absorption peak (810 cm −1 ) of the fixed deposition pressure of 2.60 Torr of FIG. 4 b is maintained and in fact slightly improved as the PH 3 flow rate is gradually increased from 0.00 std liter/min to 0.35 std liter/min. FIG. 5 c shows that a gradual appearance of the P═O oscillators (centered at 1330 cm −1 and which does not have a higher harmonics which could cause optical absorption in the 1.30 to 1.55 μm optical bands) is observed at the total deposition pressure of 2.60 Torr as the PH 3 flow rate is increased from 0.00 std liter/min to 0.65 std liter/min. This FTIR absorption peak is used to calibrate the phosphorus incorporation in core. FIG. 6 c shows that of the N═N oscillators (centered at 1555 cm −1 ) are completely eliminated at the total deposition pressure of 2.60 Torr for all PH 3 flow rate values from 0.00 std liter/min to 0.65 std liter/min. This contrasts with the upper-mentioned results of typical PECVD silica films of FIG. 6 a which require a 180 minutes thermal treatment in a nitrogen ambient at a temperature of 1000° C. in order to achieve similar results. This also contrasts with the upper-mentioned results of PECVD buffer (cladding) deposited at a non-optimized pressure of less than 2.40 Torr by our co-pending U.S. patent application Ser. No. 09/833,711' of FIG. 6 b which still incorporate a large number of N═N oscillators even after a 180 minutes thermal treatment in a nitrogen ambient at a much higher temperature of 800° C. FIG. 7 c shows that the Si═O oscillators (centered at 1875 cm −1 ) and the unknown oscillator (centered at 2010 cm −1 ) at the total deposition pressure of 2.60 Torr are not influenced by the PH 3 flow rate from 0.00 std liter/min to 0.65 std liter/min. These effects are not that important since only the fourth harmonics of the Si═O oscillators could absorb in the 1.30 to 1.55 μm optical bands; FIG. 8 c shows that the Si—H oscillators (centered at 2260 cm −1 and which third harmonics could cause an optical absorption between 1.443 and 1.508 μm) at the total deposition pressure of 2.60 Torr are still completely eliminated by any of all PH 3 flow rates from 0.00 std liter/min to 0.65 std liter/min. FIG. 9 c shows that the complete elimination of the Si:N—H oscillators (centered at 3380 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm) at the total deposition pressure of 2.60 Torr is maintained for all PH 3 flow rates from 0.00 std liter/min to 0.65 std liter/min. This contrasts with the upper-mentioned results of typical PECVD silica films which require a thermal treatment in a nitrogen ambient at a temperature of 1100° C. in order to achieve similar results. This also contrasts with the upper-mentioned results of PECVD buffer (cladding) deposited at a non-optimized pressure of less than 2.40 Torr by our co-pending U.S. patent application Ser. No. 09/833,711 of FIG. 9 b which still incorporate a lot of Si:N—H oscillators even after a 180 minutes thermal treatment in a nitrogen ambient at a much higher temperature of 800° C. FIG. 9 c also shows that the a spectacular complete elimination of the SiN—H oscillators (centered at 3420 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) at the total deposition pressure of 2.60 Torr is also maintained for all PH 3 flow rates from 0.00 std liter/min to 0.65 std liter/min. This contrasts with the upper-mentioned results of typical PECVD silica films which require a thermal treatment in a nitrogen ambient at a temperature of 1000° C. in order to achieve similar results. This also contrasts with the upper-mentioned results of PECVD buffer (cladding) deposited at a non-optimized pressure of less than 2.40 Torr by our co-pending U.S. patent application Ser. No. 09/833,711 of FIG. 9 b which still incorporate a lot of SiN—H oscillators even after a 180 minutes thermal treatment in a nitrogen ambient at a much higher temperature of 800° C. FIG. 9 c also shows that the complete elimination of the SiO—H oscillators (centered at 3510 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) at the total deposition pressure of 2.60 Torr is maintained for all PH 3 flow rates from 0.00 std liter/min to 0.65 std liter/min. This contrasts with the upper-mentioned results of typical PECVD silica films which require a thermal treatment in a nitrogen ambient at a temperature of 900° C. in order to achieve similar results. Finally, FIG. 9 c also shows that the complete elimination of the HO—H oscillators (centered at 3650 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.333 and 1.408 μm) at the total deposition pressure of 2.60 Torr is maintained for all PH 3 flow rates from 0.00 std liter/min to 0.65 std liter/min. It is clear from the various FTIR spectra that our co-pending U.S. patent application Ser. No. 09/799,491 allows the use of various PH 3 flow rates from 0.00 std liter/min to 0.65 std liter/min. to achieve the required ‘delta-n’ after a 180 minutes thermal treatment in a nitrogen ambient at a reduced temperature of 800° C. while maintaining excellent optical quality. However, with this 180 minutes thermal treatment in a nitrogen ambient at a reduced temperature of 800° C. are associated some residual stress-induced mechanical problems of deep-etched optical elements (mechanical movement of the side-walls), some residual stress-induced mechanical problems at the buffer/core interface or at the core/cladding interface (micro-structural defects, micro-voiding and separation) and some residual stress-induced optical problems (polarisation dependant power loss). FIG. 10 shows the stress hysteresis in a nitrogen ambient of buffer (cladding) and core during the heating of the silicon wafer from room temperature to 800° C., during its stabilization for 180 minutes at 800° C. and during its natural cooling from 800° C. to room temperature. FIG. 10 shows that the mechanical stress of buffer (cladding) is compressive at about −250 MPa prior to the stress hysteresis cycle; is compressive throughout the complete stress hysteresis cycle; decreases almost linearly as the temperature increases linearly; an expected situation since the (almost constant) coefficient of linear expansion of silica-based buffer (cladding) is smaller than the one of the underlying silicon; and shows three plastic deformation regions during the stress hysteresis cycle, namely Region B 1 , from 450° C. to 575° C., where it decreases much faster than what is expected from a linear decrease associated with its elastic deformation; Region B 2 , from 575° C. to 650° C., where it is almost constant; and Region B 3 , during the 180 minutes stabilization at 800° C., where it decreases as the temperature remains unchanged. The mechanical stress of buffer (cladding) is also compressive at about −150 MPa after the stress hysteresis cycle. In addition FIG. 10 shows that the mechanical stress of core is tensile at about 175 MPa prior to the stress hysteresis cycle; is tensile throughout the complete stress hysteresis cycle; and increases almost linearly as the temperature increases linearly. This is an expected situation since the (almost constant) coefficient of linear expansion of silica-based core is smaller than the one of the underlying silicon. FIG. 10 also shows two plastic deformation regions during the stress hysteresis cycle, namely Region C 1 , from 450° C. to 675° C., where the stress reverses its trends and in fact decreases as the temperature is increasing; and Region C 2 , from 675° C. to 800° C., where it is almost constant. The stress is tensile at about 40 MPa after the stress hysteresis cycle. FIG. 10 shows that the optical elements of the device are to be prepared from a (compressive stress buffer)/(tensile stress core) combination bi-layer after a thermal treatment for 180 minutes in a nitrogen ambient at a reduced temperature of 800° C. To this particular combination are associated some residual stress-induced mechanical problems of deep-etched optical elements (mechanical movement of side-walls), some residual stress-induced mechanical problems at the buffer/core or core/cladding interfaces (micro-structural defects, micro-voiding and separation) and some residual stress-induced optical problems (polarisation dependant power loss). Optical elements, such as gratings or waveguides, require deep-etched (compressive stress buffer)/(tensile stress core) with vertical side-walls and with a seamless buffer/core interface. FIG. 11 shows SEM pictures of a grating and a waveguide with deep-etched vertical side-walls and with a seamless buffer/core interface deep-etched through buffer and core. FIG. 12 shows a stress-relief mechanism involving the elastic strain of such a deep-etched (compressive stress buffer)/(tensile stress core) optical element. From this sequence of three graphical representations, it is clear that such a (compressive stress buffer)/(tensile stress core) deep-etched optical element will systematically result in a positively sloped elastic strain of the optical element's side-wall. This stress-relieve mechanism shows that the lateral strain of the compressive stress buffer forces the deep-etched side-wall of buffer to move outward; and the lateral strain of the tensile stress core forces the deep-etched side-wall of core to move inward. This combination of strains will systematically result in deep-etched (compressive stress buffer)/(tensile stress core) optical elements with a positive slope side-wall, i.e. a side-wall with an angle smaller than 90°. To estimate the amplitude of this effect, consider the hypothetical of zero bonding at the buffer/(silicon wafer) interface, of zero bonding at the buffer/core interface, and of zero bonding at the buffer/core interface. The outward elastic strain of the side-wall of the compressive stress buffer, ε B , and the inward elastic strain of the side-wall of the tensile stress core, ε C , would simply be: ε B =σ B /E B ; ε C =σ C /E C where σ B and E B are respectively the mechanical stress and the modulus of elasticity of buffer and where σ C and E C are respectively the mechanical stress and the modulus of elasticity of core. The modulus of elasticity of silica thin films measured by micro-indentation and measured by electrostatic membrane deflection are respectively reported as 70 GPa and 69 GPa in the following two references: Thin Solid Films, Vol. 283, p. 15, (1996); IEEE Transactions on Electron Devices, Vol. ED25, No.10, p.1249, (1978). To the −150 MPa compressive stress of buffer and 40 MPa tensile stress of core reported in FIG. 10 at room temperature would then be associated a strain of about −0.21% (−0.15 GPa/70GPa) for buffer and of about 0.057% (0.040 GPa/70 GPa) for core. The negative sign indicates that the strain is outward. This means that the buffer portion of a 5.0 μm wide deep-etched waveguide not bonded to the underlying silicon wafer and not bonded to the core portion of the same deep-etched waveguide would laterally expand by about 0.011 μm (0.21% of 5 μm) and that the buffer portion of a 1150 μm wide deep-etched grating not bonded to the underlying silicon wafer and not bonded to the core portion of the same deep-etched grating would laterally expand by about 2.46 μm (0.21% of 1150 μm). Similarly the core portion of the 5.0 μm wide deep-etched waveguide not bonded to the underlying buffer portion of the same deep-etched waveguide would laterally expand by about 0.0029 μm (0.057% of 5 μm) and that the core portion of a 1150 μm wide deep-etched grating not bonded to the underlying buffer portion of the same deep-etched grating would laterally expand by about 0.66 μm (0.057% of 1150 μm). In reality, since the buffer is bonded to the underlying silicon wafer and to the upper core at the buffer/core interface, the effect of the outward strain of buffer and of the inward strain of core would be observed as a noticeably different sloped side-wall for a narrow waveguide and for a wide grating. If we assume a 2.0 μm deep-etched buffer and a 5.0 μm deep-etch core than the single-sided strain of the upper core surface of the 5.0 μm wide deep-etched waveguide and of the 1150 μm wide deep-etched grating could be as high as 0.0070 μm (50% of (0.011+0.0029 μm)) and 1.56 μm (50% of (2.46+0.66 μm)) respectively with respect to the bottom of the resulting 7.0 μm deep-etch optical element. The expected 89.9° (90°-arctan(0.0070 μm/7.0 μm)) side-wall slope of the deep-etched waveguide would not be noticeable on a SEM picture but the expected 77.4° (90°-arctan (1.56 μm/7.0μm)) side-wall slope of the deep-etched grating would certainly be easy to see on a SEM picture. FIG. 13 shows four SEM pictures. The first two SEM pictures show the relative position between an isolated 5.0 μm wide deep-etched waveguide and its neighboring 1150 μm wide deep-etched grating at two different magnifications. The third SEM picture confirms that side-wall of the 5.0 μm wide deep-etched waveguide facing the neighboring grating has a slope of about 90°. The fourth SEM picture confirms that side-wall of the 1150 μm wide deep-etched grating facing the neighboring deep-etched waveguide has a much smaller slope of about 84°, slightly larger than the expected 77.4° slope. The difference between the measured and expected values will be discussed below. The mechanical stress of buffer and core must be minimized as to maintain the ideal verticality of the side-wall of the waveguides, of the grating and of the other integrated optical elements of the optical device and allow minimum power loss from undesirable reflection and refraction of the infrared optical beams at the side-wall of these optical elements. FIG. 14 shows a graphical representation of the variable intensity shear stress building at the (compressive stress buffer)/(tensile stress core) interface and at the (tensile stress core)/(compressive stress clad) interface during the stress hysteresis cycle of FIG. 10 and during the various thermal treatments in a nitrogen ambient. If the bonding of the buffer/core interface or of the core/cladding interface is strong enough, the exposure of the various optical elements to the various thermal treatments in a nitrogen ambient can result in a modification of the micro-structure near these interfaces. FIG. 14 also shows some SEM pictures demonstrating the induced modification of the microstructure of core near these buffer/core and core/cladding interfaces. FIG. 15 shows a graphical representation of the variable intensity shear stress building at the (compressive stress buffer)/(tensile stress core) interface and at the (tensile stress core)/(compressive stress clad) interface during the stress hysteresis cycle of FIG. 10 and during the various thermal treatments in a nitrogen ambient. In this case, the intensity of the shear stress is such that it results in the formation of micro-voids in core and near the interfaces as an interfacial stress relief mechanism. These micro-voids are delineated during wafer preparation for SEM using a very light acid dip etch before loading in the electronic microscope. If the bonding of the buffer/core interface or of the core/clad interface is strong enough, the exposure of the various optical elements to the various thermal treatments in a nitrogen ambient can result in such a modification of the micro-structure near these interfaces that micro-voids are forming in core and near these interfaces. FIG. 15 also shows some SEM pictures demonstrating that the induced modification of the microstructure of core near these buffer/core and core/cladding interfaces is cause the formation of micro-voids. It is clear on these SEM pictures that the micro-voids are generated and aligned horizontally in a plane about 0.5 μm away from the buffer/bore interface. This is not that surprising since the transition from the (compressive stress buffer) to the (tensile stress core) is not absolutely abrupt at the interface and since micro-voids cannot form in a material under compressive stress. FIG. 16 shows some SEM pictures which demonstrate the stress relief of the variable intensity shear stress building at the (compressive stress buffer)/(tensile stress core) interface and at the (tensile stress core)/(compressive stress cladding) interface during the stress hysteresis cycle of FIG. 10, during the various thermal treatments in a nitrogen ambient or simply during wafer cleavage for SEM pictures. In this case, the bonding of the buffer/core interface (or core/cladding interface) is no longer strong enough and the core partially slips on the buffer at the buffer/core interface (or cladding partially delaminate from core at the core/cladding interface). In one particular case, the interface separation is only observed between core and buffer, indicating that core contraction is the root cause of the delamination. The second SEM picture of FIG. 16 shows the contraction of the 1150 μm wide grating. It is clear from this picture that a portion of core has slipped aside over buffer and over a distance of about 0.40 μm at the periphery of the grating. This is in line with the upper calculated contraction of 0.66 μm. The slip is again initiated from a point located at the tip of the seam of the cladding and slightly away from the buffer/core interface from which a crack did propagate horizontally in core and about 0.5 μm away from the buffer/core interface. Since a crack cannot propagate in a material under compressive stress, this crack propagation did require core to be in tensile stress. Since the transition from the compressive stress buffer to the tensile stress core is not absolutely abrupt at the interface, it is normal to see the crack initiation slightly away from the buffer/core interface. The tensile stress-relief mechanism of core has partially releases its energy by propagating a 0.40 μm long crack in the core and by allowing its side-wall to slip by 0.40 μm. This lateral of core explains the difference between the observed 84° of FIG. 13 and the expected 77° from the upper calculation of the expected side-wall slope. FIG. 17 and FIG. 18 are re-plots from J. A. Stratton, ‘Electromagnetic Theory’, Chapter 9, McGraw-Hill Book Company, New York, 1941. FIG. 17 and FIG. 18 show the associated optical effect of the incidence angle of infrared light at the air/core interface on the reflection and transmission of infrared optical power (case where the infrared light is incoming respectively from the air side and from the core side of the side-wall of core a waveguide, a grating or of an another optical element). It is clear from FIG. 17 and FIG. 18 that a stress-induced variation of the side-wall slope from 90° to 87°, 84° or to the expected 77° will have a catastrophic effect on the loss of transmitted power of infrared light respectively propagating in Air or in core into the air/core interface of the tip of a waveguide, into the Air/core interface of the grating or into the air/core interface of other optical elements. It is clear from FIG. 17 and FIG. 18 that this stress-induced loss of power will be different for the two propagating modes states of light (i.e. TE and TM) and thus that an undesirable polarization dependent power loss effect (i.e. birefringence effect) is expected. It will be observed therefore that the mechanical stresses of core, buffer and cladding play a key role in the side-wall slope of deep-etched optical elements. It is also clearly demonstrated that the thermal treatment for 180 minutes in a nitrogen ambient at a reduced temperature of 800° C. is associated with some residual stress-induced mechanical problems of deep-etched optical elements (mechanical movement of side-walls), and some residual stress-induced mechanical problems at the buffer/core or core/cladding interfaces (micro-structural defects, micro-voiding and separation) and some residual stress-induced optical problems (polarisation dependant power loss). An optimisation of the thermal treatments which allows the optical properties to be maintained while modifying the mechanical stress of the core is very important in the manufacture of such integrated optical elements. EXAMPLE The technique in accordance with the preferred embodiment of the invention allows the simultaneous optimization of the optical and of the mechanical properties of buffer (cladding) and core in a seven-dimensional space. This consists of a first independent variable, the SiH 4 flow, fixed at 0.20 std liter/min; a second independent variable, the N 2 O flow, fixed at 6.00 std liter/min; a third independent variable, the N 2 flow, fixed at 3.15 std liter/min; a fourth independent variable, the PH 3 flow, fixed at 0.50 std liter/min; a fifth independent variable, the total deposition pressure, fixed at 2.60 Torr; and a sixth independent variable, the post-deposition thermal treatment being varied as follows: 30 minutes duration thermal treatment in a nitrogen ambient at 600° C.; 30 minutes duration thermal treatment in a nitrogen ambient at 700° C.; 30 minutes duration thermal treatment in a nitrogen ambient at 750° C.; 30 minutes duration thermal treatment in a nitrogen ambient at 800° C.; 30 minutes duration thermal treatment in a nitrogen ambient at 850° C.; 30 minutes duration thermal treatment in a nitrogen ambient at 900° C. A seventh dimension is the observed FTIR characteristics of various buffer (cladding) and core silica-based optical elements, as reported in: FIG. 3 d , FIG. 4 d , FIG. 5 d , FIG. 6 d , FIG. 7 d , FIG. 8 d , & FIG. 9 d: FIG. 3 d , FIG. 4 d , FIG. 5 d , FIG. 6 d , FIG. 7 d , FIG. 8 d and FIG. 9 d show the FTIR spectra of PECVD silica films deposited using a commercially available PECVD system, the “Concept One” system manufactured by Novellus Systems in California, USA, using the fixed optimum total deposition pressure and the fixed flow rates of silane (SiH 4 ), of nitrous oxide (N 2 O), of nitrogen (N 2 ), and of phosphine (PH 3 ) as described in our co-pending U.S. patent application Ser. No. 09/799,491. These spectra are obtained after 30 minutes thermal treatments in a nitrogen ambient at various temperatures in a standard diffusion tube. The present invention permits the thermal treatment of the buffer, core and cladding to be optimized so as to minimize mechanical stress induced in the silica-based optical elements without affecting their optical properties. FIG. 3 d shows that the intense and small FWHM Si—O—Si “rocking mode” absorption peak (centred at 460 cm −1 ) and Si—O—Si “in-phase-stretching mode” absorption peak (centred at 1080 cm −1 ) of the fixed deposition pressure of 2.60 Torr of FIG. 3 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 3 c is maintained as the temperature of the 30 minutes thermal treatments in a nitrogen ambient is gradually decreased from 900° C. to 600° C. This means that independently of the SiH 4 gas flow of the N 2 O gas flow of the N 2 gas flow and of the PH 3 gas flow and as long as the deposition pressure is fixed to 2.60 Torr, the basic FTIR spectra of silica-based optical components are not affected by the temperature variation (between 600° C. and 900° C.) of the 30 minutes thermal treatment in a nitrogen ambient; FIG. 4 d shows that the elimination of the Si—OH oscillators (centered at 885 cm −1 ) of the fixed deposition pressure of 2.60 Torr of FIG. 4 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 4 c is maintained. FIG. 4 d also shows that the elimination of the Si—ON oscillators (centred at 950 cm −1 ) of the fixed deposition pressure of 2.60 Torr of FIG. 4 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 4 c is also maintained. This very spectacular improved elimination of the residual Si—ON oscillators after a 30 minutes thermal treatment of only 600° C. contrasts with the upper-mentioned results of typical PECVD silica films of FIG. 4 a which still incorporate a lot of Si—ON oscillators even after a 180 minutes thermal treatment in a nitrogen ambient at a much higher temperature of 1100 ° C. This also contrasts with the upper-mentioned results of PECVD buffer (cladding) deposited at a non-optimized pressure of less than 2.40 Torr by our co-pending U.S. patent application Ser. No. 09/833,711 of FIG. 4 b which still incorporate a large number of Si—ON oscillators even after a 180 minutes thermal treatment in a nitrogen ambient at a much higher temperature of 800° C. The optimum separation and deep valley between the Si—O—Si “in-phase-stretching mode” absorption peak (1080 cm −1 ) and the Si—O—Si “bending mode” absorption peak (810 cm −1 ) of the fixed deposition pressure of 2.60 Torr of FIG. 4 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 4 c is also maintained. This means that this new technique allows the elimination of the Si—OH oscillators and of the the Si—ON oscillators independently of the thermal treatment of buffer, core and cladding as to allow the thermal treatment optimization of the mechanical properties of the silica-based optical elements without any interaction with the Si—OH oscillators and of the the Si—ON oscillators of these optical elements. FIG. 5 d shows the gradual appearance of the P═O oscillators (centered at 1330 cm −1 and which does not have a higher harmonics which could cause optical absorption in the 1.30 to 1.55 μm optical bands) as the temperature of the 30 minutes thermal treatment in a nitrogen ambient is increased from 600° C. to 900° C. FIG. 6 d shows that the elimination of the N═N oscillators (centered at 1555 cm −1 ) of the fixed deposition pressure of 2.60 Torr of FIG. 6 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 6 c is maintained. This also contrasts with the upper-mentioned results of typical PECVD silica films of FIG. 6 a which require a 180 minutes thermal treatment in a nitrogen ambient at a temperature of 1000° C. in order to achieve similar results. This also contrasts with the upper-mentioned results of PECVD buffer (cladding) deposited at a non-optimized pressure of less than 2.40 Torr in our co-pending U.S. patent application Ser. No. 09/833,711 of FIG. 6 b which still incorporate a large number of N═N oscillators even after a 180 minutes thermal treatment in a nitrogen ambient at a much higher temperature of 800° C. This means that this new technique allows the elimination of the N═N oscillators independently of the thermal treatment of buffer, core and cladding as to allow the thermal treatment optimization of the mechanical properties of the silica-based optical elements without any interaction with the N═N oscillators of these optical elements. FIG. 7 d shows that the Si═O oscillators (centered at 1875 cm −1 ) and the unknown oscillator (centered at 2010 cm −1 ) of the fixed deposition pressure of 2.60 Torr of FIG. 7 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 7 c are unchanged. These effects are not that important since only the fourth harmonics of the Si═O oscillators could absorb in the 1.30 to 1.55 μm optical bands; FIG. 8 d shows that the elimination of the Si—H oscillators (centered at 2260 cm −1 and which third harmonics could cause an optical absorption between 1.443 and 1.508 μm) of the fixed deposition pressure of 2.60 Torr of FIG. 8 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 8 c is maintained. This means that this new technique allows the elimination of the Si—H oscillators independently of the thermal treatment of buffer, core and cladding as to allow the thermal treatment optimization of the mechanical properties of the silica-based optical elements without any interaction with the Si—H oscillators of these optical elements. FIG. 9 d shows that the spectacular complete elimination of the Si:N—H oscillators (centered at 3380 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm) of the fixed deposition pressure of 2.60 Torr of FIG. 9 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 9 c is maintained. This contrasts with the upper-mentioned results of typical PECVD silica films of FIG. 9 a which require a 180 minutes thermal treatment in a nitrogen ambient at a temperature of 1100° C. in order to achieve similar results. This also contrasts with the upper-mentioned results of PECVD buffer (cladding) deposited at a non-optimized pressure of less than 2.40 Torr in our co-pending U.S. patent application Ser. No. 09/833,711 of FIG. 9 b which still incorporate a lot of Si:N—H oscillators even after a 180 minutes thermal treatment in a nitrogen ambient at a much higher temperature of 800° C. FIG. 9 d shows that the a spectacular complete elimination of the SiN—H oscillators (centered at 3420 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) of the fixed deposition pressure of 2.60 Torr of FIG. 9 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 9 c is also maintained. This contrasts with the upper-mentioned results of typical PECVD silica films of FIG. 9 a which require a thermal treatment in a nitrogen ambient at a temperature of 1000° C. in order to achieve similar results. This also contrasts with the upper-mentioned results of PECVD buffer (cladding) deposited at a non-optimized pressure of less than 2.40 Torr in our co-pending U.S. patent application Ser. No. 09/833,711 of FIG. 9 b which still incorporate a large number of Si:N—H oscillators even after a 180 minutes thermal treatment in a nitrogen ambient at a much higher temperature of 800° C. FIG. 9 d also shows that the complete elimination of the SiO—H oscillators (centered at 3510 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) of the fixed deposition pressure of 2.60 Torr of FIG. 9 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 9 c is maintained. This contrasts with the upper-mentioned results of typical PECVD silica films which require a thermal treatment in a nitrogen ambient at a temperature of 900° C. in order to achieve similar results. Finally, FIG. 9 d also shows that the complete elimination of the HO—H oscillators (centered at 3650 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.333 and 1.408 μm) of the fixed deposition pressure of 2.60 Torr of FIG. 9 b and of the fixed PH 3 flow rate of 0.50 std liter/min of the FIG. 9 c is maintained. This means that this new technique allows the elimination of the Si:N—H oscillators, of the SiN—H oscillators, of the SiO—H oscillators and of the HO—H oscillators independently of the thermal treatment of buffer, core and cladding as to allow the thermal treatment optimization of the mechanical properties of the silica-based optical elements without any interaction with the Si:N—H oscillators, with the SiN—H oscillators, with the SiO—H oscillators or with the HO—H oscillators of these optical elements. It is clear from these various FTIR spectra that this new technique allows the elimination of the various thermally-induced and stress-related residual mechanical problems by the optimisation of the thermal treatment (i.e. the use of the Regions B 1 , B 2 , B 3 , C 1 and C 2 of the stress hysteresis of FIG. 10) without affecting the optical absorption properties of optical elements in the 1.55 μm wavelength (and/or 1.30 wavelength) optical region. It is then clear from these various FTIR spectra, from the stress hysteresis of buffer, core and cladding and from the various presented SEM pictures that this new technique is key to achieving the required ‘delta-n’ while eliminating the undesirable residual Si:N—H oscillators (observed as a FTIR peak centered at 3380 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.515 μm), SiN—H oscillators (centered at 3420 cm −1 whose 2 nd harmonics could cause an optical absorption between 1.445 and 1.479 μm) and SiO—H oscillators (centered at 3510 cm −1 and whose 2 nd harmonics could cause an optical absorption between 1.408 and 1.441 μm) after an optimised thermal treatment in a nitrogen ambient which can provide improved silica-based optical elements with reduced optical absorption in the 1.55 μm wavelength (and/or 1.30 wavelength) optical region without the residual stress-induced mechanical problems of deep-etched optical elements (mechanical movement of side-walls), without the residual stress-induced mechanical problems at the buffer/core or core/cladding interfaces (micro-structural defects, micro-voiding and separation) and without the residual stress-induced optical problems (polarisation dependant power loss). It will be apparent to one skilled in the art that many variations of the invention are possible. The PECVD silica films could be deposited at a temperature different than 400° C. It could be deposited at any temperature between 100 and 650° C. The PECVD equipment could be different than the Novellus Concept One. The requirement is to provide independent control of the four basic control parameters: SiH 4 gas flow rate, N 2 O gas flow rate, N 2 gas flow rate and total deposition pressure. The buffer (cladding) local optimum (SiH 4 gas flow of 0.20 std liter/min, N 2 O gas flow of 6.00 std liter/min, N 2 gas flow of 3.15 std liter/min and a total deposition pressure of 2.60 Torr) is this four-independent-variables space could have a different set of coordinates (SiH 4 , N 2 O, N 2 , deposition pressure) using the same Novellus Concept One equipment. The buffer (cladding) local optimum could have a different set of coordinates (SiH 4 , N 2 O, N 2 , deposition pressure) in another PECVD equipment. The core local optimum (SiH 4 gas flow of 0.20 std liter/min, N 2 O gas flow of 6.00 std liter/min, N 2 gas flow of 3.15 std liter/min, PH 3 gas flow of 0.57 std liter/min, and a total deposition pressure of 2.60 Torr) is this five-independent-variables space could have a different set of coordinates (SiH 4 , N 2 O, N 2 , PH 3 , deposition pressure) using the same Novellus Concept One equipment. The core local optimum could have a different set of coordinates (SiH 4 , N 2 O, N 2 , PH 3 , deposition pressure) in another PECVD equipment. The ‘delta-n’ could be different than 0.015 and range between 0.005 and 0.020. The SiH 4 silicon raw material gas could be replaced by an alternate silicon containing gas, such as: silicon tetra-chloride, SiCl 4 , silicon tetra-fluoride, SiF 4 , disilane, Si 2 H 6 , dichloro-silane, SiH 2 Cl 2 , chloro-fluoro-silane SiCl 2 F 2 , difluoro-silane, SiH 2 F 2 or any other silicon containing gases involving the use of hydrogen, H, chlorine, Cl, fluorine, F, bromine, Br, and iodine, I. The N 2 O oxidation gas could be replaced by an alternate oxygen containing gas, such as: oxygen, O 2 , nitric oxide, NO 2 , water, H 2 O, hydrogen peroxide, H 2 O 2 , carbon monoxide, CO or carbon dioxide, CO 2 . The N 2 carrier gas could be replaced by an alternate carrier gas, such as: helium, He, neon, Ne, argon, Ar or krypton, Kr. The PH 3 doping gas could be replaced by an alternate gas, such as: diborane, B 2 H 6 , Arsine (AsH 3 ), Titanium hydride, TiH 4 or germane, GeH 4 , Silicon Tetrafluoride, SiF 4 of carbon tetrafluoride, CF 4 . The high temperature thermal treatment in nitrogen can be performed at a temperature different than 800° C. The preferred range is from 400 to 1200° C. The high temperature thermal treatment can be performed in a different ambient than nitrogen. Other ambient gases or mixtures of gases may include oxygen, O 2 , hydrogen, H 2 , water vapour, H 2 O, argon, Ar, fluorine, F 2 , carbon tetrafluoride, CF 4 , nitrogen trifluoride, NF 3 , hydrogen peroxide, H 2 O 2 . The optical region of interest is not limited to the 1.30 to 1.55 μm optical region since the higher oscillation harmonics of the eliminated oscillators have other optical benefits at longer or shorter wavelengths. The wavelengths of the first, second, third and fourth harmonics of these oscillators are to be covered by this patent. The invention has application in may devices other than Mux or Dmux devices. The following is a list of suitable devices, which is not intended to be exhaustive: Add-After-Drop Filters (AADF) devices; Arrayed Wave Guide (AWG) and Arrayed Wave Guide Grating (AWGG) devices; thermal Arrayed Wave Guide (AAWGG) devices; Charged Coupled Devices (CCD) devices; Distributed Feedback Laser Diode (DFB-LD) devices; Erbium Doped Fiber Amplifier (EDFA) devices; Fiber-To-The-Home (FTTH) application devices; Four Wave Mixing (FWM) devices; Fresnel Mirror (FM) devices; Laser Diode (LD) devices; Light Emitting Diodes (LED) devices; Mach-Zenhder (MZ), Mach-Zenhder Interferometer (MZI), Mach-Zenhder Interferometer Multiplexer (MZIM) devices; Micro-Opto-Electro-Mechanical Systems (MOEMS) devices; Monitor Photo Diode (MPD) devices; Multi-Wavelength Optical Sources (MWOS) devices; Optical Add/Drop Multiplexers (OADM) devices; Optical Amplifier (AF) devices; Optical Cross-Connect (OCC, OXC) devices; Optical Cross Point (OCP) devices; Optical Filter (OF) devices; Optical Interferometer (OI) devices; Optical Network Unit (ONU) devices; Optical Saw Wave (OSW) devices; Optical Splitter (OS) devices; Optical Switch (OSW) and Optical Switch Module (OSM) devices; Photonic ATM (PATM) switching devices; Planar Lightwave Circuits (PLC) devices; Positive Emitter Coupled Logic (PECL) devices; Quarter Wave (QW) devices; Receiver Photo Diode (RPD) devices; Semiconductor Optical Amplifier (SOA) devices; Spot-Size converter integrated Laser Diode (SS-LD) devices; Sub-Carrier Multiplexing Optical Network Unit (SCM-ONU) devices; Temperature Insensitive Arrayed Wave Guide (TI-AWG) devices; Thermo-Optic (TO) devices and Thermo-Optic Switch (TOS) devices; Time Compression Multiplexing—Time Division Multiple Access (TCM-TDMA) devices; Time Division Multiplexing (TDM) devices; Tunable Receiver (TR) devices; Uniform-Loss Cyclic-Frequency Arrayed Wave Guide (ULCF-AWG) devices; Vertical Cavity Surface Emitting Laser (VCSEL) devices; Wavelength Dispersive Multiplexing (WDM), Wavelength Dispersive Multiplexing Transceivers (WDMT) devices; Micro-Electro-Mechanical Systems (MEMS) device: Information Technologies MEMS devices; Medical/Biochemical MEMS devices: Biochip devices; Lab-On-A-Chip (LOAC) devices; Micro-Total Analysis System (μ-TAS) devices; Automotive MEMS devices; Industrial/Automation MEMS devices; Environmental Monitoring MEMS devices; Telecommunications MEMS devices. Although the invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example and is not to be taken by way of limitation, the spirit and scope of the invention being limited only by the terms of the appended claims.
A method is disclosed for depositing an optical quality silica film on a wafer by PECVD. The flows rates for a raw material gas, an oxidation gas, a carrier gas, and a dopant gas are first set at predetermined levels. The total deposition pressure is set at a predetermined level. The deposited film is then subjected to a post deposition heat treatment at a temperature selected to optimize the mechanical properties without affecting the optical properties. Finally, the observed FTIR characteristics of the deposited film are monitored to produce a film having the desired optical and mechanical properties. This technique permits the production of high quality optical films with reduced stress.
2
CROSS REFERENCE TO RELATED APPLICATION The present application is based on provisional patent application Ser. No. 60/034,676 filed Jan. 10, 1997. BACKGROUND OF THE INVENTION This invention relates to a modular structure for display and exhibition usage and, in particular to such a structure having ease of assembly and which provides an elevated load-bearing surface. The use of nonpermanent structural assemblies to create bounded work and exhibition spaces is ever increasing due in part to the large number of trade shows and conventions being held each year to stimulate interest in products and services. To attract trade show and convention business to cities, the city must have not only suitable lodging facilities and amenities, but also a large area, exhibition hall or convention center. The large area is typically leased in small parcels to users who define and create a workplace according to their own requirements. Since the space allotted to each exhibitor is relatively expensive, great care is taken to maximize the use of the space. Consequently, the use of modular structures designed for rapid assembly and take down which have an elevated load-bearing surface is quite advantageous since usable floor space can exceed the rented floor space. The primary objectives are to utilize the space efficiently and to provide an attractive appearing place in which to conduct business at a minimum cost for short periods of time. The cost associated with the use of the leased facilities requires that assembly and disassembly of any modular structure be accomplished in a short period of time, normally with unskilled labor. Furthermore, the design and construction of components of a modular structure favor symmetry for both ease of manufacture and assembly as well as providing interchangeability of parts wherever practical. These factors reduce the opportunity for misassembly by unskilled workers. Thus, the components used in a modular structure are preferably of standard design while being sufficiently versatile to accommodate various size constraints based on the task at hand and the work area assigned. In particular, the use of lattice works to provide a three dimensional modular structure capable of assembly at the site requires reliable and easy to operate fittings to join the parts used in the structure. One type of interengaging means used between connected components of a temporary lattice work structure is shown in U.S. Pat. No. 5,483,780 wherein hollow bars are provided with joint fittings that are received in a slotted vertical column. The bars are supported by welded fixtures which are placed on the columns at the appropriate height. The bars which are to serve as the horizontal members of the lattice work are removably inserted into slots or joint fittings in the columns. The structures created by the use of these interengaging means contained in hollow bars have tended to be fairly complex requiring the use of skilled labor to assemble the structure. Consequently, a need has arisen for the use of a smaller modular structure which can be used as a building block to form larger structures if need be. The versatility of the modular structure of the present invention enables an elemental unit to be combined with additional components of the same type and size to form larger structures. The girders used in the present invention for affixation to the vertical columns are designed for receiving both the floor panels of a load-bearing surface and ceiling panels therebelow to provide an attractive display structure. The girders maintain the load-bearing surface and the ceiling panels in spaced relation to provide a utility space therebetween. A utility space provides an opportunity to run wiring throughout the structure without being viewed by the visitor to the display area. As a result, the present invention provides an attractive modular display structure which is extremely versatile and can be assembled and taken down by unskilled labor. SUMMARY OF THE INVENTION The present invention is directed to a modular structure having an elevated load-bearing surface which utilizes three vertical columns spaced in a triangular pattern. The triangular pattern includes a right angle which is bounded by first and second girders of equal length. Each girder has a top surface with an inner sidewall and an outer sidewall depending therefrom. A third girder having a length greater than the length of the first and second girders serves as the hypotenuse of the right triangle. This girder has an identical cross-section with the first and second girders so that it has a top surface with an inner sidewall and an outer sidewall depending therefrom. The girders are affixed to the vertical columns by interengaging means which permit removable attachment. A triangular floor member is supported on the three girders for providing the elevated load-bearing surface. The girder is provided with support means located on at least the inner sidewall of each of the first, second and third girders. The triangular floor member preferably includes in the elemental or basic unit, two identical triangular panels with each panel having a right angle corner. The triangular floor panels are interchangeable and are placed on the first support means to form the elevated load-bearing surface. A second support means is provided on the inner sidewall on each of the first, second and third girders. The second support means is spaced beneath the first support means for receiving and maintaining a ceiling member in position spaced beneath the triangular floor member. A utility space is provided between the floor member and the ceiling member for receiving and distributing utility services. The columns used receive interengaging means in slots formed in the columns to establish a secure horizontal joining of girder to column. If the attachment is made to a vertical slotted column, means are used to establish the desired height of the load-bearing surface. Typically, a stop is welded to the column and establishes the height of the resultant structure. Alternatively, the column can be provided with holes to receive a support peg. The girder used in the present invention is formed of first and second hollow rectangular beams with each beam having opposing ends with a longitudinal axis extending therebetween. Each of the ends is dimensioned to receive the particular interengaging means used for that type of column with which it is to be joined. Each beam includes opposing sidewalls and top and bottom members extending therebetween. The beams are joined by attachment means, either a single web secured to the bottom walls of the first and second beams or extensions of the sidewalls. A uniform spacing is maintained between the beams along the longitudinal axis. A first flange means is affixed to the first sidewall of the upper or first beam for supporting a load-bearing surface thereon. The first flange means is positioned below the top surface of the girder and extends outwardly from the girder. Also, a second flange means is affixed to the second beam. The first and second flanges are spaced on the girder to provide a utility surface which is located beneath the upper or load-bearing surface of the modular structure. In a preferred embodiment, the first and second flange means each comprise a pair of channel flanges spaced one from the other with retaining flanges affixed to the outer ends thereof. The channel flanges define a retaining structure for the use of other fastening devices. In practice, the spacing of the channel flanges is intended to receive a nut which can be slid along the channel to a desired position and a bolt can be fastened thereto. Other types of fasteners can be utilized if desired. The top member of the first beam and the bottom member of the second beam are made significantly thicker than the sidewalls and opposing member to enhance the load-bearing capability of the girder. In manufacture, the individual beams are extruded of lightweight metal. The web is formed by central extensions welded together. The resultant girder is useful in more than one orientation thereby reducing the complexity of the modular structure. In yet another embodiment, the opposing sidewalls of the first and second beam are provided with third and fourth flange means having similar spacing. As a result, the girder is symmetrical and can be used without regard to orientation. Further features and advantages of the present invention will become more readily apparent from the following description of the preferred embodiment when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view in perspective showing one embodiment of the invention prior to the placement of the floor member. FIG. 2 is a plan view showing the embodiment of FIG. 1 as assembled. FIG. 3 is a partial cross-section view taken along line 3--3 of FIG. 1 showing the vertical column. FIG. 4 is a partial side view of a column and a girder containing a web attached thereto. FIG. 5 is a cross sectional view of the girder taken along line 5--5 of FIG. 4. FIG. 6 is a partial view in perspective showing the end of the girder of FIG. 5. FIG. 7 is a cross sectional view of a second embodiment of a girder; FIG. 8 is a layout of a modular structure utilizing a plurality of triangular modular structures formed in accordance with the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to FIG. 1, the modular assemblage of the present invention is shown partially constructed in accordance with the invention and including three vertical columns 12, 14 and 16 spaced in a triangle pattern. The pattern has a right angle as seen in FIG. 2 bounded by first and second girders 18, 20 respectively. A third and larger girder 22 is the hypotenuse of the triangle so formed and completes the pattern. The structural features of the girders are omitted in FIG. 1 and shown in FIGS. 5-7. As will later be more fully explained, girders 18 and 20 are identical and therefore interchangeable. The third beam is also identical in cross-section to the first and second beams. Thus, the same dies can be used during manufacture of extruded components. The three columns 12, 14 and 16 are identical components and are formed with a plurality of vertical retaining slots. Each column is provided with an end cap 24. The slots are formed with adjacently spaced contoured ends to receive the mating spring-loaded jaws of interengaging means positioned in the hollow ends of the girders. The column contains eight slots spaced about the circumference to permit girders to form angles of 45° with an adjacent girder. As shown in FIG. 3, the interengaging means has a pair of jaws 30 which are dimensioned to conform with the contoured ends 32 adjacent the vertical slot 34. The jaws are laterally movable and are typically biased outwardly by spring means located at the inner end of the pair of jaws. The preferred interengaging means is fully described in U.S. Pat. No. 5,483,780 and is commercially available through the MERO Company. To insure against vertical movement of the girders when coupled to a column, a welded stop 44 is affixed to the column to establish the appropriate height for the girder. Normally, a stop is provided at each vertical slot for a standard height which enables the column to be used in any rotational position during assembly. Alternatively, the column may be provided with an opening in each slot to receive a removable peg and thereby eliminate the welded stops. Each girder is provided with flanges extending outwardly therefrom to receive the load-bearing member shown in FIG. 2 which is comprised of two identically-dimensioned triangular panels 40. The panels are preferably formed of a honeycomb patterned material to reduce weight while providing rigid structural support. Although not shown, railings can be provided between columns if desired by the use of hollow rails containing similar interengaging means for attachment to the columns. The constructional features of a first embodiment of the girder used in the modular structure are shown in FIGS. 4, 5 and 6. The girder is comprised of first and second hollow rectangular beams 50 and 52. A pair of mating angle brackets 54 and 56 are formed on the bottom of beam 50 and the top of beam 52 respectively. The angle brackets are preferably formed as an integral part of an extruded aluminum beam. The angle brackets are welded together as shown in FIGS. 5 and 6 and serve as a web for the unitary girder. The top member of beam 50 and the bottom member of beam 52 are substantially thicker than the sidewalls depending therefrom in order to provide increased strength to the girder. The sidewalls of each beam are provided with a pair of channel flanges 60 having retaining flanges 62 extending inwardly into the channel. Each pair of flanges is spaced below the opposing top and bottom members of the girder by a distance equal to the thickness of the floor member. The pairs of channel flanges serve multiple functions. First, support is provided for the load-bearing surface by the uppermost channel flange 64 and support is provided by channel flange 66 for a ceiling member. Between the surface and the ceiling member (not shown) a utility space is provided to permit the running of utility cables which are then shielded from view. Also, the retaining flanges can be used to receive fasteners, such as hexagonal nuts, to allow other modular structural elements, e.g. racks and shelves, to be attached by threaded fasteners and thereby supported. Since a primary goal of the present invention is to enable the modular triangular structure to be rapidly assembled without having to determine how each part is to be oriented, it is to be noted that the girder of FIG. 5 is symmetrical with interchangeable ends and the columns and floor panels are identical. Thus, the opportunities for errors in placement being made during assembly are substantially reduced. A second embodiment of the girder is shown in FIG. 7 formed as single unit 70 thereby avoiding the welding step used to join the separate extrusions forming the girder in FIG. 5. The girder is symmetrical right to left about a vertical center line and has a uniform cross section so that it can be reversed end for end during construction of the modular structure. The mating angle brackets 54 and 56 of the embodiment of FIG. 5 have been replaced by intermediate side walls 71 and 72. The reinforcing wall 73 extends therebetween for strengthening. The top and bottom members 75 and 76 are substantially thicker than the sidewalls as is the case with the girder of FIG. 5. The sidewalls of the girder 70 each contain the upper and lower pairs of channel flanges as shown in FIG. 5. The channel flanges are provided with retaining flanges extending inwardly into the channel. The top most pair of flanges 80 and 82 are spaced below the top member 75 of the girder by a distance equal to the thickness of the floor member. The bottom pair of flanges 84 and 86 are spaced proximate to the bottom member 76 of the girder to reduce the overall height of the girder thereby providing a girder of reduced weight. The spacing of the pairs of channel flanges as shown provides a utility space between the load bearing surface resting on the top pair of flanges and a ceiling member resting on the bottom pair of flanges. The versatility of the triangular modular structure of the present invention is illustrated in the plan view of FIG. 8 which shows use of additional girders and columns to form a larger modular structure from eight of the triangular structures of FIG. 1. The assembly shown in FIG. 8 is but one of a myriad of assemblies that can be constructed by using additional basic structural units. For example, expansion of the basic triangular module is accomplished by the use of one additional column and two girders to thereby double the size of the assembly. Thus, the present invention is capable of providing any one of a wide number of larger configurations using columns and girders identical in all respects except as to the use of two lengths thereof. While the above description has referred to a specific embodiment of the invention, it is to be noted that modifications and variations may be made therein without departing from the scope of the invention as claimed.
A modular structure for use in displays and exhibitions wherein three girders are affixed to vertical columns in a triangular patter having a right triangle. Triangular floor panels are supported by longitudinal flanges on the beams to provide an elevated load-bearing surface. The structure, girders and floor panels are designed for rapid assembly and take-down.
4
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a photoelectric conversion apparatus, a method for driving the photoelectric conversion apparatus, and an information processing apparatus having the photoelectric conversion apparatus and, more particularly, to a photoelectric conversion apparatus suitably used in X-ray image pickup apparatus, facsimile devices, scanners, and so on, a driving method of the photoelectric conversion apparatus, and an information processing apparatus provided therewith. 2. Related Background Art FIG. 1 is a schematic circuit diagram to show the schematic structure of an example of the photoelectric conversion apparatus. In the figure, each pixel is composed of a photoelectric conversion element (a photodiode P 1 to P 4 in this example) and a thin film transistor (hereinafter abbreviated as TFT) T 1 to T 4 . Numeral 1 denotes a power source connected to the photoelectric conversion elements, for applying the bias voltage thereto. Charges generated in the respective photoelectric conversion elements P 1 to P 4 by incident light are transferred to a reading unit 2 by the thin film transistors (hereinafter called TFTs). The reading unit 2 is normally composed of amplifiers, an analog multiplexer, an A-D converter, a memory, etc. not illustrated. Further, numeral 3 designates a gate drive unit for applying a gate pulse Vg 1 or Vg 2 for control of on/off of the TFTs to the gate electrodes of the TFTs T 1 to T 4 . The gate drive unit 3 is normally comprised of a shift register (not illustrated) or the like. The photoelectric conversion elements P 1 to P 4 and the TFTs T 1 to T 4 are normally made of amorphous silicon materials or the like. FIG. 2 is a timing chart to explain an example of reading operation of the photoelectric conversion apparatus. In the figure “Light” represents the timing of irradiation of light. After photocharges are accumulated in the respective photoelectric conversion elements P 1 to P 4 by the light irradiation, the gate drive unit 3 applies the gate pulse, as indicated by Vg 1 and Vg 2 , to switch the TFTs T 1 , T 3 on and then switch the TFTs T 2 , T 4 on, whereby the charges generated by the light are transferred to the reading unit 2 . The transferred charges are amplified, undergo A-D conversion, and are stored as image signals in the memory in the reading unit 2 , and the signals are outputted to a monitor or the like as occasion may demand. It is, however, commonly known that the performance of TFTs is degraded, that is, the threshold voltage Vth varies during the operation, in cases of TFTs made of the amorphous silicon materials. Particularly, where the photoelectric conversion apparatus is composed of an array of many pixels, variations etc. in production can cause variations in degrees of degradation of the TFTs. There are cases wherein some heavily degraded TFTs fail to transfer the charge successfully, so as to lower the output of pixels, compose defective pixels, and degrade the image quality. In order to correct the variations of output, a potential method employed was to detect the defective pixels caused by the operation, based on a white image obtained under irradiation of light or X-rays or the like. It is, however, difficult to irradiate a large area with uniform light in general, and there were some cases wherein normal pixels were detected as defective pixels because of dust or the like on an illumination system or on the apparatus. As described above, the photoelectric conversion apparatus had the problem of degradation of image quality, where the defective pixels appeared due to the degradation or the like of the TFTs during the operation. Further, the apparatus had another problem that it was considerably hard to accurately detect the defective pixels appearing during the operation per se. SUMMARY OF THE INVENTION The present invention has been accomplished in view of the above problems and an object of the present invention is to provide a photoelectric conversion apparatus, a driving method thereof, and an information processing apparatus provided therewith which permit accurate detection of the defective pixel or the like appearing during the operation of the photoelectric conversion apparatus or due to secular change of TFTs and which permit compensation for the defective pixels, so as to obtain a good image without substantial degradation of image quality. Another object of the present invention is to provide a photoelectric conversion apparatus for reading information by arraying a plurality of pixels, each comprising a photoelectric conversion element and a thin film transistor connected to the element, and applying a voltage to gate electrodes of the thin film transistors to turn the thin film transistors on, the photoelectric conversion apparatus comprising a controllable power source for electrically charging the photoelectric conversion elements by changing a voltage applied to electrodes of the photoelectric conversion elements to which the thin film transistors are not connected, from a first voltage applied during normal reading to a second voltage and applying the second voltage to the electrodes in a dark state, and comparing means for comparing outputs read out of the charged photoelectric conversion elements with a predetermined threshold value to detect a defective pixel, and also to provide an information processing apparatus having the photoelectric conversion apparatus. A further object of the present invention is to provide a method for driving a photoelectric conversion apparatus for reading information by arraying a plurality of pixels, each comprising a photoelectric conversion element and a thin film transistor connected to an output of the element, and applying a voltage to gate electrodes of the thin film transistors to turn the thin film transistors on, the apparatus having a reading mode and a self-diagnosis mode, the driving method comprising steps of electrically charging the photoelectric conversion elements by changing a voltage applied to electrodes of the photoelectric conversion elements to which the thin film transistors are not connected, from a first voltage applied in the reading mode to a second voltage and applying the second voltage to the electrodes in a dark state in the self-diagnosis mode, and comparing outputs read out of the charged photoelectric conversion elements with a predetermined threshold value to detect a defective pixel. The present invention described above achieves the following operation; in the self-diagnosis mode the controllable power source changes and applies the voltage applied to the photoelectric conversion elements in the dark state, thereby charging the photoelectric conversion elements, not optically, but electrically, the charges are read out by the reading means, and the read outputs are compared with the predetermined threshold by the comparing means, so as to permit detection of the defective pixel. Since the means for detecting the defective pixel by self-diagnosis has the function of switching two activity states of the reading mode and the self-diagnosis mode, the self-diagnosis can be performed even after activation of the apparatus by switching the mode into the self-diagnosis mode to find a defect due to a degraded TFT during the normal reading operation. Namely, the self-diagnosis can be performed at will of user or serviceman upon on of the main power supply, or by switching a changing switch. By storing positional information of each defective pixel detected in the memory, the position of the defective pixel can be identified accurately and compensation by compensation means becomes easier. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows schematically a circuit diagram of a substantial structure of an example of a photoelectric conversion apparatus; FIG. 2 shows a timing chart for explaining an example of a reading operation by the photoelectric conversion apparatus; FIG. 3 shows schematically a circuit diagram of an example of a desirable photoelectric conversion apparatus according to the present invention; FIG. 4 shows a timing chart for explaining an example of an operation of the photoelectric conversion apparatus in FIG. 3; FIG. 5A shows schematically a sectional view of an example of a photoelectric conversion element for use in the photoelectric conversion apparatus according to the present invention; FIG. 5B shows schematically an equivalent circuit of one in FIG. 5A; FIG. 6A shows schematically a sectional view of a photoelectric conversion element desirably for use in the photoelectric conversion apparatus according to the present invention; FIG. 6B shows schematically an equivalent circuit of one in FIG. 6A; FIG. 7 shows schematically a circuit diagram of the photoelectric conversion apparatus according to a second embodiment of the present invention; FIG. 8A shows schematically a sectional view of another example of the photoelectric conversion element desirably for use in the photoelectric conversion apparatus of the present invention; FIG. 8B shows schematically an equivalent circuit of one in FIG. 8A; FIG. 9 shows a circuit diagram of photoelectric conversion apparatus according to a third embodiment of the present invention; FIG. 10A shows schematically a structural diagram of an X-ray detecting photoelectric converter to which the present invention is adopted; FIG. 10B shows schematically a sectional view of the X-ray detecting photoelectric converter in FIG. 10A; and FIG. 11 shows an example in which the photoelectric conversion apparatus of the present invention is applied to an X-ray diagnosis system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described in detail by reference to the drawings. <First Embodiment> FIG. 3 is a schematic circuit diagram to show an example of the preferred photoelectric conversion apparatus of the present invention. FIG. 4 is a timing chart to explain an example of the operation. Further, FIG. 5A shows a schematic, sectional view of an example of the photoelectric conversion elements used in the photoelectric conversion apparatus of the present invention, and FIG. 5B a schematic equivalent circuit thereof. The elements having the same functions as those in FIG. 1 are denoted by the same reference symbols. In the present embodiment the photoelectric conversion elements are comprised of pin type photodiodes made of amorphous silicon materials as illustrated in FIG. 5 A. The pin type photodiodes are usually constructed in the structure of a stack of first electrode layer 11 , p-type amorphous silicon layer 12 , amorphous silicon semiconductor layer 13 , n-type amorphous silicon layer 14 , and second electrode layer 15 on glass substrate 10 . The pin type photodiode can be represented by a diode and a capacitor as illustrated in FIG. 5 B. As illustrated in FIG. 3, the second electrode layers 15 of the pin photodiodes illustrated in FIG. 5A are connected in common to a bias line Vs and a controllable power supply 4 applies the bias thereto. The controllable power supply can apply at least two types of voltages Vs 1 , Vs 2 , as described hereinafter. The TFTs (thin film transistors) T 1 to T 4 are TFTs connected to first electrodes of the respective photodiodes P 1 to P 4 and adapted for transferring charges generated in the photodiodes P 1 to P 4 and stored in the capacitors C 1 to C 4 , to the reading unit 2 . The reading unit 2 is composed of amplifiers, an analog multiplexer, an A-D converter, a memory, etc. not illustrated. This reading unit 2 is normally composed of external IC or the like. Further, connected to the gate electrodes of the TFTs T 1 to T 4 is the gate drive unit 2 for applying the gate pulse Vg 1 or Vg 2 for control of on/off of the TFTs. A comparator 5 is also connected to the reading unit 2 to compare the output of the reading unit 2 with a threshold value (a threshold voltage Va in the example of FIG. 3) and write the comparison result in a memory for storage of defective position. The photodiodes and TFTs are normally deposited and formed by the amorphous silicon process or the like. The photoelectric conversion apparatus of the present invention has a reading mode and a self-diagnosis mode in the operation. This can be implemented as follows; the user or the serviceman for carrying out maintenance of the apparatus switches the modes at will by a mode changing switch not illustrated; or the apparatus may be designed to carry out the self-diagnosis mode automatically, for example, with on of the unrepresented main power supply of the apparatus by a logical circuit configuration often used normally, a control program of a microcomputer, or the like, and thereafter turn the mode into the reading mode. As illustrated in FIG. 3, the photoelectric conversion apparatus of the present invention has the reading mode and the self-diagnosis mode in the operation. The reading mode will be described first. The controllable power source 4 is put in the state of the voltage Vs 2 . In this example of the pin photodiodes of the present embodiment, the relation of the voltages Vs 1 and Vs 2 is Vs 1 >Vs 2 and, specifically, Vs 1 =15 V and Vs 2 =10 V, for example. The MIS type or selenium photodiodes in the subsequent embodiments are also charged in the negative even in the relation of Vs 1 <Vs 2 . In this state, the photodiodes are exposed to the light at the timing of on of Light in the figure and charges corresponding to quantities of light are stored in C 1 to C 4 . After that, the gate drive circuit successively applies the gate pulses Vg 1 and Vg 2 to the gate electrodes of the TFTs, whereupon the charges of the respective pixels are transferred to the reading unit 2 . Then the charges are amplified by the amplifiers not illustrated, are multiplexed, are converted into digital signals by the A-D converter, and are stored in the frame memory not illustrated. The digital image signals stored in the frame memory are subjected to offset correction and gain correction as occasion may demand, and are outputted to the monitor or the like. The operation in the self-diagnosis mode will be described next. In this mode, the light (or X-rays) is not radiated (the dark state). First, the controllable power source 4 is put in the state of the voltage Vs 2 . In this state the gate drive circuit applies an optional number of gate pulses to the gate electrodes to perform empty reading to read charges of the photoelectric conversion elements stored because of dark current or the like. In this description the empty reading operation turns the potential on the first electrode side of the photoelectric conversion elements to zero or the ground. The empty reading is effective, particularly, where the dark current is large and where the self-diagnosis of defect is carried out accurately. Then the controllable power source 4 is switched into the state of the voltage Vs 1 while the TFTs are kept off. This turns the potential of the first electrodes of the photoelectric conversion elements or the pin type photodiodes into the equal potential of (Vs 1 -Vs 2 ) for all the photoelectric conversion elements. Namely, the photoelectric conversion elements can be charged electrically. In this state the gate drive circuit applies the gate pulses, whereby the charges electrically charged in the photoelectric conversion elements can be read out. Signals read out here are used for the self-diagnosis of defective pixel. As long as the TFTs are free of degradation, the signal charges transferred to the reading unit are basically constant. However, if the TFTs undergo degradation because of secular change in use or the like, the transferred charges will decrease. Namely, the output becomes small. Therefore, a defect due to degradation of TFT can be detected by comparing the output in the self-diagnosis mode with the threshold by means of the comparator 5 . FIG. 3 is the illustration of the apparatus with an analog comparator, but like function can also be realized with a digital comparator using a memory. Positional information of a pixel determined as a defect because of the output below the threshold is stored in the memory for storage of defect position. The defect position storing memory of FIG. 3 indicates normal pixels by 0 and a defective pixel by 1, and shows a state in which the pixel of P 2 is detected as a defect, as an example. The positional information of the defective pixel can be specified with correspondence between an address of the memory and the position of the pixel, for example, by storing the information of the pixels in the memory in order. Further, the defective pixel is compensated for by interpolation using an average of adjacent pixel outputs by means of a compensation means not illustrated. Such interpolation means can be comprised of a DSP (digital signal processor) for carrying out an arithmetic operation by mutually referencing the data from the frame memory storing the image information and the data from the defect position storing memory. A better image can be obtained by detecting the defect by the self-diagnosis and compensating for the defect as described above. <Second Embodiment> FIG. 6A is a schematic, sectional view of a photoelectric conversion element suitably applicable to the photoelectric conversion apparatus of the present invention and FIG. 6B a schematic equivalent circuit thereof. FIG. 7 is a schematic circuit diagram of the photoelectric conversion apparatus of the second embodiment. In the present embodiment the photoelectric conversion elements are comprised of the MIS type sensors. As illustrated in FIG. 6A, the MIS type sensors of the present embodiment are constructed in the structure of a stack of first electrode layer 11 , amorphous silicon nitride film layer 16 as an insulating layer, amorphous silicon semiconductor layer 13 , n-type amorphous silicon layer 14 , and second electrode layer 15 on glass substrate 10 . As illustrated in the equivalent circuit diagram of FIG. 6B, the photoelectric conversion elements have the capacitance Csin, which is the capacitance of the amorphous silicon nitride film. The circuit diagram illustrated in FIG. 7 is different only in this point from the configuration of the circuit diagram of FIG. 3 described above, and the other structure is the same. The operations of the present embodiment in the reading mode and in the self-diagnosis mode both can be carried out in similar fashion as in the first embodiment illustrated in FIG. 4 . <Third Embodiment> FIG. 8A is a schematic, sectional view of an example of another photoelectric conversion element suitably applicable to the photoelectric conversion apparatus of the present invention and FIG. 8B a diagram to show a schematic equivalent circuit thereof. FIG. 9 is a schematic circuit diagram of the photoelectric conversion apparatus of the third embodiment. In the present embodiment the photoelectric conversion elements are constructed using amorphous selenium as a principal material. As illustrated in FIG. 8A, the photoelectric conversion elements of the present embodiment are constructed in the structure of a stack of third electrode layer 21 , first insulating layer 20 , first electrode layer 11 , charge injection inhibiting layer 19 , amorphous selenium semiconductor layer 18 , second insulating layer 17 , and second electrode layer 15 on glass substrate 10 . Since the amorphous selenium semiconductor layer 18 is sensitive to X-rays, an X-ray image can be obtained directly. As illustrated in the equivalent circuit diagram of FIG. 8B, the present embodiment is different in possession of Cins 1 , Cse, R, and Cins 2 from Embodiment 1, wherein Cins 1 is the capacitance of the first insulating layer, Cse the capacitance of the amorphous selenium semiconductor layer, R the resistance of the amorphous selenium semiconductor, and Cins 2 the capacitance of the second insulating layer. As illustrated in the circuit diagram shown in FIG. 9, the present embodiment is different only in this point from Embodiment 1, and the other structure is the same as in Embodiment 1. The operations of the present embodiment in the reading mode and in the self-diagnosis mode can be carried out in similar fashion as in the first embodiment illustrated in FIG. 4 . The photoelectric conversion apparatus of the present invention described above can replace the conventional photoelectric conversion apparatus to construct the X-ray image pickup apparatus, the facsimile machines, the scanners, or the like and can also detect and correct the defective pixels in the self-diagnosis mode described above in such apparatus. An example of the information processing apparatus will be described briefly using a preferred example of application of the photoelectric conversion apparatus of the present invention to the X-ray image pickup apparatus. FIG. 10 A and FIG. 10B show an X-ray detecting photoelectric converter 6000 which adapts the present invention; FIG. 10A is a schematically structural diagram and FIG. 10B is a schematically sectional view. The photoelectric converting element and the TFT are constituted in plural numbers inside an a-Si sensor substrate 6011 and connected with flexible circuit substrates 6010 on which shift registers SR 1 and integrated circuits IC for detection are mounted. The opposite side of the flexible circuit substrates 6010 are connected with a PCB 1 or a PCB 2 . A plurality of the a-Si sensor substrates 6011 are adhered onto a base 6012 so as to constitute a large-sized photoelectric converter. A lead plate 6013 is mounted under the base 6012 so as to protect memories 6014 in a processing circuit 6018 from X rays. A phosphor 6030 , which is a wavelength conversion element, such as CsI or the like is coated on or adhered to the a-Si sensor substrate 6011 . Further, numeral 6019 denotes a connector. In this embodiment, as shown in FIG. 10B, the whole is packed in a case 6020 made of carbon fiber. FIG. 11 shows an applied example in which the photoelectric converter of the present invention is applied to an X-ray diagnosis system. X rays 6060 emitted from an X-ray tube 6050 are transmitted through the chest 6062 of a patient or an examinee 6061 to be incident to a photoelectric converter 6040 on which a phosphor as a wavelength conversion element has been mounted. The incident X rays include the internal information of the patient. Here, the phosphor emits light in response to the incident X rays and the emitted light is photoelectrically converted to obtain the electric information. The electric information is then converted to be digitalized and an image on the electric information is processed by an image processor 6070 to be able to observe on a display 6080 in a control room. This information can be transferred to a remote place, such as a doctor room located in other place or the like, by way of a transmission means such as a telephone line 6090 and displayed on a display 6081 or stored in a storage means such as an optical disk by recorder 6085 , and this makes it possible to be diagnosed by a doctor in a remote place. Also, this information can be recorded on a film or recording medium as paper 6110 by a film processor or printer 6100 . EFFECT OF THE INVENTION As described above, the present invention permits the user or the serviceman to detect the defective pixel during the operation or with a lapse of time in use at an arbitrary time or on a periodical basis in the simple structure and with high accuracy, even after the apparatus has been mounted on equipment. In addition, the present invention permits the defective pixel with a malfunction to be specified accurately and permits the specifying operation of the defective pixel to be carried out readily by the extremely simple operation and self-diagnosis mode. Further, the present invention permits prevention of the degradation of image quality by properly compensating for the output of the defective pixel.
In order to obtain a good image without degradation of image quality by permitting accurate detection of a defective pixel and further compensation for the defective pixel even with occurrence of the defect originating in TFT during operation, it is made possible to detect the defective pixel by self-diagnosis. The detection is carried out in such a manner that in a dark state the voltage applied to the photoelectric conversion elements is changed from a first voltage in normal reading to a second voltage and outputs read out of the charged photoelectric conversion elements are compared with a predetermined threshold.
7
CROSS REFERENCE TO RELATED APPLICATIONS This application is the US National Stage of International Application No. PCT/EP2010/057197 filed May 26, 2010, and claims the benefit thereof. The International Application claims the benefits of U.S. Provisional Application No. 61/220,669 US filed Jun. 26, 2009. All of the applications are incorporated by reference herein in their entirety. FIELD OF INVENTION The invention relates to a steam power plant that comprises a cooling system, the cooling system comprises a first cooling circuit, a second cooling circuit and a third cooling circuit. The invention also relates to a method of operating a cooling system of such a steam power plant. The invention also relates to a control unit for such a steam power plant. BACKGROUND OF INVENTION In a common steam power plant three cooling circuits are used to perform various cooling operations. A first cooling circuit is often termed “circulating water piping and culvert system” or main cooling circuit, abbreviated “PAB”. It provides the highest cooling power in the power plant. It comprises a condenser and a first pipe system that is split into a hot part and a cold part. The cold part connects a cold-fluid outlet of a cooling tower with an inlet of the condenser. The hot part connects a hot-fluid inlet of the cooling tower with an outlet of the condenser. The cooling tower is used to cool a first cooling fluid. The PAB has at least one first pump, which is often termed circulating water pump or main pump. The first pump is located inside of the cooling tower. When switched on, the first pump pumps a first cooling fluid (water) from the cooling tower through the cold part of the first pipe system, through the condenser where it heats up, through the hot part of the first pipe system and back to the cooling tower. In the condenser the first fluid cools down the condenser. The cooled condenser cools down the hot steam to condense the steam. The hot steam is fed into the condenser after departing from a steam turbine. The steam turbine is driven by the steam and used to drive a generator that generates electricity. A second cooling circuit is often termed “service water piping and culvert system” or auxiliary cooling system, abbreviated “PCB”. It comprises a second pipe system and a heat exchanger. The heat exchanger comprises an inlet and an outlet. Also the second pipe system is split into a cold part and a hot part. The cold part connects the cold-fluid outlet of the cooling tower with the inlet of the heat exchanger. The hot part connects the hot-fluid inlet of the cooling tower with the outlet of the heat exchanger. At its hot part the second pipe system is partly realized by a section of the first pipe system that is connected with the cooling tower. This part is termed “first common pipe section”. Also at its cold part the second pipe system is partly realized by a section of the first pipe system that is connected with the cooling tower. This part is termed “second common pipe system”. The PCB uses the first cooling fluid to cool down the heat exchanger. Only during operation of the first pump the first cooling fluid flows from the cooling tower through the cold part of the second pipe system, the heat exchanger where it heats up and the hot part of the second pipe system back into the cooling tower. Sometimes the second cooling circuit is equipped with a small booster pump located in its cold part but not in the second common pipe section. The booster pump boosts the flow of the first fluid after it branches of from the second common pipe section. The booster pump is necessary if a plate heat exchanger is used. In operation the booster pump increase the pressure in the plate heat exchanger if the pressure drop over the PCB is higher than over the PAB. This ensures a sufficient high flow rate of the first cooling fluid that flows through the plate heat exchanger, which in turn avoids damages of the heat exchanger. The operation of the booster pump is always synchronized with the operation of the first pump. The third cooling circuit is often termed “closed cooling water system” or component cooling system, abbreviated “PGB”. It is a closed cooling circuit that comprises a third pipe system and a number of component coolers that are thermally coupled with components to be cooled. Also the heat exchanger is part of the PGB. The third pipe system connects the heat exchanger with the component coolers. The component coolers are commonly known and a non-compulsory list of such component coolers may comprise: condensate pump coolers, coolers for a HTF-system (including pumps etc.), evacuation pumps coolers (e.g. for the condenser), ST lube oil coolers, generator coolers, feed water pump coolers, sampling coolers, and so on. The PGB also shows a number of closed cooling water pumps to pump a second cooling fluid (water). In the PGB the second cooling fluid is circulated between the heat exchanger and component coolers. In the heat exchanger the first cooling fluid is thermally coupled with the second cooling fluid but physically kept separate from the second cooling fluid. Heat is transferred from the second cooling fluid into the first cooling fluid. A problem of the known steam power plant and the known method is that a proper cooling of the components can only be achieved by the aid of the first pump being in operation. The first pump is a main pump and as such without an operation of the main pump the entire cooling system is out of service. This is of particular disadvantage in case of solar steam power plants that do not have heat storage means for power generation during the night. In general, the power plant does not deliver power during its standby-mode, e.g. night operation. Typically, the solar steam power plant is driven into the standby mode on a daily basis during the night hours. Sometimes, e.g. during winter season, the standby mode is selected even multiple times a day. In contrast to its power-mode operation (power generation operation) it consumes power during the standby-mode because some components must remain in operation in order to rapidly re-start the power-mode in the morning. In addition, although no steam for generating power is produced by solar radiation, a so termed “sealing steam” is generated. In practice, saturated auxiliary steam is produced which is than overheated and becomes sealing steam. The sealing steam is fed into the turbine separately from steam used to produce electricity. From the turbine the sealing steam is at least partly guided into the condenser. Hence, in order to prevent the components and the condenser from damages due to overheating there must be a cooling operation during the standby-mode. The cooling of the components and the condenser requires the main pump to be active. In the cooling system the main pump is one of the largest power consumers and as a consequence the entire power plant shows a relatively low efficiency. A control unit of the plant keeps the main pump switched on during standby-mode. SUMMARY OF INVENTION It is an object of the invention to provide an improved steam power plant, in particular a solar steam power plant, an improved control unit and an improved method of operating a cooling system of a steam power plant, which avoids the problems mentioned above. The object of the invention is achieved by a steam power plant, a control unit and a method of operating a cooling system of a steam power plant according to the claims. According to the invention the steam power plant comprises a cooling system, the cooling system comprises a first cooling circuit, a second cooling circuit and a third cooling circuit, wherein the first cooling circuit comprises a condenser to condense steam and a first pump to pump a first cooling fluid through the condenser in order to cool the condenser, the third cooling circuit is a closed cycle cooling circuit that utilizes a second cooling fluid to cool down at least one component that is different from the condenser, and the second cooling circuit comprises a heat exchanger that thermally couples the first cooling fluid and the second cooling fluid and utilizes the first cooling fluid in the heat exchanger to cool down the second fluid and comprises a second pump to pump the first cooling fluid through the second cooling circuit independently from an operation of the first pump. Accordingly, the control unit for a steam power plant according to the invention is designed to control an operation of a first pump during a power-mode of the plant, the first pump is comprised in a first cooling circuit and is used to pump a first cooling fluid through a condenser of the first cooling circuit in order to cool the condenser, and to switch off the first pump during a standby-mode of the plant and to switch on a second pump during the standby-mode, the second pump is comprised in a second cooling circuit of the plant and is used to pump the first cooling fluid through the second cooling circuit independently from an operation of the first pump, the second cooling circuit comprises a heat exchanger that thermally couples the first cooling fluid and a second cooling fluid of a third cooling circuit and utilizes the first cooling fluid in the heat exchanger to cool down the second fluid, the third cooling circuit is a closed cycle cooling circuit that utilizes the second cooling fluid to cool down at least one component that is different from the condenser. The method according to the invention of operating a cooling system of such a steam power plant comprises the following steps, namely using the first pump during a power-mode, and using a second pump to pump the first cooling fluid through the second cooling circuit during a standby-mode, in which the first pump is stopped. Herein the term “power-mode” shall mean that mode of operation of the steam power plant in which a primary source of energy, e.g. fossil fuels or the sun, causes steam to be produced for driving a turbine in order to generate electrical power. This is sometimes also termed power generation operation or power generation mode. In the power-mode the first (main) cooling circuit is in operation and the first pump is switched on in order to deliver the maximum cooling power to the condenser. The term “standby-mode” shall mean that mode of operation of the steam power plant in which the primary source of energy is not used to cause steam to be produced but some components of the plant still need to be in operation for various reasons, e.g. to allow a rapid re-start of the power-mode. Hence, not the entire plant is put out of operation. Only the power generation is temporary switched off or interrupted for a period. According to the invention, the second pump performs the pumping of the first fluid in its cool state through the second cooling circuit in case of a switched off first pump. But in contrast to the first pump the second pump can be designed to consume much less power when compared with the first pump because also the required cooling power of the second cooling circuit is lower than the cooling power of the first cooling circuit. As a consequence, the steam power plant—in particular if the cooling system is under control of the above mentioned control unit according to the invention—and the method of operating a cooling system of a steam power plant according to the invention realizes a more efficient steam power plant. In detail, the flow of the first fluid in the second cooling circuit is de-coupled from its dependency on the first pump being in operation. In particular, when the power-mode of the steam power plant is shut off, the (main) first cooling circuit for cooling the condenser with a high cooling power is not needed any longer to be in operation. The circulation of the first cooling fluid driven by the first pump can be stopped by shutting off the first pump and consequently the relatively high consumption of electrical power of the first pump does not occur any longer. Although the main pump is shut off, the components will still be cooled by the aid of the second cooling circuit. This is of particular advantage for solar power plants, which do not deliver power during the standby-mode but still require some components to be cooled during the standby-mode. The maintained cooling of components provided by the relatively low power consuming second pump has two advantages. Firstly it increases the overall efficiency of the solar power plant. Secondly, even under shut off condition of the main pump, the solar power plant can be re-started relatively fast during the morning hours because the components can be kept in operation under chilled condition during standby-mode. The control unit controls the state of the pumps, which is switched on or switched off. In particular the control unit distinguishes between the standby-mode and the power-mode in order to set the operation of the first pump and the second pump appropriately. It may also control the pumping power. The control unit may also be connected with all valves in the cooling circuits and adjust the state of the valves (open/closed/semi-open) by control signals which control state-setting-motors of the valves. The control unit may also receive a number of sensor signals from temperature or pressure sensors in order to appropriately adjust, synchronize or de-synchronize the operation of the pumps and to individually switch a pump on while the other pump is switched off and/or to open/close individual valves. Particularly advantageous embodiments and features of the invention are given by the dependent claims and the following description. In particular the method according to the invention may be further developed according to the dependent claims of the steam power plant and advantages elaborated in the context of the device claims do apply as well for the method claims. In the following the term “PAB hot part” shall mean a hot part of the first cooling circuit. It describes that part of the first cooling circuit that is located downstream to the condenser with regard to the flow direction of the first cooling fluid under operation of the first pump and connects the condenser and the cooling tower. “PAB cold part” shall mean a cold part of the first cooling circuit. It describes the other part of the first cooling circuit located upstream to the condenser. Further, the term “PCB hot part” shall mean a hot part of the second cooling circuit. It describes that part of the second and/or the first cooling circuit that is used to guide the first fluid heated up in the heat exchanger from the heat exchanger back into the cooling tower. “PCB cold part” shall mean a cold part of the second cooling circuit. It describes the other part of the second and/or first cooling circuit used to feed the heat exchanger with the first cooling fluid from the cooling tower. According to one aspect of the invention the steam power plant comprises a cooling tower, which is comprised in the first cooling circuit and the second cooling circuit and the second cooling circuit is independently from the first cooling circuit connected at its cold part to the cooling tower. Advantageously this allows to bypass the first cooling circuit at its cold part and to directly feed the second cooling circuit with the first cooling fluid in its cool state. Hence, a decoupling of the cold parts of the second cooling circuit from the first cooling circuit is achieved. According to a first embodiment of invention the second pump is installed inside a water containing part of the cooling tower, e.g. in a so termed pump pit, in which the cold cooling fluid is collected after it was cooled down in the cooling tower. If the second pump is located inside of the cooling tower it can be supported in such a way that it can be located at different levels, or in other words it is submersible. However, once installed at a certain position the second pump remains in the selected position. According to a second embodiment of invention the second pump is installed outside of the cooling tower. If the second pump is located outside of the cooling tower it can serve two purposes. During standby-mode it is used to pump the first fluid in the second cooling circuit independently from the first pump. During power-mode it may be used as a booster pump in the second cooling circuit, which increases the pressure of the first cooling fluid in the second cooling circuit, which in particular is reasonable if a plate-type heat exchanger is used in the second cooling circuit and the pressure drop in the second cooling circuit is higher than in the first cooling circuit. In this embodiment, the control unit according to the invention or an additional booster pump controller may control the second pump during a booster pump operation mode. During power-mode the booster pump would perform normal boosting operation in synchronisation with the operation of the first pump. But during standby-mode the booster pump will perforin independent auxiliary cooling operation completely independent from the main pump that is switched off during standby-mode. The use of the second pump for two different operations is highly efficient and cost saving. Advantageously, in a preferred embodiment the second pump is installed in the cold part of the second cooling circuit, which would be either in the cooling tower or preferably close to it outside of the cooling tower. In a preferred embodiment of the invention the first cooling circuit comprises a valve to bypass the first pump. This is of particular advantage if the first cooling circuit and the second cooling circuit have a common pipe section for returning the heated first cooling fluid into the cooling tower. In the following, this valve is termed “bypass valve”. The state (open/closed) of the valve may be controlled by the control unit. A further valve may be located in this common pipe section and inhibits the flow of the first cooling fluid back into the cooling tower. The state (open/closed) of the further valve may be controlled by the control unit. In this case—at the junction where the second cooling circuit and the first cooling circuit are connected behind the heat exchanger (in flow direction of the first cooling fluid)—the first fluid can take its way back into the cooling tower in opposite direction as it would be the case if the main pump would be in operation. The first cooling fluid will flow from the heat exchanger back in direction of the first pump where it bypasses the first pump via said bypass valve directly into the cooling tower. Starting from the condenser on its way back to the cooling tower the first cooling fluid flows through parts of the cold part of the first cooling circuit. As a particular advantage, on its way back to the cooling tower the first cooling fluid passes through the condenser in opposite direction as it would pass if the first pump would be in operation. In this configuration not only the components but also the condenser can be cooled without the necessity of a switched on first pump. The backward flow of the first cooling fluid through the condenser advantageously provides for a longer lifetime of a turbine of the power plant because even during temporary power-mode interruption the turbine can still be kept under sealing steam, which after departing from the turbine may be partly fed into the condenser, while another part may be fed into a so-termed gland steam condenser where it is cooled. The use of the sealing steam is necessary to keep the seals of the turbine tight. This prevents air to enter into the turbine and the condenser. However, also the sealing steam must be cooled in the condenser, because otherwise the condenser could be damaged due to overheating. The cooling of the condenser and in turn also the cooling of the sealing steam is provided by the first cooling fluid pumped though the condenser before entering into the cooling tower through the bypass valve. The cooling of the sealing steam does not require the high cooling power provided by the main pump that generates a high throughput of the first cooling fluid. The cooling power provided by the second pump, which serves for lower throughput of the first cooling fluid, is sufficient to appropriately cool the condenser and the components. But also the power-mode of the power plant can be ramped up much faster after an interruption because also the condenser is still in (reduced) operation and kept evacuated. It would also be possible to realize the invention without said bypass valve, if the first pump allows the first cooling fluid to flow in direction reverse to the pumping direction. If the first pump does not provide this feature the first cooling fluid may not circulate through the condenser. After cooling the heat exchanger the third fluid would immediately find its way back into the cooling tower because it could only flow in the direction as it would flow during normal power generating operation, so to say when the first pump is in operation. According to a further aspect of the invention and in order to better control the direction of the flow of the first fluid a further valve is located in a first common pipe section of the first cooling circuit and the second cooling circuit. The first common pipe section is realized between the cooling tower and a point of the cooling system where a hot part of the second cooling circuit joins a hot part of the first cooling circuit and the cooling tower. As a result the further valve can be used to block or to enable any fluid flow through the common pipe section, preferably in dependency of the actual operation. As an operation condition the control unit that controls the valve may decide between power-mode (valve open) or standby-mode (auxiliary cooling/valve closed). In a further embodiment a bypass pipe section with a further valve is located in parallel to a PAB hot part of the first cooling circuit and connects the heat exchanger with the cooling tower. The state (open/closed) of the further valve may be controlled by the control unit. This configuration provides a higher degree of flexibility of the cooling system. In particular it allows the hot part of the second cooling circuit to be operated completely independently from the hot part of the first circuit or in combination with the first circuit, as the case may be. A further aspect of the invention relates to the control of the flow of the first cooling fluid in the second cooling circuit. In this context it is of advantage if the second cooling circuit comprises in its cold part a first pipe branch directly connected with the cooling tower and a second pipe branch connected with the a cold part of the first cooling circuit and a number of further valves for selectively controlling the flow of the first fluid in the cold part of the second cooling circuit. The states (open/closed) of the individual valves may be controlled by the control unit. The configuration of branches and valves allows activating an inflow of the first cooling fluid from the cold part of the first cooling circuit into the cold part of the second cooling circuit, which is of interest under main pump operation during power-mode. This configuration of branches and valves also allows selectively switching on a direct inflow of the first cooling fluid from the cooling tower into the second cooling circuit, which is of interest if the main pump is switched off during standby-mode. During standby-mode it further allows to select the direction the flow of the first cooling fluid through the heat exchanger. For example, during standby-mode, if, behind the heat exchanger, the backflow directly into the cooling tower is blocked, the first fluid can flow through the condenser in backward direction and e.g. bypass the first pump via a bypass valve. In a further example, in which the bypass valve does not exist and the first branch comprises the second pump, the flow of the first cooling fluid may also be directed to branch off via the second pipe branch from the cold part of the second cooling circuit into the cold part of the first cooling circuit. Following the first cooling circuit, the first cooling fluid flows through the condenser in a forward direction as it would flow under main pump operation during power-mode. Hence, in both examples described above, the condenser is cooled by the first cooling fluid under operation of the second pump only. The flow of the first cooling fluid through the condenser may be in a forward direction as would be the case under main pump operation, or in a backward direction. In a preferred embodiment the steam power plant is a solar thermal power plant that comprises an energy conversion circuit that comprises the condenser, a steam turbine and a solar energy converter system that is designed to use solar energy to produce steam for driving the steam turbine that is located between the solar energy converter system and the condenser. The application of the invention in the context of a solar power plant is of particular advantage because such a solar power plant must be driven down daily or even multiple times a day. The event that triggers the need to drive down the plant may be e.g. night hours, a sand storm or cloudy or foggy weather condition or in other words a general lack of sufficient sunlight to be in power-mode. For the duration of the event the plant must be kept in standby-mode under sealing steam. Thereafter it must be ramped up back to power-mode. Now, advantageously, during the standby-operation the first pump is not any longer required to be operated for cooling the components. This cooling function is now achieved by the independent operation of the second cooling circuit. In comparison to the known configuration the invention provides for significantly increased energy efficiency because the energy saving effect achieved is an accumulation of a daily contribution accumulated over the entire lifetime of the solar thermal power plant. Other objects and features of the present invention will become apparent from the following detailed descriptions considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for the purposes of illustration and not as a definition of the limits of the invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a first embodiment of a steam power plant in a first operation mode; FIG. 2 shows the first embodiment in a second operation mode; FIG. 3 shows a second embodiment of the steam power plant; FIG. 4 shows a third embodiment of the steam power plant; FIG. 5 shows a fourth embodiment of the steam power plant; FIG. 6 shows a fifth embodiment of the steam power plant. In the drawings, like reference numbers refer to like objects throughout. Objects in the diagrams are not necessarily drawn to scale. DETAILED DESCRIPTION OF INVENTION In FIG. 1 a solar steam power plant 1 is schematically depicted. In this solar steam power plant 1 , during power-mode, solar energy is converted into electrical power. The power plant 1 comprises an energy conversion circuit 2 that comprises a solar energy converter system 3 that is designed to use solar energy to produce steam 4 A during power-mode. Therefore, in the solar converter system 3 a medium, normally water, is heated up (not shown in detail). The heating up of the medium may be achieved directly by utilizing the radiation of the sun to heat the medium. The heating of the medium may also be achieved indirectly by utilizing the radiation of the sun to heat up a heat transfer fluid, e.g. oil or any other substance. Thereafter the heat energy stored in the hot heat transfer fluid is transferred into the medium. The energy conversion circuit 2 further comprises a steam turbine 5 connected to the converter system 3 . The turbine 5 is driven by the steam 4 A in order to generate electrical power for a grid (not depicted). The conversion circuit 2 also comprises a condenser 6 connected to the turbine 5 , which is used for cooling down the steam 4 A and to produce a condensate 4 B of the steam 4 A. Also a conversion circuit pump 7 is installed in the conversion circuit 2 to pump the condensate 4 B back into the conversion system 3 . Also depicted is a sealing steam generator 8 , which is used to generate a sealing steam 9 A during standby-mode of the power plant 1 when the steam 4 A cannot be generated. The sealing steam 9 A is fed into the turbine 5 at a separate inlet of the turbine 5 . Departing from the turbine 5 the sealing steam 9 A is also fed into the condenser 6 , where it is cooled down and departs as a condensate 9 B of the sealing steam 9 A. The use of the sealing steam 9 A allows the rapid ramp up of the plant 1 back to power-mode during the morning hours and increases the lifetime of the turbine. The conversion circuit pump 7 also pumps the condensate 9 B of the sealing steam 9 A. For the sake of clarity is to note that—although two different reference numbers are used for the steam 4 A and the sealing steam 9 A—in both cases the evaporated medium forms the steam 4 A or 9 A. During the power-mode the sun causes the medium to evaporate and to form the steam 4 A. During the standby-mode the sealing steam generator 8 acts as an auxiliary heating device that substitutes the sun to cause the medium to evaporate and to form the sealing steam 9 A. Only the steam 4 A, when compared with the sealing steam 9 A, typically provides the steam mass that can be used to generate electricity via the turbine 5 . The individual components 3 , 5 , 6 , 7 and 8 of the conversion circuit 2 are connected by conversion circuit pipes 10 . These and other components used for the power-mode of the power plant 1 are not depicted in details because they are common to steam power plants. The design of the conversion circuit 2 or its individual components 3 , 5 , 6 , 7 and 8 can be more complex. For example, the converter circuit 2 typically comprises more than one turbine 5 . The flow direction of the steam 4 A and its condensate 4 B are indicated by first (solid) arrows 11 . The flow direction of the sealing steam 9 A and its condensate 9 B are indicated by second (dashed) arrows 12 . In the following a cooling system 13 of the power plant 1 is discussed, which is in the focus of the present invention. The cooling system 13 comprises a first cooling circuit, abbreviated “PAB” 101 (a circulating water piping and culvert system or main cooling circuit), a second cooling circuit, abbreviated “PCB”, 102 (service water piping and culvert system) and a third cooling circuit, abbreviated “PGB”, 102 (closed cooling water system or component cooling system). Also depicted is a cooling tower 14 , which is a part of the PAB 101 and the PCB 102 . The cooling tower 14 cools down a first cooling fluid 15 , which is water. The first cooling fluid 15 is used to perform cooling operations in the PAB 101 and the PCB 102 . During the power-mode the first cooling fluid 15 circulates from the cooling tower 14 through the PAB 101 and the PCB 102 and back to the cooling tower 14 . This circulation is achieved by the aid of two main pumps 16 of the PAB 101 , which are often termed circulating water pumps and located inside the pump pit of the cooling tower 14 close to cold-water outlets 17 of the cooling tower 14 . Outside of the cooling tower 14 the PAB 101 comprises two first non-reversal valves 18 to prevent the first cooling fluid 15 to flow in reverse direction into the first pumps 16 . Also the condenser 6 belongs to the PAB 101 . In the condenser 6 the first cooling fluid 15 and the steam 4 A are thermally coupled during the power-mode. During the standby-mode only sealing steam 9 A is thermally coupled with the first cooling fluid 15 . In both cases the first cooling fluid 15 cools down the steam 4 A, 9 A. The PAB 101 also comprises a PAB pipe system 19 , which is thematically split or named according to the thermal condition of the first cooling fluid 15 during power-mode into a PAB cold part 20 and a PAB hot part 21 . The PAB cold part 20 connects the condenser 6 with the cold-water outlets 17 of the cooling tower 14 while the PAB hot part 21 connects the condenser 6 with a first hot-water inlet 23 A of the cooling tower 14 . At the end of the PAB hot part 21 a first flow control valve 22 is installed. It is open during the power-mode. At the cold-water outlet 17 a bypass valve 24 is installed in parallel to the first pumps 16 . It is closed during power-mode. Third (bold) arrows 25 indicate the circulation of the water 15 through the PAB 101 during the power-mode. The PCB 102 comprises a heat exchanger 26 , which thermally couples the first cooling fluid 15 with a second cooling fluid 27 that circulates in the PGB 103 . The PGB 103 cools down components (not depicted) of the power plant 1 , which are different from the condenser 6 . Therefore it comprises a PGB pipe system 28 , which connects heat exchangers, located on or in the components to be cooled, and a closed cooling water pump 30 with the heat exchanger 26 . For the sake of simplicity, only one component heat exchanger 29 is shown in the figures. The closed cooling water pump 30 drives the flow of the second cooling fluid 27 , which may also be water. A second non-reversal valve 31 is located downstream to the closed cooling water pump 27 . Most of the components connect to the PGB 103 have to be cooled not only during power-mode but also during the standby-mode. This is achieved by a particular design of the PCB 102 and a control unit 48 , which will be explained in details below. The PCB 102 comprises a PCB pipe system 32 , which is named according to the temperature of the first cooling fluid 15 into a PCB cold part 33 and a PCB hot part 34 . During the power-mode the PCB hot part 34 is realized by the aid of a first pipe section 35 that connects the heat exchanger 26 with the PAB hot part 21 . Also that part of PAB hot part 21 that is used to lead the first cooling fluid 15 back to the first hot-water inlet 23 A is part of the PCB hot part 34 . During the power-mode the PCB cold part 33 is realized by the aid of a second pipe section 36 and a third pipe section 37 . The second pipe section 36 comprises a second flow control valve 38 and the third pipe section 37 comprises a third flow control valve 39 , which acts as a shut-off valve, wherein both valves 38 and 39 are open during the power-mode. The PCB 102 also comprises a fourth pipe section 40 and a fifth pipe section 41 . At one end the forth pipe section 40 is directly connected with a second cold water outlet 42 of the cooling tower 4 . At the other end the forth pipe section 40 joins the second pipe section 36 . The forth pipe section 40 comprises a forth flow control valve 43 , which acts as a further shut-off valve and which is closed during the power-mode. The fourth pipe section 40 realizes a first pipe branch that directly connects the cooling tower 14 with the PCB 102 . The second pipe section 36 realizes a second pipe branch that connects the PAB cold part 20 with the second cooling circuit PCB 102 . At one end the fifth pipe section 41 is connected with the fourth pipe section 40 . At its other end the fifth pipe section 41 is connected with the heat exchanger 26 . The fifth pipe section 41 comprises a second pump 44 . A third non-reverse valve 45 is located downstream to the second pump 44 . Downstream to the second non-reversal valve 45 the fifth pipe section 41 comprises a service cooling water debris filter 46 . During the power-mode the second pump 44 can be used to boost the flow of the first cooling fluid 15 through the heat exchanger 26 . If the second pump 44 is switched on, the fourth pipe section 40 becomes a part of the PCB cold part because cold first fluid flows through it into the PCB 102 . For the purpose of performing the standby-mode, when the first pumps 16 are switched off, the first flow control valve 22 , the second flow control valve 38 and the third flow control valve 39 are closed. The bypass valve 24 and the fourth flow control valve 43 are opened. The second pump 44 is switched on and pumps the first cooling fluid 15 through the PCB 102 independently from the operation of the first pumps 16 . The PCB cold part 33 is now realized by the aid of the fourth pipes section 40 and fifth pipe section 41 . Now, the PCB hot part 34 changes its configuration and is realized by a part of the PAB hot part 21 , which connects the first pipe section 35 with the condenser 6 , and the PAB cold part 20 , except for the first pumps 16 , which are bypassed by the bypass valve 24 . In FIG. 1 forth (dashed) arrows 47 indicate the flow of the first fluid 15 driven by the second pump 44 through the cooling system 13 . It is highlighted that the first cooling fluid 15 flows through the condenser 6 in opposite direction when compared with the direction in the power-mode (herein termed “reverse direction”=in opposite direction with regard to the third arrows 25 ). During the standby-mode a control unit 48 controls the operation of the second pump 44 . The control unit 48 is also used to control the valve states of valve 22 , 24 , 38 , 39 and 43 . Valve 38 and/or 39 and/or 43 realize a number of valves for selectively controlling the flow of the first cooling fluid 15 in the PCB cold part 33 . As depicted in FIG. 2 , if the bypass valve 24 is in its closed state and the first flow control valve 22 is open, the flow of the first cooling fluid 15 will take place according to fifth (dashed) arrows 49 . Now the PCB hot part 21 is the same as it is during the power-mode. The first cooling fluid 15 does not flow through the condenser 6 , but component cooling is achieved. FIG. 3 shows a second embodiment of the power plant 1 . In this embodiment the second pump 44 together with the third non-reversal valve 45 is shifted from the fifth pipe section 41 into the fourth pipe section 40 . The bypass valve 24 is omitted. Without the first pumps 16 being in operation this configuration allows two different operation scenarios. In a first scenario the first flow control valve 22 is open, the second flow control valve 38 is closed, the third flow control valve 39 is closed and the fourth flow control valve 43 is open. Now, the second pump 44 pumps the first cooling fluid in a direction indicated by the fifth arrows 49 . This operation is identical to that one depicted in FIG. 2 . The first cooling fluid 15 does not flow through the condenser 6 . But component cooling is achieved. In the second scenario the second flow control valve 38 is opened and the condenser 6 is cooled because the second pump 44 pumps the first cooling fluid 15 not only through the heat exchanger 26 but also through the condenser 6 . In this configuration the flow direction of the first cooling fluid 15 in the condenser 6 is the same as it is during the power-mode, so to say in forward direction. This is indicated by seventh (dashed) arrows 53 . FIG. 4 depicts a third embodiment, in which the first flow control valve 22 , the bypass valve 24 , the second pipe section 36 and the second flow control valve 38 , the third pipe section 37 and the third flow control valve 39 and the fourth pipe section 40 and the fourth flow control valve 43 are omitted. What remains in the PCB 102 is the fifth pipe section 41 , which is directly connected with the second cold-water outlet 42 . In contrast to the earlier discussed embodiments the second pump 44 is now located within a pump pit of the cooling tower 14 and forms an entry point of the fifth pipe section 41 . In this configuration only component cooling can be achieved. The second pump 44 pumps the first cooling fluid 15 as indicated by the fifth arrows 49 through the PCB 102 . In FIG. 5 a fourth embodiment is shown. In contrast to the third embodiment, now the bypass valve 24 and the first flow control valve 22 are installed as it was depicted in the embodiments displayed in FIG. 1 and FIG. 2 . During standby-mode the second flow control valve 22 is closed and the bypass valve 24 is open. The second pump 44 pumps the first cooling fluid 15 from the cooling tower 14 through the heat exchanger 26 and in reverse direction through the condenser 6 back into the cooling tower 14 . The direction of flow is indicated by the forth arrows 47 . Cooling of the components as well as cooling of the condenser 6 is achieved. In FIG. 6 a fifth embodiment is visualized. In contrast to the fourth embodiment a sixth pipe section 50 with a fifth flow control valve 51 connects the first pipe section 35 with a third hot-water inlet 23 C of the cooling tower 14 . During standby-mode the first flow control valve 22 is closed, the fifth flow control valve 51 is open and the bypass valve 24 is also open. The second pump 44 pumps the first cooling fluid 15 from the cooling tower 14 through the heat exchanger 26 and in reverse direction through the condenser 6 and back into the cooling tower 14 , which is indicated by the fourth arrows 47 . A part of the first cooling fluid 15 passes along the sixth pipe section 50 back into the cooling tower 14 , which is indicated by a sixth (dashed) arrow 52 . If also the bypass valve 24 is closed, all of the first cooling fluid 15 will depart from the heat exchanger 26 and flow back into the cooling tower 14 , as indicated by the sixth arrow 52 . Hence, the cooling of the condenser 6 may be selectively switched on or off. Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention. In general, although only two first pumps 16 and one second pump 44 are used to explain the various embodiments, it is evident that the number of pumps shall not be limited. Dependent on the actual technical requirements the number may be selected appropriately. In the figures the control unit 48 is shown with connection only to the second pump 44 for the sake of simplicity. Although this is not visualized, it is clarified at this point that the control unit 48 is also connected with the first pumps 16 and the valves 22 , 24 , 38 , 39 and 43 and with the closed cooling water pump 30 . The invention my also be realized if instead of a cooling tower a fresh water cooling is used in a flow-though cooler. The term “flow control valve” shall be understood either as a valve that defines the flow rate of the respective cooling fluid and/or as a valve that enables or inhibits any flow of the respective cooling fluid, as the case may be. For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements. A “unit” or “module” can comprise a number of units or modules, unless otherwise stated.
In a steam power plant, a first cooling circuit includes a condenser for condensing steam and a first pump for pumping a first cooling fluid through the condenser in order to cool the condenser. A third cooling circuit is a closed cycle cooling circuit that utilizes a second cooling fluid for cooling down at least one component that is different from the condenser. A second cooling circuit includes a heat exchanger that thermally couples the first cooling fluid and the second cooling fluid and utilizes the first cooling fluid in the heat exchanger for cooling down the second fluid and further includes a second pump for pumping the first cooling fluid through the second cooling circuit independently from an operation of the first pump.
5
TECHNICAL FIELD The invention relates to a sustainer for a vehicle roof rail, and more particularly to a sustainer that is self-adjusting and does not require protrusions or bumps to be formed in the roof surface of a vehicle to assist in holding the sustainer stationary during assembly to the vehicle roof. BACKGROUND OF THE INVENTION A generic sustainer is shown in EP0780267A1. This known sustainer features a fastening bolt with a first threaded portion and a second threaded portion running in the opposite direction to the first. A support part, which separates the threaded portions from each other, is located between the threaded portions. During assembly, the support part comes to rest on a support sheet upon which rib-shaped bumps have been molded. The bumps are supposed to prevent the fastening bolt from rotating further than desired while a nut is being screwed on. A disadvantage of this known sustainer is the unavoidably necessary manipulation on the vehicle's roof (i.e., on the roof panel or on the floor of a roof channel) for the purpose of molding rib-shaped bumps. It has been shown in practice that automobile manufacturers strongly resist forming such bumps or protrusions during manufacture of the vehicle. SUMMARY OF THE INVENTION It is the objective of the present invention to provide automatic compensation for tolerances between a sustainer and a roof, or a roof channel, without the need for additional steps of forming rib-shaped bumps on the roof to assist in securing the sustainer to the roof. The sustainer of the present invention comprises a fastening bolt assembly having a fastening bolt. The fastening bolt has a head portion and a shank. The head portion includes a first threaded portion and the shank portion includes a second threaded portion. The second threaded portion is formed with its threads opposite to the first threaded portion. The head portion also includes a through bore within which is disposed a spring positioned inbetween opposing blocking elements. A pair of channels are also formed in the head portion which each receive moveable pins. The head portion is screwed into a journal piece of a roof rail prior to fastening of the roof rail to the vehicle roof. During assembly, when a nut is tightened onto the shank of the fastening bolt, this causes the head portion to be unscrewed from the journal piece. As this occurs, the pins move into positions whereby the blocking elements are able to extend through openings formed in each of the pins, and into integrally formed structure on the journal piece. This prevents further rotation of the fastening bolt as the nut is tightened further onto the shank. The present invention accomplishes self-adjustment of the sustainer and prevents unwanted rotation of the fastening bolt relative to the journal without requiring special surface projections to be formed on the vehicle roof. BRIEF DESCRIPTION OF THE DRAWINGS The various advantages of the present invention will become apparent to one skilled in the art by reading the following specification and subjoined claims and by referencing the following drawings in which: FIG. 1 is an exploded perspective view of the fastening bolt assembly forming a sustainer in accordance with a preferred embodiment of the present invention; FIG. 2 is a side cross-section view of the fastening bolt assembly of FIG. 1 placed in position ready to secure a journal piece of a roof rail to the roof of the vehicle; and FIG. 3 illustrates the fastening bolt assembly in a fully secured position relative to the vehicle roof. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a fastening bolt assembly 1 in accordance with a preferred embodiment of the present invention, which is designed as a tolerance compensator for a sustainer of a roof rail (not shown). The fastening bolt assembly 1 contains a bolt 1 a having a cylindrical bolt head 2 and a cylindrical bolt shank 4 . The shank 4 is offset from the bolt head 2 by a step 3 , whose diameter is substantially smaller than that of the bolt head 2 . Bolt head 2 features a left-handed thread and bolt shank 4 a right-handed thread. Bolt head 2 features a cross hole or bore 5 , which is designed as a through-hole, and which is used to accommodate two blocking elements 6 and a spring 7 installed between them. The spring is preferably a compression spring. The bolt head 2 also features two channels or bores 8 passing axially therethrough which each intersect the cross bore 5 . The bores 8 each are used to accommodate one pin 9 in each. The bores 8 can be designed closed, as illustrated, or also could be formed as channels that open on the rim and be undercut at the same time, if necessary. Each bore 8 features a cross-sectional opening that is matched to the cross sectional shape of the pins 9 , such as square, rectangular, or even rounded shapes. The pins 9 are detachably fastened within the bores 8 , preferably by an adhesive bond. The pins 9 each feature an opening 10 that is shaped strongly conical. A washer 11 , which can be milled from a steel part or cast out of various materials, is also preferably part of the fastening bolt assembly 1 . Referring to FIG. 2, when a roof rail is delivered, each sustainer, respectively, is equipped with a fastening bolt assembly 1 which serves as a tolerance compensator at the same time. In this regard, the bolt head 2 is located within a tapped hole of a journal piece 12 of the roof rail. Bolt head 2 is screwed sufficiently far into the tapped hole so that the step 3 and the open end of journal piece 12 are at approximately the same height. The pins 9 , which are detachably fastened within the channels 8 preferably via adhesives, are located in a position in which they protrude over the open end of the journal piece 12 on the one hand and on the other hand prevent the blocking elements 6 from coming out of the cross bore 5 . The actual fastening process can be executed according to the fitting arrangement shown in FIGS. 2 and 3, wherein a fixing nut 15 (FIG. 3) is screwed onto bolt shank 4 . When the fixing nut 15 is being screwed on, the bolt head 2 is forced to unscrew itself downwards out of the left-handed thread of the journal piece 12 because of the small degree of friction between it and the thread of the journal piece. During this process, the fastening of pins 9 becomes detached because the relatively weak adhesive bond tears. By additional rotation of the fixing nut 15 in the tightening direction, bolt head 2 continues to be unscrewed out of journal piece 12 until the step 3 abuts the washer 11 . In this position of assembly, the blocking elements 6 , which each feature a conical tip, are pressed through the openings 10 of the pins 9 and out of the cross bore 5 , as a consequence of the prestressing force of the spring 7 acting upon them. The blocking elements 6 are urged against the wall of the tapped hole of journal piece 12 . Since this wall features several longitudinal slots 16 distributed over the perimeter, the fastening bolt 1 a will only continue to rotate until the blocking elements 6 each engage one of the longitudinal slots 16 and lock the bolt head 2 into position with the journal piece 12 . At this point, the screw connection can then be tightened fully and the roof 14 can be braced between the step 3 , the washer 11 , and the fixing nut 15 . FIG. 2 shows the delivery state as well as the start of assembly. The bolt shank 4 passes through the washer 11 and an opening 13 in the vehicle's roof 14 . he washer 11 rests on the roof 14 and supports the open end of the pins 9 . The term “roof” should also be understood to encompass the floor of a roof channel designed within a vehicle roof. The actual fastening process can be executed according to the fitting arrangement shown in FIGS. 2 and 3, wherein a fixing nut 15 (FIG. 3) is screwed onto bolt shank 4 . When the fixing nut 15 is being screwed on, the bolt head 2 is forced to unscrew itself downwards out of the left-handed thread of the journal piece 12 . During this process, the fastening of pins 9 becomes detached because the relatively weak adhesive bond tears. By additional rotation of the fixing nut 15 in the tightening direction, bolt head 2 continues to be unscrewed out of journal piece 12 until the step 3 abuts the washer 11 . In this position of assembly, the blocking elements 6 , which each feature a conical tip, are pressed through the openings 10 of the pins 9 and out of the cross bore 5 , as a consequence of the prestressing force of the spring 7 acting upon them. The blocking elements 6 are urged against the wall of the tapped hole of journal piece 12 . Since this wall features several longitudinal slots 16 distributed over the perimeter, the fastening bolt 1 a will only continue to rotate until the blocking elements 6 each engage one of the longitudinal slots 16 and lock the bolt head 2 into position with the journal piece 12 . At this point, the screw connection can then be tightened fully and the roof 14 can be braced between the step 3 , the washer 11 , and the fixing nut 15 . The position of the openings 10 in the pins 9 define the path that can still be reached after everything is locked into position, and that can be used for pressing a conventional base, not depicted here, that is installed between the sustainer and the roof 14 . The gap arising between the sustainer and the roof panel can largely be kept constant by the described measures. In particular, the described system is assembly-friendly and insensitive to its own and external tolerances. Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification and following claims.
A sustainer for securing a roof rail to a vehicle surface, which does not require protrusions or bumps to be formed on the vehicle surface to prevent unwanted rotation of the sustainer during tightening of an external bolt onto the sustainer.
1
This application claims the benefit of U.S. Provisional application Ser. No. 60/997,261, filed Oct. 1, 2007, the entire disclosure of which is incorporated herein by reference. TECHNICAL FIELD The present application relates to cellulosic materials treated with amine-containing polymers, which materials exhibit no discoloration and no degradation of physical strength as a result of the treatment. BACKGROUND OF THE INVENTION Cellulosic fiber and fabrics could be enhanced certain desired performance through finish. Various amine-containing finishes have been developed to enhance different performances on fabrics. Durability is a basic requirement for commercial textile chemical finishes. While U.S. Pat. No. 4,244,059, issued to Pflaumer, teaches application of water-soluble polyamines on a panty type garment, there is no laundry durability expected from this finish because water-soluble polyamines dissolve in water and wash away after laundry. U.S. Pub. No. 2004/0166753, Millward and Ware, teaches finishes for cellulosic fibrous substrates comprising polymers with amine groups containing primary, secondary and/or tertiary amines, crosslinkers and a volatile solvent. However, color change is a challenge for amine-containing finish on celluosic materials. Amino groups can cause yellowing or discoloration upon exposure to high heat during curing. U.S. Pub. No. 2006/0162090 A1, Offord, describes durable finish comprising hydroxyl-containing amines combined with the preferred crosslinker dimethyloldihydroxyethyleneurea (DMDHEU) on fibrous substrate to reduce body odor. U.S. Pat. No. 5,139,530, issued to Blanchard et al., teaches production of anionically dyeable cellulosic materials by treatment of hydroxyalkyamine and DMDHEU prior to dyeing. However, it is well known in the textile industry that treatment of cellulosic fabrics with the resin system DMDHEU dramatically impairs cotton physical properties, e.g., tensile strength, tear strength, etc. The mobility of the cellulosic molecule is frozen during thermosetting in the presence of DMDHEU. This leads to brittleness of the fabrics treated with DMDHEU. Thus, it is desirable to provide a method to attach tertiary amine on the cellulosic fabrics without damaging the physical properties, while at the same time preventing discoloration of the treated fabric. SUMMARY OF THE INVENTION The present invention is directed to durable finishes for cellulose-containing fibers and fibrous substrates. The durable finish comprises (i) a tertiary amine-containing polymer, (ii) a suitable crosslinker, and (iii) a volatile solvent. More particularly, the invention is directed to a durable finish for cellulosic fibrous substrates comprising a tertiary amine-containing polymer of formula (I): wherein each of R 1 , R 2 and R 3 is independently an alkyl group, a hydroxyalkyl group or a tertiary amine-containing alkyl group; R 4 is hydrogen or an alkyl group; R 5 is a hydroxyl-reactive functional group; R 6 is an ester group, an ether group, an amide group or a tertiary amine-containing alkyl group; each of m and n is independently a positive integer of about 10 to about 1,000,000; and x is zero or one. The tertiary amine-containing polymers are polymerized from appropriate monomers. Polymer (I) can be a copolymer of any constitution, such as, for example, a block copolymer or a random copolymer. The finishes of this invention impart durable control of certain odors, such as body odor, to the cellulosic fabric surface. At the same time, the fibrous substrates treated with the finish exhibit substantially improved physical strength compared to prior art treatments, and the color change of dyed fabrics and yellowing of white fabrics are also eliminated. This invention is further directed to the cellulosic fibers; yarns; woven, knitted or nonwoven fabrics and textiles; and finished goods (all of which are encompassed herein under the terms “fibrous substrates” and “fabrics”) treated with the tertiary amine-containing polymer finish of the invention. The cellulosic fabrics treated with the durable finish of the invention take on properties that are not found in the native fabric, including the ability to eliminate or greatly diminish the most offensive component of malodorous body odor, while surprisingly reducing the yellowing of the substrates experienced with certain prior art amine treatments and at the same time preserving the physical strength of the native fabric, contrary to other prior art amine treatments. DESCRIPTION OF THE INVENTION As used herein and in the appended claims, “a” and “an” mean one or more, unless otherwise indicated. The terms “durable” and “durability”, as used herein and in the appended claims, describe a finished fibrous substrate in which the desired properties imparted to the substrate by the finish are observed after multiple launderings or dry cleanings. In one aspect, the finish of the invention is durable for at least 10 home launderings. In one aspect, the finish of the invention is durable for at least 25 home launderings. In one aspect, the finish of the invention is durable for at least 40 home launderings. In one aspect, the finish of the invention is durable for at least 50 home launderings. The “cellulose-containing” or “cellulosic” fibrous substrates to be treated according to the present invention include any cellulosic fiber and any blend of fibers that contain a cellulosic, whether as a majority or a minority component. Cellulosic-based substrates include paper, cotton, rayon and other regenerated cellulosics and cellulose-containing materials, linen, jute, ramie, industrial hemp, and the like. In one aspect of the invention, the cellulose-containing fabric or fibrous substrate is cotton. The finish of the invention comprises a tertiary amine-containing polymer of formula (I): wherein each of R 1 , R 2 and R 3 is independently an alkyl group, a hydroxyalkyl group or a tertiary amine-containing alkyl group; R 4 is hydrogen or an alkyl group; R 5 is a hydroxyl-reactive functional group; R 6 is an ester group, an ether group, an amide group or a tertiary amine-containing alkyl group; each of m and n is independently a positive integer of about 10 to about 1,000,000; and x is zero or one. Polymer (I) can be a copolymer of any constitution, such as, for example, a block copolymer or a random copolymer. The tertiary amine-containing polymers are polymerized by free radical polymerization, ionic polymerization or condensation polymerization. The ratio of m to n is generally from about 1:100 to about 100:1. In one aspect, the ratio is from about 1:50 to about 50:1. In another aspect, the ratio is from about 1:10 to about 10:1. In one embodiment, the tertiary amine-containing polymer is attached onto the cellulosic fabrics through a reactive group. In one aspect, the reactive group is N-(hydroxymethyl)acrylamide. Physical strength, e.g. tear strength, of the fibrous substrate treated with the tertiary amine-containing polymer (I) is improved dramatically due to the absence of a resin system that includes DMDHEU and catalyst. “Alkyl group” as used herein and in the appended claims refers to a lower alkyl group, straight-chain or branched, having from one to eight carbon atoms. In one aspect, the alkyl group has from one to six carbon atoms. The “hydroxyl-reactive functional group” contains a terminal hydroxyl that is capable of forming bonds with cellulosic fibrous substrates, resulting in attachment of the polymer to the fibrous substrate. Hydroxyl-reactive functional groups include, but are not limited to, epoxides, halohydrins, oxiranes, carbonyl diimidazole, N,N′-dissuccinidyl carbonate, and N-hydroxylsuccinimethylol ureas. In one aspect of the invention, the hydroxyl-reactive functional group is N-(hydroxymethyl)acrylamide. The “tertiary amine-containing polymer” encompasses oligomers as well as polymers. The tertiary amine-containing polymer may be a homopolymer, a copolymer, or a terpolymer. A copolymer may contain one or more polyacrylates with tertiary amine groups. Exemplary tertiary amine-containing polymers include, but are not limited to, poly[N,N-(dimethylaminoethyl)aminoethyl methacrylate], poly[N,N-(diethylamino)ethyl methacrylate] and poly[N,N-(diethylamino)methyl methacrylate]. In one aspect, the tertiary amine-containing polymer is poly[N,N-(dimethylaminoethyl)aminoethyl methacrylate]. The substituent R 6 , when present, is, in one aspect of this invention, an ester. In another aspect of the invention R 6 , when present, is an ether group. A catalyst may optionally be included in the finish of the invention to improve reaction efficiency. If a hydroxyl-reactive functional group is not present, the tertiary amine-containing polymer may form a network on the surface of the fibrous substrate through the tertiary amine groups. Anionic polymers may be added to crosslink the tertiary amine-containing polymer on the substrate. The finish solution of the invention that is applied to the fibrous substrate comprises a tertiary amine-containing polymer, a suitable crosslinker, and a volatile solvent. The solvent may be chosen from any solvent that dissolves or emulsifies the polymer and/or the crosslinker but does not react adversely with either the polymer, the crosslinker or the fibrous substrate. In one aspect of the invention, the solvent is water. In this aspect, it is desirable that the polymer and/or the crosslinker will dissolve or be emulsified in water. The “crosslinker” as used herein may be present in the tertiary amine-containing polymer chain, or it may be a separate molecule that contains two or more functional groups that form bonds with the polymer. The pad solution preferably contains tertiary amine-containing polymer at between about 0.01% and about 75% by weight, more preferably between about 0.05% and about 50% by weight. The pad solution preferably contains a crosslinker at between about 0.001% and about 40% by weight, more preferably between about 0.01% and about 30% by weight. The finish solution may also include other additives. For example, the finish solution may also contain a wetting agent, such as WetAid NRW (BF Goodrich Corp.), to aid the equal spread of the finish over the fibers. Additional additives can be added to the solution as needed and as known by those generally skilled in the art. The present invention relates, in part, to a method for attaching tertiary amine-containing polymers to a fibrous substrate comprising the steps of: a) obtaining one or more tertiary amine-containing monomers, from those known in the art or by synthesis; b) copolymerizing the tertiary amine-containing monomer(s) with one or more monomers comprising a hydroxyl-reactive functional group to give a tertiary amine-containing polymer; c) applying the polymer, together with an appropriate crosslinker, to a fibrous substrate; and d) curing the substrate. The substrate can be of natural fabrics or a blend of natural and synthetic fabrics. The finish of the invention can be applied to the cellulosic fibrous substrate by exposing the substrate to the finish solution by methods known in the art, such as dip-pad-cure, spray, fluid-flow or print. After the finish has been applied to the fibrous substrate, the substrate is dried and the finish is cured and bonded on the substrate by heating. The finish solution may be applied to the fibrous substrate at any temperature above the freezing point and below the boiling point of the solvent. In one embodiment, the application temperature is preferably between 5 and 90° C., more preferably between 10 and 50° C., and most preferably at room temperature. The treated fabric should be cured at a temperature high enough to induce the crosslinking reaction in a short time, preferably less than five minutes, more preferably a minute or less. In one present embodiment, the curing temperature is preferably between 80 and 200° C., more preferably between 100 and 180° C. One advantage of the finish of the present invention is that a fibrous substrate finished as described above will absorb malodor from the human body, while maintaining breathability, soft hand and hydrophilicity. Another advantage of the present invention is that color changes and the loss of physical strength (such as tensile strength and tear strength) and other physical characteristics following treatment of cellulosic fabrics with the tertiary amine-containing acrylic polymer finish are very limited or are eliminated. The attachment of amine groups to any substrate, not just textiles, is considered to provide a “performance enhancement” to the substrate, since amine groups serve multiple functions in addition to those discussed above. For example, amine groups serve as reactive sites for additional chemical reactions to modify the properties of the substrate, such as the attachment of other chemical moieties such as enzymes, dyes, etc. EXAMPLES The following information is provided to give those of ordinary skill in the art with a complete disclosure and description of how to make and use the preferred embodiments of the invention, and is not intended to limit the scope of what the inventor(s) regard(s) as his or her/their invention. Modifications of the above-described modes for carrying out the invention that are obvious to persons of skill in the art are intended to be within the scope of the claims. All publications, patents, and patent applications cited in this specification are incorporated herein by reference as if each such publication, patent or patent application were specifically and individually indicated to be incorporated herein by reference. Example 1 Synthesis of Acrylic Tertiary Amine Monomer A 500 mL three-neck flask was charged with 38 g of 2-{[2-(dimethylamino)-ethyl]methylamino}ethanol (1), 101 g of triethyl amine and 100 g of methylene chloride. The solution was stirred at 350 rpm under nitrogen. 26 g of methacryloyl chloride (2) in 100 g of methylene chloride was added in the flask slowly. The suspension was refluxed for an additional 4 hours. The suspension was filtered and the solvent was removed by distillation at 40° C. Triethyl amine was removed by vacuum distillation at 50° C. Yield of product (3): 39 g, 74% (w/w). Example 2 Polymerization A 50-mL flask was charged with 352 mg of N-(hydroxymethyl)acrylamide (4), 2.14 g of the amine methacrylate (3) from Example 1 and 5 g of methyl isobutyl ketone. 35.4 mg of the initiator 1,1′-azobis(cyclohexanecarbonitrile) (Vazo® 88, Dupont) and 9.93 μl of 2-mercaptoethanol were then charged in the flask. The solution was stirred overnight at 80° C. under nitrogen. The solvent was removed under vacuum and a light yellow solid acrylic polymer (5) was obtained (where the ratio of m to n is about 6:1). Example 3 Other acrylic polymers with tertiary amine were also polymerized according to the same procedure as in Example 2. The starting monomers are shown in Table A below: TABLE A Starting monomers i ii iii Example 4 Formulation and Fabric Treatment from Tertiary Amine-containing Polyacrylics of the Invention An aqueous solution of the tertiary amine poly(methacrylate) from Example 2 (11.6% w/w), acetic acid (6.0% w/w) and MgCl 2 (1.5%, w/w) was prepared. Cotton fabric samples (15×13 inch square) were dipped in the above finish solution. After padding under pressure at 30 psi, the fabric swatches were cured at 150° C. for 1 minute. Example 5 Formulation and Fabric Treatment from Prior Art Resin System An aqueous solution of triethanol amine (4%), DMDHEU resin (20%) and MgCl 2 (4%, w/w) was prepared. Cotton fabric samples (15×13 inch square) were dipped in the above solution. After padding under pressure at 30 psi, the fabric swatches were cured at 150° C. for 1 minute. Example 6 Formulation and Treatment from Prior Art Alkanol Amines A 100.0 g aqueous solution was prepared by adding 11.3% of polyethyleneimine (PEI) into 50 g of water and adjusting the pH to 4.0 with hydrochloric acid, followed by addition of 0.1% WetAid NRW (Noveon). 2.9 Grams of alkylated DMDHEU (Sedgere PCR-2) and additional water were added to make up 100.0 g. Cotton fabric samples (15×13 inch square) were dipped in the above solution. After padding under pressure at 30 psi, the fabric swatches were cured at 150° C. for 1 minute. Example 7 Performance Testing on Fabrics Standard home launderings (HL) were done based on AATCC method 124-2001, but using 28 grams of granular detergent with bleach instead of using 66 grams of 1993 AATCC standard reference detergent. a. Odor Absorption Butyric acid is one of the byproducts after sweat is decomposed by bacteria. It is responsible for body odor, so it was chosen to simulate body odor in sniff testing. During testing, different concentrations of butyric acid were dropped onto fabric samples. The smell panel sniffed the spot on the fabric from 1 inch away using a paper guide. The concentration of butyric acid that could be detected by the panel member was considered to be the butyric acid absorption level of the fabric. Dropping and smelling were continued until all people can smell butyric acid on the fabric. The average of the smell test results for each sample was determined. The treated fabrics from Example 4 of the present invention and from Examples 5 and 6, having prior art finishes, were tested for odor absorption according to the above. The results are shown below in Table B. It shows that all of the treated fabrics can absorb organic acid malodor at least for 30 home laundries. The chemical finishing is durable. TABLE B 1 HL 30 HL Untreated (ppm) 500 500 Example 4 (ppm) 2500 2500 Example 5 (ppm) 2000 2000 Example 6 (ppm) 2000 2000 b. Physical Strength Tearing strength (“Elmendorf tear”) is measured by ASTM test method D 1424-96 after one home laundry and tumble dry. Tensile strength is according to ASTM test method D5304-95 after one home laundry and tumble dry. The tearing strength and tensile for fabrics finished according to Example 4 and Example 5 were compared in Table C. It is clear that the tear strength and tensile strength were damaged dramatically when the fabrics were finished with the resin system of Example 5. However, physical strength loss, including both tear and tensile strengths, has been substantially improved by finishing with tertiary amine-containing polyacrylics of the invention. TABLE C Tensile Strength Tear Strength Warp Fill Warp (N) (N) (N) Fill (N) Untreated 754.9 285.3 13.7 7.0 Example 4 594.3 241.4 13.0 6.0 Example 5 244.5 67.7 7.1 3.3 c. Yellowing Whiteness index of untreated fabrics and treated fabrics was measured by Datacolor 600 spectrum following AATCC Test Method 110-2000. The whiteness index for fabrics treated according to Example 4 and Example 6 were compared with untreated fabrics right after treatment and after 30 home laundries, as shown in Table D. Whiteness index for fabrics treated with PEI (Example 6) dropped 40% right after treatment. After continuous 30 home laundries, the whiteness index decreased almost 60%. In contrast, the whiteness index for fabrics treated with the tertiary amine-containing polymers of the invention (Example 4) only dropped 13% after treatment, and it remained almost the same after 30 HLs. This whiteness index difference could be fixed by fluorescent whitening agent (FWA) easily. TABLE D 0 HL 30 HL Untreated 105 93 Example 6 62 41 Example 4 91 89 Example 8 Synthesis of Ether-Containing Poly(Tertiary Amine) Allyl glycidyl ether (7) and dimethyl amine (8) are charged into a flask with methylene chloride. The solution is stirred for 2 hours. The suspension is refluxed and filtered. Product (9) is obtained after the solvent is removed by distillation. N-(hydroxymethyl)acrylamide (4), amine-containing allyl glycidy ether (9) and the initiator 1,1′-azobis(cyclohexanecarbonitrile) (Vazo® 88, Dupont) are then charged in the flask. The solution is stirred overnight at 80° C. under nitrogen. The copolymer (10) of tertiary amine-containing allyl glydidyl ether and N-(hydroxylmethyl)acrylamide is obtained.
A finish for cellulosic fibrous substrates containing tertiary amine-containing polymers for providing durable control of body odors and the cellulosic materials treated with the finish, which materials exhibit little or no discoloration and little or no degradation of physical strength as a result of the treatment.
3
This application is a continuation of my application Ser. No. 769,869 filed Feb. 18, 1977 abandoned which is a continuation in part of my prior application filed Mar. 16, 1975, Ser. No. 559,492 now U.S. Pat. No. 4,070,146. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to burner heads and more specifically to such heads utilized in apparatus for the combustion of combustible waste gas from refineries and the like. 2. Description of the Prior Art It is common practice to use flare gas burners to burn waste gas from refineries and the like. One commonly used flare gas burner for this purpose includes a central gas pipe, surrounded by a large insulated cylinder containing burner heads therein which supply waste combustible gas for burning. The major objection to the available burner heads is that they concentrate gas being burned in one central area with inadequate surface area for mixing of air for efficient combustion with the gas. The surface area of the flare has a great effect upon diffusion of the gas and air, and this was not taken into account with many of the previously available burner heads. Waste gas diffusion is also dependent upon the Reynolds number, that is to say--whether it is a laminar or turbulent type of mixing. The U.S. Pat. No. 2,971,605 to Frost et al. shows a method and apparatus for flaring combustible gaseous materials but the burner heads shown therein do not provide for sufficient admixture of air with gas for complete smokeless combustion. While over the years, combustion can and has been inproved by using different types of burner heads, the burner heads heretofore and now employed are expensive and difficult to construct, do not provide for adequate mixing of air with the gas to be burned and often have maintenance problems aggravated by the variety of types of waste gas they are called upon to burn. SUMMARY OF THE INVENTION In accordance with the present invention, burner heads are provided for use in a flare gas burner for waste gas burning with a plurality of heads utilized for simultaneous operation, which burner heads may be utilized in a ground flare or in an elevated flare. It is the principal object of the invention to provide improved burner heads for use in burning waste combustible gas which provides for highly effective gas air mixing for complete combustion and smokeless operation. It is a further object of the invention to provide burner heads which operate at low and high BTU content gases levels and do not become plugged with carbon or other materials. It is a further object of the invention to provide burner heads which have a low pressure drop. It is a further object of the invention to provide burner heads that are simple to construct and enjoy a long service life. Other objects and advantageous features of the invention will be apparent from the description and claims. BRIEF DESCRIPTION OF THE DRAWINGS The nature and characteristic features of the invention will be more readily understood from the following description taken in connection with the accompanying drawings forming part hereof in which: FIG. 1 is a view in elevation and as seen from one side of one form of flare burner for use on the ground and its associated components within which the burner heads of my invention are uitlized, parts being broken away to show the details of construction; FIG. 2 is a horizontal sectional view, on a reduced scale, taken approximately on the line 2--2 of FIG. 1; FIG. 3 is a fragmentary elevational view showing a pair of burner heads in accordance with the invention; FIG. 4 is an enlarged vertical central sectional view of one preferred form of burner head employed in connection with the invention; FIG. 5 is a fragmentary plan view of the burner head of FIG. 4; FIG. 6 is a side elevational view of a combustible gas directing tip which is employed with the burner heads of FIGS. 4 and 5; FIGS. 7 and 8 are side elevational views of attachments for use with the burner tip of FIGS. 4 and 5; and FIG. 9 is an end elevational view of the burner heads and the combustible gas supply piping therefor. It should, of course, be understood that the description and drawings herein are illustrative merely and that various modifications and changes can be made in the structure without departing from the spirit of the invention. Like numerals refer to like parts throughout the several views. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now more particularly to the drawings, a flare burner of the ground flare type is shown generally at 20 with a combustible waste gas supply pipe 21 in communication therewith which in the form of the invention illustrated in FIGS. 1 and 2 is preferably buried beneath the ground a distance of the order of one or two feet for protection against the heat released by the combustion. The pipe 21 may extend above ground and be capped as at 22. The pipe 21, at spaced locations therealong, has connected thereto spaced pairs of vertically extending gas delivery pipes 23. The pipes 23, at their upper ends have outwardly extending hollow horizontal vanes 25, tangentially as shown in FIGS. 1 and 2, or radially as shown in FIGS. 4, 5, and 9. The vanes 25, as illustrated in FIGS. 6, 7, 8 and 9 have tilted converging tips 26 with upper slots 27 for discharge of gas in a vortex pattern for admixture with air for combustion. While the vanes 25 with their converging tips 26 are satisfactory for some types of waste gas, greater turbulence of discharge of the waste gas and improved admixture of the burning gas and air and a better flame pattern can be achieved with the attachment 28 shown in FIGS. 4 and 7 mounted and retained on the tip 26. The attachment 28 which fits over the end of tip 26 is of an open box-like configuration with end walls 29, and side walls 30 connecting the end walls 29. The side walls 30 are of a lesser height than the end walls 29 providing openings 31 for the combustible waste gas to escape for admixture with air and subsequent combustion. In FIG. 7, the attachment 28 has an inverted upper V shaped cap 32 with which the combustible gas is in contact and which directs the gas out the openings 31 in a sidewise pattern angularly directed with respect to the centerline through the tip 26. In FIG. 8, in another embodiment of my invention, attachment 28a is illustrated which is also of an open box-like configuration similar to attachment 28 with end walls 29a and side walls 30a, also of a lesser height than end walls 29a forming openings 31a with the cap 32a to permit gas to escape for admixture with the air and subsequent combustion. The cap 32a is of V shape so that the combustible gas striking it is diverted outwardly in a generally perpendicular pattern with respect to the centerline of the tip 26. Referring now more particularly to FIGS. 1 and 2, the vanes 25 are shown as disposed within a combustion chamber 35, preferably rectangular in horizontal cross section, which is open at the top, and enclosed within a plurality of vertical end walls 36 and side walls 37; as shown in detail in my prior application Ser. No. 559,492. The end walls 36 are illustrated as composed of a plurality of horizontal extending upright panels 38 having spaced horizontal ribs 39 engaged with upright H beams 40 forming part of the supporting frame. The panels 38 have vertical end flanges (not shown). The side walls 37 are similar to the end walls 36 except for the provision of a plurality of H beams 42 to provide the desired horizontal dimension. The side walls 37 have upright panels 38 with ribs 44. The vertical end flanges (not shown) of the panels 38 of the end walls 36 and of the side walls 37 are secured to vertical angles (not shown) by bolts (not shown) while the vertical flanges of the panels 38 of the side walls 37 are held in assembled relation by bolts (not shown) extending therethrough, a fiber lining 52 is provided secured to the inner faces of panels 38 to provide for noise reduction and insulation. The panels 38 of the walls 36 and 37 are terminated in spaced relation to the ground to provide air inlet openings 53 for induction of air for combustion and may be surrounded by a fence 60 which serves as a wind break and accoustical barrier. A pilot 55 is provided having a gas supply pipe 56 connected thereto and an igniter pipe 58 for supplying a flame if required to light the pilot 55, providing ignition for the gas delivered through burner heads 28 and 28a. The mode of operation will now be pointed out. Combustible waste gas, which may be, but is not limited to, low BTU content and of relatively low pressure of the order of a few inches of water can be employed, the burner tips 26 as shown in FIGS. 3, 5, and 6 being particularly suitable for burning such gas at such pressures. The gas is supplied through the pipe 21 and the pipes 22 to the burner tips 26 where it exits, is mixed with air, and ignited by pilot 55. The disposition of the burner tips 26 aids in providing turbulence while inducing air around the flat sheets of gas discharged through the slots 27 for combustion of the exiting gas. The waste combustible gas may also contain small entrained liquid particles that are to be burned, and also at times difficulty may be encountered with slugs or plugs of liquid or of solid carbonaceous material which tend to clog other types of tips but which can successfully pass out of tips 26 to be burned. The burner tips 26 with the attachments 28 or 28a shown in FIGS. 4, 7, and 8 are better suited for smokeless burning of gas having a high BTU content and provide greater turbulence and direct the waste gas through the slots 31 or 31a outwardly or transversely to a greater extent or at a flatter angle for contact with the air, induced by the flow. It should be noted that due to the efficient mixing of gas with air by the tips 26, 28 or 28a, all of the waste gas is burned in the combustion chamber 35. The delivery of the combustible waste gas through the pipe 21, the pipes 22 and the burner tips 26, without obstruction, is utilized to induce air through the air inlet openings 53 in addition to the natural draft in the combustion chamber 35 which supports effective combustion. It is thus apparent that the combustible gas pattern induced by the tips 26, attachments 28 and 28a is such that greater quantities of the air are caused to mix therewith with the resultant combustion being more efficient and smokeless.
Burner heads for incinerating waste combustible gas from refineries and the like are disclosed, for use in flare gas burners wherein a plurality of waste gas burner heads are provided for simultaneous operation at the same level, which heads may be utilized in a ground flare, or utilized in an elevated version of a ground flare burner. The burner heads provide for efficient admixture of gas with air, do not plug up, have a low pressure drop, burn both low and high BTU gases, and provide for smokeless combustion.
5
FIELD OF THE INVENTION [0001] This invention relates to the processing of organic and inorganic fibers used to reinforce composite materials. More particularly, the invention relates to novel sizing agents applied to natural and man-made fibers prior to being chopped into staple. BACKGROUND OF THE INVENTION AND PRIOR ART [0002] Non-woven fabrics have certain advantages over woven materials including using less-costly equipment in manufacture, the facile mixing of numerous fibers into a fabric and the ability to incorporate slick fibers such as glass and carbon. [0003] After man made fibers are spun, the mass of fibers is treated with a size to lubricate the fibers for protection against rubbing before and after chopping of the long strand bundles to form staple. This wet chop, typically kept in closed containers or plastic bags, is ultimately dumped into large tanks for dispersion. The tanks contain whitewater, a mixture of water and a variety of agents including viscosity modifiers and defoaming agents. Polyacrylamide (PAM)-based whitewaters are common in the industry. The sizing of the wet chop is critical to good dispersion in the whitewater. [0004] Once the fibers have been dispersed evenly, the slurry is introduced to a Fourdrinier or other web type sheet former device. The fibers are treated with a binder such as acrylate or phenol formaldehyde and dried. Ideally, residual sizing on the fibers helps with the coating by binder. [0005] Sizing used on wet chop, especially wet chop fiberglass, is typically non-ionic materials such as polyvinyl alcohol (PVA) and hydroxymethyl cellulose which is quite soluble in whitewater and buildup in whitewater as it is recycled. As a result, whitewater must be treated to remove sizing or disposed of as a regulated waste since the additives are not biodegradable and raise BOD in waters. [0006] Cationic polyvinyl alcohol compositions which are graft copolymers in methyl chloride quaternary salt form or methyl sulfate quaternary salt form are taught for use as wet end additives in the papermaking process in conjunction with a separate sizing agent in U.S. Pat. No. 7,144,946. [0007] A polyol in conjunction with a cationic lubricant (alkyl imidazoline) a water dispersible amide is taught as a sizing for glass fiber stands in U.S. Pat. No. 4,465,500. [0008] There remains an unmet need for a wet chop sizing which is inexpensive, effective for the protection of wet chop and dispersion in whitewater while remaining on the fiber during further processing. BRIEF DESCRIPTION OF THE INVENTION [0009] A cationized polyvinyl alcohol or hydroxyl methyl cellulose is the form of a quaternized ammonium compound or is provided as a sizing for spun organic and inorganic fibers. DETAILED DESCRIPTION OF THE INVENTION [0010] Poly vinyl alcohols having an average molecular weight between 13,000 and 100,000, preferably between 13,000 and 500,000 are preferred. A degree of hydrolysis of 70 to 99%, preferably 72-89%. A quaternized salt is prepared by reacting a polyvinyl alcohol with a quaternary salt of a dialkylamino ethyl acrylate in the presence of a catalyst such as a persulfate or peroxide. Preferred salts are chloride and sulfate. Ammonium persulfate is the preferred catalyst. [0011] The effective molecular weight of PVA can be raised significantly by the addition of borate ions due to extensive cross-linking. Borated PVA are preferred embodiments of this invention. [0012] Hydroxy cellulose, especially carbon methyl cellulose are also cross- linked by borate which can be used to adjust effective molecular weights and viscosity. Mixtures of cationized PVA and hydroxyl celluloses are included within the scope of the invention. Specific amounts used depend upon the ratio of alcohol precursors and their relative molecular weights. [0013] The cationized PVA may be produced as an aqueous suspension which is adjusted to a water content of 20%-80% by weight. [0014] The cationized PVA improves dispersion of fibers when wet chop is added to whitewater due to polar nature of the sized fibers. The low degree of dissolution into whitewater improves wet tack of the fibers on the wet web and allows increased processing speed. The polarity of the cationized size reduces the need for biocides in the whitewater. The lower solubility in whitewater reduces the number of changes of whitewater required and reduces the BOD of the waste whitewater. [0015] The invention has been described in terms of examples which demonstrate the utility but do not limit the scope of the invention. Changes or additions apparent to one with skill in the art are within the scope and spirit of the invention. [need paragraph of hydroxyl cellulose, CME]. INDUSTRIAL UTILITY [0016] The use of cationized polyvinyl alcohol as a sizing agent for wet chop improves performance and lowers production costs for products made using fiber, non-woven fabrics as a basis for construction. Construction materials such as shingles and roll goods are exemplary.
The catonized sizes poly vinyl alcohol and hydroxy celluloses are used in the manufacture of wet chop to improve product quality, cut cost and reduce the expenses incurred disposing of whitewater.
3
FIELD OF THE INVENTION Pilings which are formed from parent soil combined with a dry binder such as lime or cement. The diameter of the resulting piling can be varied from station to station to fulfill local structural requirements. BACKGROUND OF THE INVENTION Stabilization of soil, and providing in-situ pilings with various physical properties that differ from their surroundings are known. The general technique is to bore into the soil, and while there, inject lime or cement, and sometimes water. The procedure mixes these materials together, and when they harden, they form a piling. The term“piling” is used to denote a vertical rigid cylindrical structure, a body of revolution, having a strong vertical compressive strength, and often a lesser permeability compared to surrounding structure such as a clay soil. These pilings have a longitudinal vertical axis, and a peripheral side wall that extends from the surface of the soil to the bottom of the piling. For convenience, its locations along the axis will be referred to as“stations”, with station zero at the surface. The formation of such pilings is known, for example in Ichise et al U.S. Pat. No. 3,802,203 and Mitani et al U.S. Pat. No. 4,606,675 the injection of cement into a surrounding formation while an augur is pressed into the earth is shown. These systems rely on the presence of existing water, and cement or lime is added to make an appropriate mixture that will harden to form the piling. Applicant's Gunther U.S. Pat. No. 5,967,700 performs the same function, but builds a piling constituted of a hardened stoichiometric mixture of the reactive ingredients. In particular this means adding the appropriate amount of water for the cement or lime from station to station. In most of Europe, for example, usually there is enough water present to make at least a marginally effective piling. However this is not always the situation. For example in some areas around dams the soil is so dry that pits must be dug and water confined in them to soak the soil to the extent that a piling can ultimately be made, often many days later. The problem of dryness and variability of water content was solved by the said Gunther patent. The established art enables cylindrical in-situ pilings to be formed to various degrees of certainty as to their properties. Especially the process defined in the Gunther patent can provide assurance that a stoichiometric mixture of water, lime and/or cement will be provided to assure the ultimate structural properties of the piling. There remains, however, the limitation on all of the known processes that only a cylindrical piling is formed. This is not surprising, because the art of pilings has evolved from the driving of poles into the ground by percussive or vibration forces, or by drilling holes and later filling them with a material such as concrete, or as described above, mixing additives into a cylindrical structure to form an in-situ piling. What is assumed in the established art is that a piling, even an in-situ piling that includes native soil in its composition will necessarily be consistent from top to bottom (which is the situation only with the said Gunther patent), and that its structural requirements will be the same from top to bottom. To give assurance that the cylindrical shape will be adequate requires it to be over-designed for its location. This is because local conditions may vary from station to station. For example, an enlarged bulk might be needed near or at the lower end to anchor the piling in place or to take advantage of a very hard striation. To provident such a capacity there, the entire piling would have to be made as large. Another example is the need for greater rigidity at some station where the surrounding earth is more fluid, or when an anchoring flange could usefully be formed to take advantage of a surrounding region of greater strength. It is an object of this invention to provide a method to form a in-situ piling with a diameter which can selectively differ from station to station in a running manner so as to form a body of revolution with a structure suited to the requirement of localized regions in which it is generated. BRIEF DESCRIPTION OF THE INVENTION This invention can utilize many types of apparatus to accomplish its objectives. The necessary requirements are apparatus such as a rotary augur or drill which will be rotated around its axis while it is being driven into the ground and withdrawn from it. Its function is to enable its own progress into the ground and to mix or stir the loosened soil as it goes in and out. According to this invention, the device develops a column with a selectible diameter to create an in-situ piling of optimum cross-section, and even to form pilings of different diameters from station to station, using the same apparatus. According to a preferred but optional feature of the invention, the apparatus can provide water in an amount to supplement the existing water so that their total volume is stoichiometrically related to the amount needed for the strength of the piling of cement, lime, or other dry binder that acts with water to develop a hard body. Dry binders composed of synthetic materials are known and are included in this invention. By “dry” is meant their condition when injected into the soil, where upon they meet the water to solidify the piling. The above and other features of this invention will be fully understood from the following detailed description and the accompanying drawings, in which: BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic illustration of apparatus useful for the process of this invention; FIG. 2 is a schematic illustration of another suitable apparatus; and FIGS. 3-7 are schematic elevations of pilings which are made with this invention. DETAILED DESCRIPTION OF THE INVENTION Apparatus will be employed to augur into the earth, and while doing so mix lime or cement into the earth it engages, and optionally may also add water in an amount to supplement existing water for a stoichiometric between the amount of cement or lime needed for strength of the piling. The details of such apparatus are of no particular importance to this invention, and are shown only schematically herein for purposes of illustration of the process. Gunther U.S. Pat. No. 5,967,700 is hereby referred to and is incorporated herein by reference in its entirely for its showing of a system that does augur in and mix lime/cement and water as appropriate. It lacks provision for adjustably and selectively varying the diameter (and the outer configuration) of the piling, which it is the object of this invention to utilize. FIG. 1 illustrates the scheme of apparatus 10 useful for this process. A central rotatable shaft 11 with a central axis 11 a has a cutting bit 12 on its lower end adapted to make the leading entry into a body 13 of soil from its surface 14 . The bit may be a rotary sharp edged plate or a fluted cone as preferred. A pair of blades 15 , 16 are pivoted to the shaft at hinges 17 , 18 , so they will be rotated around the central axis of the tool. At least theoretically, only one blade could be used, but the desirability of a balanced pair of blades is obvious. A pair of adjustment rods 20 , 21 are pivoted to respective blades 15 , 16 by hinges 22 , 23 . At their other end they are pivoted to an adjustment sleeve 24 which is axially movable along the shaft, under control of some device which can move it, preferably located at the surface. It will be observed that the distance D between the ends of the blades will be diameter of the piling 19 at that station (twice the radius of one tip). It is the purpose of this invention adjustably to select the value of diameter D. The blades are provided to drill into the soil on the way down, and to mix the soil, water and cement on the way up. The blades are rotated while moving both up and down, as shown in the Gunther patent. Also, depending on the conditions, water may be injected through ports from the shaft (not shown), and powdered dry binder, of which cement and lime are examples, also from ports in the shaft (not shown). The specific construction of the apparatus is of no importance to the instant invention. For example, FIG. 2 shows the use of multiple piece, horizontal mixer-cutter blades 30 , 31 , each having a base blade 32 , 33 , and a secondary blade 34 , 35 . Both blades cut and mix. The secondary blades can be moved radially in and out by rods 36 , 37 pivoted to a sleeve 38 , so the diameter D of the bore will be that of the distance between the tips 39 , 40 of the secondary blades, as established by movement of the sleeve. There are many other conceivable mechanisms for this purpose, the two examples being merely exemplary. Regardless of the mechanism used, the resulting piling will be a solid surface of revolution with an outer boundary, whose outer wall diameter will be established by the dimension D between the tips of the blades. This invention contemplates using the same apparatus to form cylindrical pilings of different diameters from one piling to another. However, its principal advantages are in the process of providing a piling with different diameters from station to station in the same piling. Frequently a piling will pass through regions of various hardness and wetness at different stations. In some of these, it may be desirable to have a larger diameter, perhaps to form an enlarged footing, or perhaps a collar to rest on harder soil, or perhaps to interface in a key-like manner with an adjacent piling. For example, FIG. 3 shows a piling 45 with a cylindrical shaft 46 depending from an enlarged head 47 . This structure will give additional support for the piling from above. FIG. 4 shows the reverse, an enlarged footing 50 on a piling 51 supporting a rising shaft 52 . This structure will provide a strong upward support and stabilizer for the piling. FIG. 5 shows a piling 53 with an undulating silhouette 54 . The enlargements 55 , 56 are spaced apart. For example they might “key” to a hard soil layer, or merely add resistance to vertical displacement of the piling. FIG. 6 illustrates a keying relatively between two pilings 60 , 61 with undulating silhouettes that engage one another. This provides for mutual support of the pilings. FIG. 7 illustrates a piling 65 with a continuously changing diameter. It is shown as a conical structure with an enlarged lower end. In practice the enlarged end could instead be the upper end. This illustrates the wide range of diameters and silhouettes that can be attained with this invention. Accordingly, the process of this invention comprises forming in-situ pilings of selected diameter or diameters which may be different from piling to piling, or which may be varied from station to station along the length of the piling. As the blades move through the soil, a dry binder, examples of which are cement and lime, and sometimes water will be added so as to be mixed with the soil and form the piling when cured. The preferred embodiment of the invention provides water to establish a wetness appropriate to a stoichiometric reaction with a dry binder such as cement or lime which is later mixed in with the appropriately wetted soil, as described in the Gunther patent. This invention is not to be limited by the embodiments shown in the drawings and described in the description, which are given by way of example and not of limitation, but only in accordance with the scope of the appended claims.
A process to make in-situ pilings comprised of soil, cement, lime and water, the pilings being bodies of revolution formed by rotating a mixer-cutter blade whose cutting diameter is selectably adjustable, preferably on a running basis so as to have the capability of producing piling with a diameter that differs from station to station.
4
BACKGROUND OF THE INVENTION Conventional mechanical stages for microscopes have manually actuable drive mechanism mounted below the table, with a coaxial arrangement of the drive means for the two directions of displacement. The transmission of the rotary actuation of the drive knobs is translated into table displacement via pinions which mesh with racks on individually displaceable table parts. When scanning large-area objects, the user of such tables frequently desires to bring the table rapidly into an approximate desired position without time-consuming rotation of the drive mechanism, which operates with a very high reduction ratio. A simple direct shifting of the table by hand is, however, not readily possible since the drive mechanism is characterized by friction which is necessary to assure stability of the table; this friction, in the context of the transmission-reduction ratio, makes a rather large expenditure of force necessary, whereby the racks or pinions could be damaged. For rapid displacement of the table, it is already known to disconnect the drive mechanism from the table by means of an additional handle. Such devices are described, for instance, in German Pat. Nos. 3,025,974 and 3,037,710 and German Offenlegungsschrift application Nos. OS-3,027,461 and OS-3,037,741. For this purpose, friction-wheel gearing is interposed between the table and the drive mechanism, and for disconnection, the drive mechanism is either moved axially or the entire drive-mechanism housing is moved radially, so that both the drive-side and the driven-side friction wheels become disengaged. The known solutions are, however, unsatisfactory, since, on the one hand, the drives should be relatively secure with respect to the table while, on the other hand, the engagement and disengagement process should take place easily so as to avoid accidential displacement of the table. Both of these requirements can be satisfied from a design standpoint only with difficulty or by relatively expensive measures. BRIEF STATEMENT OF THE INVENTION The object of the present invention is to provide a selectively engageable/disengageable coupling for the drive of a mechanical stage, wherein there is no displacement of drive mechanism in order to engage or disengage coupling. The invention achieves this object by selectively interposing a pressure roller in the drive train for each of two components of stage drive. For each of these components of drive, there is a drive-side friction wheel and a driven-side friction wheel which are engaged only when the pressure roller is in loaded contact with both these wheels. A single actuating device establishes the engaged or disengaged condition of both component drive trains. This solution has the advantage over the prior art that it is of simple and uncomplicated construction since, for an uncoupling, a pressure roller, or two rollers seated on a common shaft, one for each component of table displacement, need only be retracted from engagement with friction wheels which are mounted on fixedly spaced axes. The pressure roller is illustratively carried by a pivoted lever which is readily displaceable via a knob-operated eccentric. DETAILED DESCRIPTION The invention will be described in detail for a preferred embodiment, in conjunction with the accompanying drawings, in which: FIG. 1 is a vertical section through a mechanical stage wherein the displacement drive mechanism incorporates coupling means of the invention; FIG. 2 is a horizontal section, along the line II--II of FIG. 1; and FIG. 3 is a view similar to FIG. 2 to show a modification. The drawings show the invention in application to the table 1 of a mechanical stage (e.g., a microscope stage) which is displaceable in two orthogonally related component directions. The table 1 carries a rack 2 which meshes with a pinion 8 on a driven shaft 7; shaft 7 is rotatable in a bearing 6 and also mounts a driven-side friction wheel 12. Drive for shaft 7 originates with a rotary knob 18 of coaxial drive mechanism, rotatably mounted by a drive-mechanism housing 4. Knob 18 is on a tubular shaft 17 which carries a drive-side friction wheel 16, and a pressure roller 20, selectively engageable to both friction wheels 12, 16 is the means of coupling knob 18 to shaft 7. The bearing 6 for driven shaft 7 is secured to a carriage 3 which is guided by coacting guide means 105 on the fixed part or base 106 of the mechanical stage, so that bearing 6 is displaceable in the plane of the drawing. Bearing 6 also carries a tubular shaft 10 having a pinion 9 which meshes with a rack 5 that is bolted at 107 to the fixed stage part. Shaft 10 is driven by a rotary knob 15 via second friction-wheel mechanism consisting of a drive-side friction wheel 13 fastened to the shaft 14 of knob 15, a pressure roller 19, and a driven-side friction wheel 11 on shaft 10. The drive-mechanism housing 4, in which the coaxial drive-mechanism 13-18 is mounted, is also fastened to carriage 3. Accordingly, upon rotation of knob 15, carriage 3 and the drive mechanism housing 4 move along the rack 5, and table 1 is carried along in this component direction. The pressure rollers 19 and 20 couple the friction wheels 11/13 and 12/16 to each other via a resiliently loaded engagement. Both rollers 19 and 20 are mounted on a shaft 21 which is held with play, via a rod 27, to a lever 22 which is pivotable about a support pin 30. Rod 27 is guided in a bore in lever 22 and has limited freedom of longitudinal and rotary movement with respect to lever 22, the limits being determined by a small-diameter transverse securing pin 29 in rod 27, with pin 29 trapped in a large-diameter transverse hole 28 in lever 22. A spring 31 resiliently biases lever 22 in the direction of pressure-roller engagement. The play which is thus afforded for mounting rollers 19 and 20 provides assurance that both rollers 19 and 20 will always engage with constant resiliently loaded force against the two pairs of friction wheels 11/13 and 12/16. To disengage the described drive mechanism, a cam 23 which can be actuated by another rotary knob 24 is provided in the drive-mechanism housing. Upon rotating cam 23 against a stop 25, lever 22 is swung, in the direction indicated by an arrow 26, and the pressure rollers 19 and 20 are lifted away from the corresponding friction wheels. In the described embodiment, the two pressure rollers 19 and 20 are actuated jointly by a single rotary knob 24, and in this way table 1 is disengaged from the drive mechanism with respect to both component directions of displacement. It is, of course, just as possible to mount each of the two rollers 19 and 20 for individually pivoted displacement, and to provide each of them with its own rotary knob, should rapid displacement in only one coordinate direction be desired. Such is the arrangement of FIG. 3, wherein lever 22 is shown to have a forked end via which roller 19 is supported in a first plane of engageability to friction wheels 11-13, and wherein a second lever 22' is shown to have a forked end via which roller 20 is supported in a second plane of engageability to friction wheels 12-16. Separately actuable rotary cams 23-23' enable selective operation of these levers, in opposite swing directions 26-26'. It is furthermore possible, in the case of FIGS. 1 and 2, to mount knob 24 coaxially to the two rotary knobs 15 and 18 of the drive mechanism.
The invention contemplates selectively engageable/disengageable coupling mechanism within the respective drive trains which impart two-component displacement to a mechanical stage such as a microscope stage. For each component of drive, a pressure roller is selectively interposable between a drive-side friction wheel and a driven-side friction wheel which are engaged only when the pressure roller is in loaded contact with both of these wheels.
8
FIELD OF INVENTION [0001] The field of invention relates generally to networking; and more specifically, to a method and apparatus for inserting user data into a SONET data communications channel. BACKGROUND [0002] [0002]FIG. 1 shows a standard format 100 for an STS- 1 signal. STS- 1 signals are typically viewed as basic building blocks for Synchronous Optical NETwork (SONET) based architectures. An STS- 1 signal includes a payload 101 , a path overhead 102 and a transport overhead 103 . The payload 101 and the path overhead 102 , the combination of which are referred to as the synchronous payload envelope (SPE), consume 783 bytes of information (i.e., 87 bytes×9 bytes). [0003] A transport overhead 103 is appended to each SPE to form an STS- 1 signal. The transport overhead 103 includes 27 bytes per SPE (i.e., 3 bytes×9 bytes). Thus, the standard format for an STS- 1 signal is an 810 byte structure (i.e., 783 bytes+27 bytes). To construct an STS- 1 signal, the format 100 outlined in FIG. 1 is transmitted from a first network node to a second network node every 125 us. Thus, an STS- 1 signal corresponds to a 51.84 Mbps signal (i.e., 810 bytes/125 us=51.84 Mbps). [0004] A SYNnchronous Optical Network (SONET) frame may be viewed as a timed data structure that carries “n” standard STS- 1 signal formats 100 per 125 us. For example, a SONET networking line having only one STS- 1 signal format 100 per frame (i.e., n=1) corresponds to a line speed of 51.840 Mbps (i.e., 810 bytes every 125 us). Similarly, a SONET networking line having forty eight STS- 1 signal formats per frame (i.e., n=48) corresponds to a line speed of 2.488 Gbps (i.e., 38880 bytes every 125 us), and a SONET networking line having one hundred and ninety two STS- 1 signal formats per frame (i.e., n=192) corresponds to a line speed of 9.952 Gbps (i.e., 155520 bytes every 125 us). Note that if the applicable networking line is optical “OC” is typically used instead of “STS” (e.g., OC- 48 , OC- 192 etc.). [0005] The transport overhead 103 is divided into a “section” overhead and a “line” overhead (which are not shown in FIG. 1 for simplicity). The section overhead consumes nine bytes of information within the transport overhead 103 and the line overhead consumes eighteen bytes of information within the transport overhead 103 . [0006] Three bytes of the section overhead are reserved for a section data communication channel (DCC) that is traditionally used to communicate control information for repeaters within a SONET network. Nine bytes of the line overhead are reserved for a line DCC that is traditionally used to communicate control information for terminating equipment within a SONET network. [0007] Control information is used to control the operation of the network and is therefore distinguishable from the random “customer” data that is transported by the network within payload 101 . Both the section DCC and line DCC are traditionally used to carry alarms, network maintenance data, commands, network performance data and other administrative data to/from any node within a larger SONET network. [0008] Three bytes per STS- 1 correspond to a 192 kbps communication channel (i.e., 24 bits/125 us=192 kbps) while nine bytes per STS- 1 signal correspond to a 576 kbps communication channel (i.e., 72 bits/125 us=576 kbps). Thus, per STS- 1 signal, the section DCC corresponds to a 192 kbps channel and the line DCC corresponds to a 576 kbps channel. [0009] Note that the bandwidth of the DCC channels expand linearly with the line speed of a SONET networking line. For example, for an OC- 192 SONET line, the bandwidth reserved for the line DCC corresponds to 36.864 Mbps (i.e., 192×192 kbps) while the bandwidth reserved for the section DCC corresponds to 110.592 Mbps (i.e., 192×576 kbps). [0010] [0010]FIG. 2 shows a networking architecture 200 typically associated with Ethernet (E/N). Ethernet is any of the IEEE 802.3 based communication standards. Ethernet based networks are typically comprised of a switching hub 220 that is communicatively coupled to a plurality of client nodes 210 1 through 210 n . The switching hub 220 collects outbound traffic that is transmitted from each of its client nodes (e.g., along outbound network lines 203 1 through 203 n ) and transmits inbound traffic to each of its client nodes (e.g., along inbound network lines 202 1 through 202 n ). [0011] The switching hub 220 allows the client nodes 210 1 through 210 n to communicate with one another or communicate with a larger network coupled to the switching hub (e.g., via trunk line 215 ). In alternate networking architectures, switching hub 220 may be replaced by a router. LIST OF FIGURES [0012] [0012]FIG. 1 shows a standard format for an STS- 1 signal. [0013] [0013]FIG. 2 shows a switching hub based networking architecture. [0014] [0014]FIG. 3 shows an STS- 1 signal having high priority traffic allocation and low priority traffic allocation. [0015] [0015]FIG. 4 shows an embodiment of a framer that may be used to implement the STS- 1 signaling format shown in FIG. 3. [0016] [0016]FIG. 5 shows an embodiment of a method that may be utilized by the framer of FIG. 4. DETAILED DESCRIPTION [0017] The Institute of Electronic and Electrical Engineers (IEEE) P802.3ae task force is developing a specification for a Wide Area Network (WAN) physical layer interface (PHY) that employs SONET OC- 192 c framing (hereinafter referred to as “10 Gbps E/N PHY”). The switching hub architecture discussed in FIG. 2 is an envisioned network architecture that is likely to be implemented with the 10 Gbps E/N PHY. [0018] That is, for example, outbound network lines 203 1 through 203 n and inbound network lines 202 1 through 202 n may each correspond to an OC- 192 c SONET line and therefore may each possess a line speed of approximately 10 Gbps (recalling that the line speed of a SONET OC- 192 line is 9.952 Gbps). Notably, the task force has not specified any use for the section DCC and line DCC discussed above in the background. [0019] Networking technology is generally challenged with prioritizing the different types of traffic that exist. For example, real time voice traffic or real time video traffic (such as, respectively, a telephone call or video conference call) should suffer low latency (i.e., a small end to end transit time across the network) so that users of the network do not suffer through a cumbersome communication experience. Non real time traffic (such as emails, documents, etc.) generally can tolerate greater latency because the user is generally indifferent as to how long it takes to receive such information. [0020] Network providers and their equipment suppliers may therefore wish to emphasize, in some manner, the ability to distinguish between the two types of traffic so that they may be treated differently. Specifically, real time traffic may be labeled as “high priority” and therefore provided a low latency path through the network while non real time traffic may be labeled as “low priority” and therefore provided a higher latency path through the network. [0021] [0021]FIG. 3 shows an STS- 1 signaling format 300 that allocates for high priority data within the transport overhead 303 and allocates for low priority data within the payload 301 . In an embodiment, the section and line DCC channels within the transport overhead 303 are utilized to supply a combined bandwidth of 768 kbps per STS- 1 signal for high priority user data. [0022] Note that, unlike the prior art where the DCC channels are only used to transport control information, the approach of FIG. 3 utilizes the DCC channels to carry “random” customer data (also referred to as user data) that has been traditionally carried only within payload 301 . That is, a user data is data offered by a customer of a network as opposed to the provider of a network (who offers control information data). [0023] In an embodiment, low latency is provided for a user's high priority traffic by keeping the offered load of the high priority traffic equal to or less than the bandwidth of the DCC channels. For example in a further embodiment, if a particular user consumes one STS- 1 signal, the user's combined high priority offered load (i.e., the rate at which the user's high priority traffic is presented to the network for transportation) is limited to 768 kbps or less. As a single STS- 1 signal payload 301 corresponds to a data rate of 50.112 Mbps (i.e., 87 bytes×9 bytes per 125 us), note that the same user may be allowed to present a low priority offered load (i.e., the rate at which the user's low priority traffic is presented to the network for transportation) that is greater than 50.112 Mbps. [0024] From basic queuing theory, as the user's low priority offered load increasingly exceeds 50.112 Mbps, the greater the delay will be imposed upon the user's low priority traffic. However, as discussed above, delay added to the transit time of low priority traffic is more easily tolerated than the delay added to high priority traffic. [0025] [0025]FIG. 4 shows an embodiment of a framer that may be used to implement the STS- 1 signaling format shown in FIG. 3. A framer 401 is one or more semiconductor chips that provide framing organization for a network line. For example, the exemplary framer 401 of FIG. 1: 1) formats STS- 1 signals into frames that are transmitted on an outbound networking line 403 to another network node (such as a switching hub if framer 401 corresponds to a framer located within in a client node); and 2) retrieves STS- 1 signals from frames received from another network node on an inbound networking line 402 . [0026] In the case of outbound transmission, other portions of the networking system (i.e., a machine that acts as a node within a network such as a client node or switching hub) that house the framer 401 individually provide each STS- 1 signal carried by the outbound network line 403 to the framer 401 . For example, a first STS- 1 signal is presented to the framer at input 406 1 , a second STS- 1 signal is presented to the framer at input 406 2 , etc. Consequently, for example, the framer 401 maps into a SONET frame on outbound networking line 403 : the STS- 1 signal received at input 406 1 ; the STS- 1 signal received at input 406 2 ; etc. [0027] Correspondingly, in the case of inbound transmission, each STS- 1 signal carried by the inbound network line 402 is individually presented by the framer 401 to higher layers of the networking system that houses the framer 401 . For example, a first STS- 1 signal received from a SONET from on network line 402 is mapped to framer output 405 1 , a second STS- 1 signal is mapped to framer output 405 2 , etc. [0028] Note that different types of framers may exist. In one respect, the granularity of the inbound and outbound signals may vary. For example, each of the individual inbound signals 405 1 through 405 n and each of the individual outbound signals 406 1 through 406 n may be comprised of a signal that consumes less bandwidth than an STS- 1 signal (e.g., down to a 64 kbps signal) or more bandwidth than an STS- 1 signal (e.g., each individual input signal may correspond to a group of STS- 1 signals such as an STS- 3 rate signal or an STS- 12 rate signal, or higher). [0029] Regardless of granularity, the framer 401 may be designed to include “high priority data” inputs for each outbound signal 406 1 through 406 n where the high priority data inputs accept an amount of data that is commensurate with the DCC bandwidth associated with the total number of STS- 1 signals consumed by an outbound signal. For example, if framer 401 corresponds to an OC- 192 framer that receives sixteen OC- 12 rate outbound signals (i.e., n=16 in FIG. 4 where each outbound signal 406 1 through 406 16 corresponds to a 601.344 Mbps interface(50.112 Mbps×12), the input for each outbound signal 406 1 through 406 n includes an interface for receiving 9.216 Mbps worth of high priority data. [0030] The 9.216 Mbps worth of high priority data is fed to the twenty four DCC channels (i.e., twelve section DCCs and twelve line DCCs) that are, per frame, associated with the twelve STS- 1 payloads used to transport the low priority traffic of a single outbound signal. The framer 401 may be similarly designed to include “high priority data” outputs for each inbound signal 405 1 through 405 n where the high priority data outputs present an amount of data that is commensurate with the DCC bandwidth associated with the total number of STS- 1 signals consumed by an inbound signal. [0031] Regardless of the granularity (i.e., the number of STS- 1 signals) associated with inbound signals 405 1 through 405 n and outbound signals 406 1 through 406 n , for each STS- 1 signal worth of data processed by the framer, 768 kbps of bandwidth may be allocated for high priority user data. Note that various architectural approaches may be used to allocate the DCC channels for high priority user data. [0032] For example, in one embodiment, the high priority user data transportation services that are provided by the line and section DCC channels for a particular STS- 1 signal can only be used to support that user associated with the payload of that STS- 1 signal. That is, if the line and section DCC channels within a particular STS- 1 signal are used to carry a user's high priority data, the user's low priority data must be carried by the payload associated with the particular STS- 1 signal. [0033] Thus, for example, if a user is allocated for 3 STS- 1 signals (e.g., an OC- 3 rate user) the user is automatically allocated 2.304 Mbps worth of high priority data transportation (3×0.768 Mbps). If the user has no traffic to offer the DCC channels, the DCC channels are effectively “wasted” because other users may not gain access to them. [0034] In an alternate architectural approach, the DCC channels associated with a particular STS- 1 signal may be configured for any user irrespective of the user that is being serviced by the payload of the particular STS- 1 signal. Here, the total DCC channel bandwidth for a SONET line (e.g., 192×0.768 Mbps=147.456 Mbps for an OC- 192 line) is viewed as a 147.456 Mbps “pipe” that may be used to transport high priority traffic. The 147.456 Mbps pipe can service the high priority traffic of various users on an as needed basis. [0035] [0035]FIG. 5 shows an embodiment of a method that may be utilized by the framer of FIG. 4. Processing in both the outbound and inbound directions is shown. In the outbound direction, a payload 500 of low priority data is formed and the transmit path overhead is added 501 . Then, the transmit line overhead is added 502 . Associated with the addition 502 of the transmit line overhead is the introduction of high priority user data 504 into the bytes reserved for the line DCC. [0036] Then, the transmit section overhead is added 503 . Associated with the addition 503 of the transmit section overhead is the introduction of high priority user data 505 into the bytes reserved for the section DCC. At this point, the STS- 1 signal may be mapped into and transmitted 506 within a SONET frame. The inbound process is effectively a reverse of the outbound process. [0037] The section overhead of an STS- 1 signal received from a SONET frame 507 is extracted 508 . Associated with the extraction 508 of the section overhead is the extraction of high priority user data 512 found within the bytes reserved for the section DCC. Then, the line overhead is extracted 509 . Associated with the extraction 509 of the line overhead is the extraction of high priority user data 513 found within the bytes reserved for the line DCC. The path overhead is then extracted 510 leaving low priority user data 511 . [0038] Note also that embodiments of the present description may be implemented not only within a semiconductor chip but also within machine readable media. For example, the designs discussed above may be stored upon and/or embedded within machine readable media associated with a design tool used for designing semiconductor devices. Examples include a netlist formatted in the VHSIC Hardware Description Language (VHDL) language, Verilog language or SPICE language. Some netlist examples include: a behavioral level netlist, a register transfer level (RTL) netlist, a gate level netlist and a transistor level netlist. Machine readable media also include media having layout information such as a GDS-II file. Furthermore, netlist files or other machine readable media for semiconductor chip design may be used in a simulation environment to perform the methods of the teachings described above. [0039] Thus, it is also to be understood that embodiments of this invention may be used as or to support a software program executed upon some form of processing core (such as the CPU of a computer) or otherwise implemented or realized upon or within a machine readable medium. A machine readable medium includes any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer). For example, a machine readable medium includes read only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; electrical, optical, acoustical or other form of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.); etc. [0040] Note also that embodiments of the present description may be implemented not only within a semiconductor chip but also within machine readable media. For example, the designs discussed above may be stored upon and/or embedded within machine readable media associated with a design tool used for designing semiconductor devices. Examples include a netlist formatted in the VHSIC Hardware Description Language (VHDL) language, Verilog language or SPICE language. Some netlist examples include: a behaviorial level netlist, a register transfer level (RTL) netlist, a gate level netlist and a transistor level netlist. Machine readable media also include media having layout information such as a GDS-II file. Furthermore, netlist files or other machine readable media for semiconductor chip design may be used in a simulation environment to perform the methods of the teachings described above. [0041] Thus, it is also to be understood that embodiments of this invention may be used as or to support a software program executed upon some form of processing core (such as the CPU of a computer) or otherwise implemented or realized upon or within a machine readable medium. A machine readable medium includes any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer). For example, a machine readable medium includes read only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; electrical, optical, acoustical or other form of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.); etc.
A SONET framer having a user data input that feeds a data communication channel. The data communication channel is located within a transport overhead. The transport overhead is appended to a SONET payload envelope. A method of inserting user data into a data communication channel. The data communication channel is located within a transport overhead. The transport overhead appended to a SONET payload envelope.
7
TECHNICAL FIELD The present invention relates to the field of fluorinated products intended for the water-repellency and oil-repellency treatment of substrates such as textiles moquette carpets, wall coverings, wood, building materials, metals, plastics, and its subject is especially products which can be used more particularly for protecting leather whose finish and maintenance should have the following characteristics: suppleness, pleasant apperarance and feel. BACKGROUND ART The use of fluoroacrylic resins in these types of applications is well known, but current compounds have a number of disadvantages: a slightly sticky feel, poor cleaning and abrasion resistance and slight alteration in the appearance of the substrate. Compositions comprising perfluoro groups and urethane linkage have already been proposed; see, for example, the following patents: U.S. Pat. Nos. 3,468,924, 3,503,915, 3,528,849, 3,896,035, 3,896,251 and 4,024,178 FR No. 2,062,244, DE No. 1,620,965, CA No. 1,071,225, EP No. 103,752 and CH No. 520,813 and 512,624. Unfortunately, these products are not always satisfactory, either because the synthesis of the intermediates is diffiult, or because they must be combined with acrylic copolymers because they are not film-forming, do not withstand dry cleaning and/or do not have good stainrepellent properties, or alternatively because they must be supplied as an aqueous emulsion because of their low solubility in solvents. A new class of fluoroacrylic monomers has now been discovered, whose polymers have outstanding water-repellency and oil-repellency properties and are perfectly adapted to the treatment of leather because of the mechanical properties of their films (adhesion to the substrate, transparency and abrasion resistance). SUMMARY OF THE INVENTION The fluoroacrylic monomers according to the present invention, which simultaneously contain a urethane linkage and a urea linkage or two urea linkages, may be denoted by the general formula: ##STR2## in which: R f denotes a straight- or branched-chain perfluoroalkyl radical, R denotes hydrogen or a methyl radical R' denotes an alkyl or cycloalkyl radical or --NR' denotes 1,4-piperazinylene radical, W denotes a divalent linking group attached to Q via a carbon atom and capable of containing one or more oxgen, sulphur and/or nitrogen atoms, Q denotes oxygen or sulphur or an --NR"-- group. R" denoting hydrogen or an alkyl radical, Z denotes a divalent aliphatic, alicyclic or aromatic connecting group and A denotes an alkylene group containing 2 or 3 carbon atoms. The perfluoroalkyl radical R f may contain from 2 to 20 carbon atoms. However, compounds in which R f is a linear perfluoroalkyl radical containing 6, 8 qr 10 carbon atoms are preferred. The alkyl radical R' may have a straight or branched chain and may contain from 1 to 12 carbon atoms. Compounds in which R' contains 2 to 4 carbon atoms, and more especially those in which R' is the tert-butyl radical are preferred. When R" is alkyl, it may contain from 1 to 4 carbon atoms. Z may contain from 6 to 14 carbon atoms. DETAILED DESCRIPTION OF THE INVENTION The fluoroacrylic monomers of formula (I) according to the invention may be prepared by reacting a diisocyanate of the formula: O═C═N--Z--N═C═O (II) with substantially equimolar quantities of a polyfluoro compound of the formula: R.sub.f --W--Q--H (III) and an acrylic ester of the formula: R'--N(H)--A--O--C(O)--C(R)═CH.sub.2 (IV) As examples of diisocyanates which may be used include aromatic diisocyanates such as 2,4- and/or 2,6-toluene diisocyanate, 4,4'-diphenylmethane diisocyanate and xylylene diisocyanate; aliphatic diisocyanates such as hexamethylene diisocyanate and decamethylene diisocyanate; and alicyclic diisocyanates such as 4,4'-methylene bis(cyclohexyl isocyanate), 2-methyl-1,4-cyclohexane diisocyanate and isophorone diisocyanate. Among these diisocyanates, 2,4-toluene diisocyanate is especially preferred by itself or mixed with the 2,6-isomer. The polyfluoro compound (III) is a compound containing a mobile hydrogen atom in the form of a terminal hydroxyl, thiol or primary or secondary amino group, attached to the perfluoroalkyl radical directly via, alkylene bridge or indirectly via a concatenation consisting of one or more alkylene bridges and of a sulphonamido, carbonamido, ether, thioether, sulphonyl or carboxylic ester group. As examples of such polyfluoro compounds, the invention particularly includes those of the following formulae: ##STR3## in which R f and R" have the same meaning as defined above, and the symbols p and q, which can be identical or different, each denote an integer ranging from 1 to 20 and preferably equal to 2 or 4. For economic and practical reasons, it is especially advantageous to use a mixture of compounds representing various radicals R f . Among the compounds (III), those of formulae (III -a), (III -c) and (III -k), in which p and q are equal to 2, are most especially preferred. As examples of esters of formula (IV), the acrylic and methacrylic esters of 2-t-butylamino ethanol, 2-t-octylamino ethanol, 2-cyclohexylamino ethanol, 2-laurylaminoethanol and 2-piperazino ethanol have been found to be particularly useful. A preferred compound of formula (IV) is 2-t-butylaminoethyl methacrylate of formula: ##STR4## The synthesis of the fluoroacrylic monomers (I) according to the invention may be carried out in an organic solvent such as ketonic solvents (e.g., methyl ethyl ketone or methyl isobutyl ketone), esters (e.g., ethyl acetate or butyl acetate), aromatic solvents (e.g., toluene, xylene or benzene), alkanes (e.g., hexane, heptane or cyclohexane), ethers (e.g., diisopropyl ether or tetrahydrofuran), halogenated solvents (e.g., 1,1,1-trichloroethane or trichlorotrifluoroethane), dimethylformamide and N-methylpyrrolidone. The addition reactions of the polyfluoro compound R f --W--Q--H and of the acrylic ester (IV) to the --N═C═O groups are carried out between 30° and 90° C. under an inert atmosphere, for example under dry nitrogen. Since the addition of the polyfluoro compound is slow, it is preferable to conduct this reaction in the presence of a catalyst such as, for example, a tertiary amine like triethylamine, triethylene diamine and N-methylmorpholine, a tin salt like dibutyltin dilaurate and tin octoate, or a lead salt like lead naphthenate, the catalyst being used in a proportion of 0.05 to 1% based on the total weight of the reactants. In order to limit the formation of symmetrical diaddition products, the perfluoro compound R f --W--Q--H is added dropwise, under dilution and temperature conditions such that the reaction is virtually instantaneous and that there is always a deficiency of R f --W--Q--H relative to the isocyanate (i.e., an excess of isocyanate). The acrylic ester bearing the more active --NH group is added in a second step. It reacts very readily with the remaining free--N═C═O groups. The formation of symmetrical diaddition compounds cannot be avoided altogether; but it is possible, if desired, to remove them by filtration, since their solubility in the reaction solvents is lower than that of the urethane/urea monomers of formula (I). The invention also relates to the polymers containing repeat units of formula: ##STR5## in which the various symbols have the same meanings as defined above. These polymers may be prepared from the monomers of formula (I) by homopolymerization or by copolymerization with other monomers (fluorinated or otherwise) in a proportion ranging up to 90% by weight based on the total weight of monomers. As examples of comonomers which may be used within the scope of the present invention, the following are included: lower (halogenated or otherwise) olefinic hydrocarbons such as ethylene, propylene, isobutene, 3-chloro-1-isobutene, butadiene, isoprene, chloro- and dichlorobutadiene, fluoro- and difluorobutadienes, 2,5-dimethyl-1,5-hexadiene and diisobutylene; vinyl, allyl or vinylidene halides such as vinyl or vinylidene chloride, vinyl or vinylidene fluoride, allyl bromide and methallyl chloride; styrene and its derivatives, such as vinyltoluene, α-methylstyrene, α-cyanomethylstyrene divinyl benzene and N-vinylcarbazole; vinyl esters such as vinyl acetate, vinyl propionate, vinyl esters of acids known commercially under the name of "Versatic Acids", vinyl isobutyrate, vinyl senecioate, vinyl succinate, vinyl isodecanoate, vinyl stearate and divinyl carbonate; allyl esters such as allyl acetate and allyl heptanoate; alkyl vinyl ethers or alkyl allyl ethers (halogenated or otherwise), such as cetyl vinyl ether, dodecyl vinyl ether, isobutyl vinyl ether, ethyl vinyl ether, 2-chloroethyl vinyl ether and tetraallyl oxy ethane; vinyl alkyl ketones such as vinyl methyl ketone; unsaturated acids such as acrylic, methacrylic, α-chloroacrylic, crotonic, maleic, fumaric, itaconic, citraconic and senecioic acids, their anhydrides and their esters such as vinyl, allyl, methyl, butyl, isobutyl, hexyl, heptyl, 2-ethylehexyl, cyclohexyl, lauryl, stearyl or alkoxy ethyl acrylates and methacrylates, dimethyl maleate, ethyl crotonate, methyl hydrogen maleate, butyl hydrogen itaconate, glycol or polyalkylene glycol diacrylates and dimethacrylates such as ethylene glycol dimethacrylate or triethylene glycol dimethacrylate, dichlorophosphatoalkyl acrylates and methacrylates such as dichlorophosphatoethyl methacrylate, and bis(methacryloyloxyethyl) hydrogen phosphate and methacryloyloxy propyltrimethoxysilane; acrylonitrile, methacrylonitrile, 2-chloroacrylonitrile, 2-cyanoethyl acrylate, methyleneglutaronitrile, vinylidene cyanide, alkyl cyanoacrylates such as isopropyl cyanoacrylate, tris(acryloyl)hexahydro-s-triazine, vinyltrichlorosilane, vinyltrimethoxysilane, vinyltriethoxysilane and N-vinyl-2-pyrrolidone; allyl alcohol, allyl glycolate, isobutenediol, allyloxyethanol, o-allylphenol, divinylcarbinol, glycerol allyl ether, acrylamide, methacrylamide, maleamide and maleimide, N-(cyanoethyl)acrylamide, N-isopropyl acrylamide, diacetoneacrylamide, N-(hydroxymethyl) acrylamide and methacrylamide, N-(alkoxymethyl)acrylamides and methacrylamides, glyoxal bisacrylamide, sodium acrylate or methacrylate, vinylsulphonic and styrene-p-sulphonic acids and their alkali metal salts, 3-amino-crotononitrile, monoallylamine, vinylpyridines, glycidyl acrylate or methacrylate, allyl glycidyl ether, acrolein, N,N-dimethylaminoethyl methacrylate or N-tert-butylamino ethyl methacrylate; and the unsaturated fluoroesters of general formula: ##STR6## in which R f , R and W have the same meanings as defined above. These comonomers may be prepared by known methods, for example by esterification of the corresponding polyfluoro alcohols of formula: R.sub.f --W--OH (VII) by means of an alkenemonocarboxylic acid of formula: ##STR7## such as, for example, acrylic acid, methacrylic acid or crotonic acid, in the presence of a catalyst such as sulphuric acid or p-toluenesulphonic acid. Instead of the acids of formula (VIII), it is also possible to use their esters, anhydrides or halides As examples of polyfluoro alcohols of formula (VII), there may be more particularly mentioned those of formulae (III a) to (III j). Comonomers which may also be employed in the present invention include: the unsaturated esters of formula: ##STR8## obtained by condensation of a fluoro epoxide: ##STR9## with an alkene monocarboxylic acid of formula (VIII); and acrylates and methacrylates of ethers of polyethylene glycols or of polypropylene glycols of formula: ##STR10## in which R denotes hydrogen or a methyl radical, R", denotes an alkyl radical and n is an integer from 2 to 10. The fluoropolymers according to the invention may be prepared by a method which is known per se by polymerization in an organic solvent or in aqueous emulsion, at a temperature which may range from ambient to the boiling point of the reaction medium. The process is usually carried out between 70° and 110° C. The total monomer concentration may vary from 5 to 60% by weight. The polymerization in a solvent medium may be performed in ketonic solvents (e.g., acetone, methyl ethyl ketone, methyl isobutyl ketone), alcohols (e.g., isopropanol), esters (e.g., ethyl acetate or butyl acetate), ethers (e.g., diisopropyl ether, ethyl or methyl ethylene glycol ether, tetrahydrofuran, dioxane), aliphatic or aromatic hydrocarbons, halogenated hydrocarbons (e.g., perchloroethylene, 1,1,1-trichloroethane or trichlorotrifluoroethane), dimethyl formamide or N-methyl-2-pyrrolidone. The polymerization is carried out in the presence of initiator(s) used in a proportion of 0 1 to 1.5% based on the total weight of the monomers employed. It is possible to use as initiators peroxides such as, for example, benzoyl peroxide, lauroyl peroxide, succinyl peroxide and tert-butyl perpivalate, or azo compounds such as, for example, 2,2'-azobisisobutyronitrile, 4,4,-azobis(4-cyanopentanoic acid) and azodicarbonamide. It is also possible to operate in the presence of UV radiation and of photoinitiators such as benzophenone, 2-methylanthraquinone or 2-chlorothioxanthone. If required, the length of the polymer chains may be regulated by means of chain transfer agents such as alkyl mercaptans, carbon tetrachloride or triphenylmethane, used in a proportion of 0.05 to 0.5% based on the total weight of monomers. The polymerization in aqueous emulsion may be carried out according to well-known methods, noncontinuously or continuously. The surface-active agents to be used for emulsifying may be cationic, anionic or nonionic, depending on the required ionicity of the final latex, and are preferably chosen from the best oil-in-water emulsifiers which wet as little as possible. Pairs of cationic/nonionic or anionic/ nonionic surfactants are preferably used. Examples of surface-active agents which may be used include: in the cationic series, salts of long-chain tertiary amines such as N,N-dimethyloctadecylamine acetate, and quaternary ammonium salts of fatty amines such as trimethylcetylammonium bromide or trimethyldodecyl ammonium chloride; in the anionic series, the alkali metal salts of long-chain alkylsulphonic acids and alkali metal arylalkylsulphonates; in the nonionic series, the condensation products of ethylene oxide with fatty alcohols or alkyl phenols. It may also be advantageous to use surface-active agents containing a perfluorinated water-repellent chain such as, for example, ammonium perfluorooctanoate or potassium N-perfluorooctyl sulphonyl-N-ethylamino acetate. To make it easier to emulsify the monomers, it is generally necessary to use organic solvents such as, for example, ketones (acetone, methyl ethyl ketone, methyl isobutyl ketone), glycols or ethylene glycol ethers, alcohols (methanol, ethanol, isopropanol), or mixtures of these solvents. In general, the quantity of solvent should not exceed the total weight of the monomers. Water-soluble products such as inorganic peroxddes (for example hydrogen peroxide) and persalts (for example potassium persulphate), or water-insoluble initiators such as organic peroxides and the azo compounds referred to earlier may be used as polymerization initiators in an aqueous emulsion. The fluoropolymers according to the invention may also be prepared by grafting a fluoro isocyanate-urethane of ##STR11## onto an acrylic polymer containing pendent --NH groups, produced by homopolymerization of an acrylic ester of formula (IV) or by copolymerization of such an ester with one or more of the comonomers referred to earlier. The isocyanatesurethanes of formula (XII) may be prepared in the same manner and under the same conditions as the monomers of formula (I) by reacting a diisocyanate (II) with a substantially equimolar quantity of a polyfluorinated compound (III). These operating conditions also apply to the grafting of the isocyanate-urethane (XII) onto the acrylic polymer containing pendent --NH groups. This polymer may itself be obtained by polymerization in a solvent medium under conditions which are similar to those described earlier for the polymerization of monomers of formula (I). Whatever the method by which they are obtained, the fluoropolymers according to the invention may be isolated, if appropriate, by following methods which are known per se such as, for example, precipitation or evaporation of the solvent. The fluoropolymers according to the invention are found to be outstanding water-repellent and oil-repellent agents on very diverse materials such as paper, non-woven articles, textiles based on natural artificial or synthetic fibres, plastics, wood, metals, glass, stone and cement, but are more particularly intended for the protection of leathers, where their finish is involved, or for the maintenance of leather articles such as clothes, shoes, leather goods, seats, etc. For application to the substrate, the polymer solutions are generally diluted with a solvent identical to or compatible with that used for the polymerization, while the polymer emulsions are diluted with water. Application of the diluted products may be carried out by following various methods such as spraying, brush-coating or padding. Depending on their nature, the treated substrates may be dried at ambient temperature or at temperatures which may range up to 200° C. The quantity of polymer to be employed may vary within wide limits, depending on the nature of the substrate and of the fluorine content of the polymer. On leather, this quantity is generally between 1 and 10 g/m 2 . EXAMPLES The following examples, in which, unless stated otherwise, the parts and the percentages are on a weight basis, illustrate the invention without limiting it. EXAMPLE 1 370 parts of dry methyl isobutyl ketone and 69.6 parts (0.4 mole) of toluene diisocyanate (mixture of 80% 2,4-isomer and 20% 2,6-isomer) and 0.4 part of dibutyltin dilaurate are charged into a reactor of a capacity of 1000 parts by volume, fitted with a stirrer, a thermometer, a reflux condenser, a dropping funnel, a nitrogen inlet and a heating device. Air is purged from the reactor with a stream of dry nitrogen, and then the temperature of the reaction mixture is raised to 80° C. by means of a thermostated oil bath and a solution, dried beforehand by distillation, containing 145.6 parts of perfluorohexyl ethanol C 6 F 13 C 2 H 4 OH (0.4 mole) and 145.6 parts of methyl isobutyl ketone, is then added dropwise over one hour. The mixture is kept stirred at 80° C. for 1/2 hour. Analysis by chromatography (GPC) shows that the reaction has ended and that 25% of a symmetrical diaddition product has formed. 0.120 part of hydroquinone monomethyl ether is then added, and a solution of 74 parts of t-butylaminoethyl methacrylate (0.4 mole) in 74 parts of methyl isobutyl ketone is added at 80° C. over 10 min. The mixture is kept at 80° C. for 1 h 30 min and is then cooled. 875 parts of a yellow solution (S 1 ) of a monomer according to the invention are obtained in this manner. This solution contains 33% solids and partially crystallizes when stored cold. EXAMPLE 2 125 parts of solution S 1 are charged into a reactor of a capacity of 250 parts by volume, fitted with a stirrer, a thermometer, a reflux condenser, a nitrogen inlet and a heating device. After its surface has been purged with nitrogen, the solution is heated to 90° C. and 0.3 part of lauroyl peroxide and 0.2 part of t-butyl perpivalate are then added. The temperature is then maintained at 90° C. for 6 hours, the same quantity of initiators being added after 2 and 4 hours. Analysis by chromatography shows complete disappearance of the monomer. After cooling, 124 parts of a yellow-brown solution (S 2 ) of homopolymer according to the invention are obtained. This solution contains 33.1% solids and 11.3% of fluorine EXAMPLE 3 17.4 parts of toluene diisocyanate (0.1 mole), 88 parts of dry methyl isobutyl ketone and 0.1 part of dibutyltin dilaurate are charged into a reactor of a capacity of 500 parts by volume, fitted as that of Example 1. The atmosphere in the reactor is made inert with a stream of dry nitrogen and then the temperature is raised to 80° C. A solution, dried by distillation, of 36.4 parts of perfluorohexylethanol (0.1 mole) in 36.4 parts of methyl isobutyl ketone is then added dropwise over 40 min. The reaction is complete ten minutes after the end of the addition. A solution of 18.5 parts of tert-butylaminoethyl methacrylate (0.1 mole) in 18.5 parts of dry methyl isobutyl ketone is then added over 5 min and the temperature is maintained at 80° C. for another 15 min. 72.3 parts of 2-ethylhexyl methacrylate and 74.4 parts of methyl isobutyl ketone are then added and the temperature of the solution is raised to 90° C. Polymerization is initiated by adding 0.6 part of lauroyl peroxide and 0.4 part of t-butyl perpivalate and maintained by adding the same quantities of initiators at two-hourly intervals. After 6 hours the solution is cooled and filtered. A copolymer according to the invention is thus obtained, containing 50% of urethane-urea monomer and 50% of ethylhexyl methacrylate, in the form of a viscous, amber-yellow solution (S 3 ) which contains 39% solids and 6.64% of fluorine. EXAMPLE 4 Into a reactor which is identical to that of Example are added 88.65 parts of solution (S 1 ) containing 33% of urethane-urea monomer, 9 parts of butyl methacrylate, 11.35 parts of a mixture of polyfluoro monomers of the formula: ##STR12## where n is equal to 5, 7, 9, 11, 13 and 15 in mean proportions by weight of 1:56:22:9:3:3 respectively, and 11.4 parts of methyl isobutyl ketone. Air is purged from the reactor with a stream of nitrogen for 15 min and then the temperature is raised to 90° C. 0.3 part of lauroyl peroxide and 0.2 part of t-butyl perpivalate are then added, this addition being repeated at two-hourly intervals. The polymerization is complete after 6 hours. The yellow-brown solution is filtered at 40° C. When cold, a fluid gel (S 4 ) is obtained, which contains 42% nonvolatiles and 15.5% of fluorine. EXAMPLE 5 Into a reactor which is identical to that of Example 2 are added 88.65 parts of solution (S 1 ) containing 33% of urethane-urea monomer, 9 parts of 2-ethyl hexyl methacrylate, 16 parts of polyfluoro monomers of formula: ##STR13## where n=3, 5, 7, 9, 11, 13 and 15 in mean proportions by weight of 1:50:31:10:3:1:1 respectively, together with 4.4 parts of acetone and 7 parts of methyl isobutyl ketone. Polymerization is then carried out as in Example 4 and a yellow-brown gel (S 5 ) is obtained, whose nonvolatiles content is 42.6% and the fluorine content is 13.5%. EXAMPLE 6 A solution containing 92.8 parts of perfluorooctylethanol C 8 F 17 C 2 H 4 OH (0.2 mole) and 92.8 parts of methyl isobutyl ketone is added dropwise over one hour and at 80° C., to a solution of 34.8 parts (0.2 mole) of toluene diisocyanate (mixture containing 80% of 2,4- and 20% of 2,6-isomer), 0.2 part of dibutyltin dilaurate and 254 parts of methyl isobutyl ketone, in a reactor identical to that in Example 1 and using the same operating procedure. 37 parts of t-butylaminoethyl methacrylate (0.2 mole) in 37 parts of methyl isobutyl ketone are then added, still at 80° C. After 1 h 30 min at 80° C., the reaction has ended and a solution (S 6 ) of urethane-urea monomer according to the invention is obtained. This solution contains 30% solids and 11.78% of fluorine. EXAMPLE 7 83.3 parts of the solution (S 6 ), 18 parts of methyl isobutyl ketone and 25 parts of butyl methacrylate are introduced into a reactor identical to that in Example 2. After the reactor has been purged with nitrogen, the temperature is raised to 90° C. and 0.3 part of lauroyl peroxide and 0.2 part of t-butyl perpivalate are added. The mixture is heated at 90° C. for 6 hours while polymerization is maintained by adding the same charge of initiators at two-hourly intervals. The copolymer solution obtained (S 7 ) is homogeneous, but is opaque and viscous. It contains 39.3% nonvolatiles and 7.7% of fluorine. EXAMPLE 8 The method of Example 1 is followed. A previously topped solution of 48.5 parts of a fluorinated sulphamidoalcohol of formula ##STR14## in 37.7 parts of methyl isobutyl ketone is added dropwise over one hour and at 80° C., to a mixture of 17.4 parts of toluene diisocyanate (0.1 mole), 0.1 part of dibutyltin dilaurate and 140 parts of methyl isobutyl ketone. 0.030 part of hydroquinone methyl ether and 18.5 parts of t-butylaminoethyl methacrylate (0.1 mole) are then added and the mixture is maintained at 80° C. for another 2 hours. A solution (S 8 ) of urethane-urea monomer according to the invention is obtained in this manner, containing 30% solids and 8.8% of fluorine. EXAMPLE 9 The method of Example 7 is used to copolymerize 83.4 parts of solution (S 8 ) with 25 parts of stearyl methacrylate in 17 parts of methyl isobutyl ketone. The yellow-brown solution obtained (S 9 ) contains 39.5% of nonvolatiles and 5.8% of fluorine. EXAMPLE 10 The method of Example 8 is followed, the fluorinated sulphamidoalcohol being replaced by 48 parts of perfluorooctylthioethanol C 8 F 17 C 2 H 4 SH (0.1 mole). The solution (S 10 ) obtained contains 30% nonvolatiles and 11.5% of fluorine. EXAMPLE 11 83.4 parts of solution (S 10 ) are copolymerized under the same conditions as in Example 7 with 25 parts of 2-ethylhexyl methacrylate in 17 parts of methyl isobutyl ketone. The yellow-brown solution (S 11 ) obtained contains 35.5% nonvolatiles and 6.8% of fluorine. EXAMPLE 12 By using the same procedure as in Example 7, 83.4 parts of solution (S 8 ) are copolymerized with 9 parts of stearyl methacrylate and 16 parts of a fluoroacrylic ester of formula: ##STR15## where n is equal to 3, 5, 7, 9, 11, 13 and 15 in mean weight proportions of 1:50:31:10:3:1:1 respectively, in 13 parts of methyl isobutyl ketone and 4 parts of acetone. A yellow-brown solution (S 12 ), inhomogeneous when cold, is obtained, containing 40.4% non-volatiles and 11.9% of fluorine. EXAMPLE 13 13-a: By following the same method as in Example 7, a copolymer is prepared which is based on 18.5 parts of t-butylaminoethyl methacrylate (0.1 mole), 49.3 parts of butyl methacrylate and 55.5 parts of a mixture of fluoroalcohol methacrylates of formula: ##STR16## where n=5, 7, 9, 11, 13 and 15 in mean proportions by weight of 1:56:22:9:3:3 respectively, in 125 parts of methyl isobutyl ketone. 13-b Proceeding as in Example 1, 72.8 parts of a solution containing 50% of perfluorohexyl ethanol C 6 F 13 C 2 H 4 OH (0.1 mole) in methyl isobutyl ketone are added over one hour at 80° C. to 17.4 parts of toluene diisocyanate (containing 80% 2,4- and 20% 2,6-isomer) in 110 parts of methyl isobutyl ketone. 13-c: The polymer 13-a containing pendent --NH groups is added to the isocyanate-urethane obtained in 13-b. The mixture is then heated to 100° C. for 2 hours. A solution (S 13 ) of a copolymer according to the invention is obtained in this manner. This yellow-brown solution, slightly viscous, contains 38.4% nonvolatiles and 12.8% of fluorine. EXAMPLE 14 The polymer solutions S 2 , S 3 , S 4 , S 5 , S 7 , S 9 , S 11 , S 12 and S 13 are diluted with methyl isobutyl ketone so as to produce solutions S 2d , S 3d , S 4d , S 5d , S 7d , S 9d , S 11d , S 12d S 13d , each containing 0.15% of fluorine. These dilute solutions are then applied by spraying onto a vegetable tanned full grain kip leather, at a rate of 200 g/m and are left to dry for 4 hours at ambient temperature before the following tests are carried out: W.P. TEST (water penetration): consists in measuring the penetration time of a drop of water deposited on the leather. O.P. TEST (oil penetration): consists in measuring the penetration time of a drop of paraffin oil deposited on the leather. The results obtained are collated in the following table, compared with the same leather untreated. ______________________________________Treatmentsolution Water-repellency Oil-repellencyNil (untreated W.P. O.P.leather) Less than 30 seconds Less than 10 seconds______________________________________S.sub.2d 5.5 hours 20 minutesS.sub.3d 6.5 " 50 minutesS.sub.4d 8 " more than 24 hoursS.sub.5d 8.5 " more than 9 hoursS.sub.7d 3.5 " 30 minutesS.sub.9d 7.5 " more than 24 hoursS.sub.11d 4.5 " 1 hourS.sub.12d 5.5 " more than 24 hoursS.sub.13d 1 hour 3 hours______________________________________ EXAMPLE 15 92.5 parts of methyl isobutyl ketone, 17.4 parts (0.1 mole) of toluene diisocyanate (containing 80% of 2,4- and 20% of 2,6-isomer) and 0.1 part of dibutyltin dilaurate are introduced into a reactor of 250 parts by volume capacity, fitted with a stirrer, a thermometerm a reflux condenser, a dropping funnel and a heating system (thermostated oil bath). The solution is heated to 80° C. in a nitrogen atmosphere, and then a mixture of 36.4 parts of perfluorohexylethanol C 6 F 3 C 2 H 4 OH (0.1 mole), 18.5 parts of t-butylaminoethyl methacrylate (0.1 mole) and 54 parts of dry methyl isobutyl ketone are added dropwise over one hour. The solution is kept at 80° C. for another 2 hours and a mixture is thus obtained, containing mostly the addition product of t-butylaminoethyl methacrylate in the 2 position and of perfluorohexylethanol in the 4 and 6 positions, together with a molar proportion of 42% of products of symmetrical diadditions. This mixture is heated to 90° C. and 0.5 part of lauroyl peroxide and 0.2 part of t-butyl perpivalate are then added to it and this addition of initiators is repeated after 2 and 4 hours reaction. After 6 hours at 90 the reaction is finished. The solution (S 15 ) obtained is yellow-brown and clear; it contains 32.8% nonvolatiles and 11.2% of fluorine. This solution is diluted with methyl isobutyl ketone to a fluorine content of 0.15% and is then applied to the same leather as in Example 14 at a rate of 200 g/m 2 . After drying overnight at ambient temperature, the following results are obtained: W.P.=7.5 hours and O.P.=30 minutes EXAMPLE 16 180 parts of trichlorotrifluoroethane, 34.8 parts (0.2 mole) of toluene diisocyanate (mixture containing 80% of 2,4-isomer and 20% of 2,6-isomer) and 0.2 parts of dibutyltin dilaurate are introduced into a reactor which is identical to that in Example 1. After the air in the reactor has been purged with a stream of dry nitrogen and the temperature has been raised to 50° C. (solvent reflux), a solution of 72.8 parts of perfluorohexylethanol C 6 F 13 C 2 H 4 OH in 72.8 parts of trichlorotrifluoroethane are added dropwise over an hour and a quarter. Refluxing is then maintained for 1/2 hour and a whitish suspension is obtained, whose analysis by chromatography shows that it contains a molar proportion of approximately 20% of 2,4- and 2,6-diaddition product. 0.06 part of hydroquinone methyl ether is then added to the whitish suspension obtained, and 37 parts of t-butylaminoethyl methacrylate (0.2 mole) are then run in over 15 minutes, followed by 40 parts of trichlorotrifluoroethane. The reaction is slightly exothermic and the whitish product is seen to dissolve. Refluxing is maintained for one hour and then 293 parts of isopropanol are added and the trichlorotrifluoroethane is removed by distillation. A practically colourless solution (S 16 ) is obtained, containing 33% nonvolatiles and 11.3% of fluorine. EXAMPLE 17 Into a reactor of 500 parts by volume capacity, fitted out as that in Example 2, are introduced 25 parts of a mixture of polyfluoro monomers of formula: ##STR17## where n is equal to 5, 7, 9, 11, 13 and 15 in mean weight proportions of 1:56:22:9:3:3 respectively, 20 parts of methoxytriethylene glycol methacrylate: ##STR18## 5.15 parts of the solution and 50 parts of isopropyl alcohol. After air has been purged from the reactor with a stream of nitrogen, the mixture is heated to 82° C. and 0.5 part of 4,4'-azobis(4-cyanopentanoic acid) is added. Refluxing is maintained for 5 hours, 0.1 part of tert-butyl perpivalate being added every hour. 50 parts of a 50/50 mixture by weight of isopropanol and water are then added. After cooling and filtration, a solution (S 17 ) is obtained, which contains 30.7% nonvolatiles and 10.5% of fluorine. A part of this solution is diluted to 100 with a 50/50 mixture of water and isoproopanol and the clear solution obtained (S 17d ) is applied by spraying to two types of leather, at a rate of 400 g/m 2 . These are allowed to dry for four hours at ambient temperature before assessment of performance is carried out using the method indicated earlier. Results are shown below in Table II. ______________________________________Material W.P. O.P.______________________________________Chrome-tanned full Less than 30 Less than 1grain kip leather seconds minuteUntreatedSame Leather treated 2.25 hours More than 9with S.sub.17d hoursVegetable-tanned full Less than 30 Less than 10grain kip leather seconds secondsUntreatedSame Leather treated 3.25 hours More than 9with S.sub.17d hours______________________________________ EXAMPLE 18 Example 3 is repeated with the following modifications; (a) Toluene diisocyanate is repalced by 25 parts of 4,4'-diphenylmethane diisocyanate (0.1 mole) and the initial amount of methyl isobutyl ketone is increased to 132 parts; (b) In the polymerization step, 79.9 parts of 2-ethylhexyl methacrylate and only 53 parts of methyl isobutyl ketone are used, while initiation is effected with 1 part of lauroyl peroxide and 0.6 part of t-butyl perpivalate. After 6 hours, the solution is cooled. A copolymer according to the invention is thus obtained, based on 50% of urethane-urea monomer and 50% of 2-ethylhexyl methacrylate, in the form of a thick solution (S 18 ) which cfontains 40% of non volatiles and 6% of fluorine. This solution is diluted with perchloroethylene to a fluorine content of 0.15% and is then applied at the rate of 200 g/m 2 onto vegetable tanned full grain kip leather. Results of the tests are as follows: W.P.: more than 9 hours. O.P.: more than 30 hours. While it is apparent that the invention herein disclosed is well calculated to fulfill the objects above stated, it will be appreciated that numerous modifications and embodiments may be devised by those skilled in the art, and it is intended that the appended claims over all such modifications and embodiments as fall within the true spirit and scope of the present invention.
The invention relates to fluoroacrylic monomers of formula: ##STR1## in which R f denotes a perfluoroalkyl radical, R is hydrogen or a methyl radical, R' denotes an alkyl or cycloalkyl radical, or --NR'-- denotes a 1, 4-piperazinylene radical, W and Z denote divalent connecting groups, Q is oxygen or sulphur or an --NR"-- group, R" denoting hydrogen an alkyl radical, and A is a C 2 or C 3 alkylene group. The polymers (homo- or copolymers) derived from these monomers may be used for the water-repellency and oil-repellency treatment of various substrates, particularly leather.
2
FIELD OF THE INVENTION [0001] The present invention relates to the field of water saving urinal apparatus (“WSUA”). More particularly, the invention relates to the WSUA in which at least one component of the urinal apparatus is easily attachable to a conventional flush toilet. BACKGROUND OF THE INVENTION [0002] Nowadays, water is in short supply worldwide as the world's population and a large number of industries constantly grow. The water shortage is estimated to be a global problem in the near future according to the ecology researches. Leaving a smaller ecological foot-print and protecting the environment by conserving water is becoming a priority in many countries. [0003] A flush toilet is one of the most well-known indoor systems to discard human waste by using water. Although the flush toilets are designed to discard the human waste cleanly, most of the existing designs are not created with the outmost water conservation in mind. As the world's population have exceeded seven billion people in 2011, the amount of water used by people daily to discard human waste accounts for a substantial portion of the daily water consumption worldwide. Furthermore, the majority of the water used daily to discard human waste is used to discard urine, where the existing flush toilet designs use, on average, thirty liters of water to discard less than one liter of urine. Accordingly, a need for ecologically-efficient and environment-conscious water-saving urinal apparatus is becoming a single most important ecological issue in conserving world's water supply. The present invention is directed to solve the stated ecological problem. [0004] The object of the present invention is to provide a urinal apparatus which: i) is capable of substantially reducing consumption of water used to discard by-products of human body, namely human urine, and ii) convenience in upgrading existing conventional flush toilet systems. Other objects and advantages of the invention will become apparent as the description proceeds. SUMMARY OF THE INVENTION [0005] The present invention is a water-saving urinal apparatus adapted to be connected to any conventional flush toilet system. The WSUA of the present invention includes a relatively slim bowl (e.g., about 10 cm height) having an inclined inner structure that downwards towards its distal end, a top opening, an optional bottom opening equipped with an optional filter and a closure mechanism, at least one drain pipe, connecting means and optionally a seat that is provided on the top opening to accommodate a female user of the water-saving urinal apparatus. [0006] As aforementioned, the bowl has an inclined basin-like structure, a top portion, and a bottom portion. The top opening is provided at the top portion of the bowl. The optional bottom drain opening is provided at the bottom portion of the bowl. The drain pipe extends from the distal end. The connecting means, provided at the distal end of the urinal, is for connecting the urinal to the flush toilet system. [0007] The WSUA may further comprise at least one nozzle provided at the inside edge of the urinal. The WSUA may further include a water intake connected to the at least one nozzle and a flush lever for controlling the flow of water to the water intake, wherein the other end of the water intake is connected to a water system. [0008] The WSUA is adapted to be connected directly to a sewer system via the at least one drain pipe. In another embodiment, the WSUA may be connected to the sewer system via a conventional flush toilet system. [0009] In one of the embodiments, the WSUA may be directly connected to at least one water supply system. [0010] In yet another embodiment, the WSUA may comprise a dedicated water tank. BRIEF DESCRIPTION OF THE DRAWINGS [0011] In the drawings: [0012] FIG. 1A schematically illustrates a cross sectional front view of the WSUA, according to an embodiment of the invention; [0013] FIG. 1B schematically illustrates a cross sectional side view of the WSUA, according to an embodiment of the invention; [0014] FIG. 2 schematically illustrates a side view of the WSUA attached to a typical toilet system; and DETAILED DESCRIPTION OF THE INVENTION [0015] Throughout this description the term “flush toilet” is used to indicate a conventional system adapted to discard human waste. This term does not imply any particular shape, construction material or geometry, and invention is applicable to fit any suitable toilet. For example, such as a typical flush toilet system having 1) a flush toilet having a top opening, a concave water pan, a bottom drain opening, and a water intake; 2) a first water tank connected to the water intake of the flush toilet; and 3) a first flush system having flush flipper, a manual handle, and a main drain pipe connected to the bottom drain opening of the flush toilet for flushing out waste-containing water in the concave water pan of the flush toilet. [0016] The advantages of the present invention are: (1) a substantial conservation of water in comparison with contemporary models of flush toilets; and (2) ease in installation of the WSUA. [0017] Reference will now be made to several embodiments of the present invention(s), examples of which are illustrated in the accompanying figures. Wherever practicable similar or like reference numbers may be used in the figures and may indicate similar or like functionality. [0018] The figures depict embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein. [0019] FIG. 1A shows a cross-sectional front view of the WSUA, according to an embodiment of the present invention. The WSUA is adapted to be connected to almost any type of flush toilet system (e.g., the toilet system 10 shown in FIG. 4 ). [0020] The WSUA comprises a bowl 2 , a top opening 3 within the top portion 21 , a bottom drain opening 4 within the bottom portion 22 , a support element 8 for supporting the WSUA on top of the conventional flush toilet, at least one water intake 6 , and a support element 8 connected to the top portion 21 and extending downward. The basin-like curvature (a U-like shape that inclined along the length) of the bowl 2 allows consumption of a small (300-500 milliliter per use) quantity of water to adequately discard the urine residue from the entire inner surface of the bowl 2 . Also, the uniquely-designed shape of the bowl 2 is adopted to prevent drops of urine from escaping the inner space of the bowl 2 regardless of whether the WSUA is used by a male or a female. In other words, the inner surfaces of the bowl 2 are configured in such a concave manner that drops of fluids remain within the inner space of the bowl 2 . [0021] FIG. 1B shows a cross-sectional side view of the WSUA, according to an embodiment of the present invention. The bowl 2 has an inclined basin-like shape and comprises a top portion 21 and a bottom portion 22 . The top portion 21 of the bowl 2 comprises a top opening 3 and connecting means 7 , provided at the distal end of the bowl 2 , for connecting the WSUA to the conventional flush toilet of FIG. 4 . The bottom portion 22 of the bowl 2 comprises a bottom drain opening 4 , at least one drain pipe 5 , at least one water intake 6 , and support element 8 for supporting the WSUA on top of the conventional flush toilet. The support element 8 is attached to the top portion 21 and extends from said top portion 21 downward. [0022] The bottom drain opening 4 may comprise a filter-like element (e.g., in form of mesh or net). In another embodiment, the bottom drain opening 4 may also be covered by a corresponding closure element (not shown). The bottom drain opening 4 can be opened or closed upon demand by a suitable closure element (e.g., a cover). The opening of such suitable closure mechanism may be controlled by a lever mechanism (not shown) to discard the incidental non-fluid residue such as used toilet paper or other human body secretions. [0023] The drain pipe 5 extends from the bottom portion 22 of the bowl 2 and can be connected directly to the main drain pipe of the sewer system or to any other draining mechanism. [0024] FIG. 1B depicts an embodiment where the drain pipe 5 is located on a rear side of the bottom portion 22 of the bowl 2 . One skilled in the art may appreciate that the drain pipe 5 may be located on any side of the bottom portion 22 of the bowl 2 . Also, one skilled in the art may appreciate that the bowl 2 may comprise more than one drain pipe 5 . [0025] FIG. 1B depicts an embodiment where the at least one water intake 6 is located on a front side of the bowl 2 . One skilled in the art may appreciate that the at least one water intake 6 may be located on any side of the bowl 2 . Also, one skilled in the art can appreciate that the support element 8 may be of any shape to accommodate the adequate support and leverage of the WSUA when it is situated upon the conventional flush toilet system. Further, one skilled in the art can appreciate that the support element 8 may be adopted to adjust the height and an angle of the WSUA to accommodate the users' comfort demand. [0026] The connecting means 7 for connecting the WSUA to the conventional flush toilet system may also operate as a swivel to ensure convenient change of position of the WSUA from its operational (essentially horizontal) position to its “stored” (essentially vertical) position. One skilled in the art can appreciate that the WSUA may be completely detached from the conventional flush toilet system then it is not in use. [0027] Referring now to FIG. 2 , the WSUA is shown attached to the conventional flush toilet system. Specifically, the WSUA is shown attached on top portion of the bowl 15 of the conventional flush toilet system. [0028] FIG. 2 further presents an optional top cover 17 for covering the system when it remains in the lowered position but not in use, said optional cover 17 operates in a flip manner similar to top covers of regular toilets. As discussed above, the WSUA, as depicted on FIG. 2 , comprises the support element 8 for supporting the WSUA on top of the conventional flush toilet and connecting means 7 , provided at the distal end of the bowl 2 , for connecting the WSUA to the conventional flush toilet. In a preferred embodiment, the connecting means 7 also serve as a point of attachment of the optional top cover 17 to the WSUA. [0029] One skilled in the art can appreciate that the WSUA may also be combined with a well-known bidet system, a bottom washer and the like. One skilled in the art can also appreciate that the size of the WSUA is adopted to fit and match the size of any common toilet seat. [0030] The terms, “for example”, “e.g.”, “optionally”, as used herein, are intended to be used to introduce non-limiting examples. While certain references are made to certain example system components or services, other components and services can be used as well and/or the example components can be combined into fewer components and/or divided into further components. [0031] It should be understood that the above description of the preferred embodiments, alternative embodiments, and specific examples, are given by way of illustration and should not be viewed as limiting. Further, many changes and modifications within the scope of the present embodiments may be made without departing from the spirit thereof, and the present invention includes such changes and modifications. For example, the present invention is not limited to the portable systems used by individuals in the comfort of their homes as described hereinbefore, and those skilled in the art will understand that the WSUA also be used in various public facilities. [0032] The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.
A water-saving urinal apparatus in which at least one component is attachable to a conventional flush toilet is provided. In one of the preferred embodiments, the water-saving urinal apparatus includes a bowl which has a basin-like curvature, a top portion, and a bottom portion, wherein the top portion comprises a top opening, at least one water intake, and a connector, wherein the bottom portion comprises a bottom opening, at least one drain pipe and at least one support element.
4
This application is a continuation of Ser. No. 08/568,193 Dec. 6, 1995 U.S. Pat. No. 5,925,189. BACKGROUND OF THE INVENTION The present invention relates to delivery systems for liquid phosphorous precursors, and in particular to stainless steel containers, piping and injection valves for injecting liquid triethylphosphate (TEPO), TMP or TEP into a chemical vapor deposition (CVD) chamber. A variety of different systems can be used to deliver processing gases to a chemical vapor reaction chamber. In a boiler system, the liquid is heated into vapor form. In a “bubbler” system, gaseous helium is introduced into a liquid in a container, resulting in some of the liquid being bubbled out of solution. When the liquid contains a phosphorous precursor, such as TEPO, TMP or TEP, and the container or piping is stainless steel, residue build-up has been observed, in particular where the stainless steel is exposed to heat. Injection valves are often used for providing a processing gas to a CVD chamber. In one method of doing this, the active gas component is provided in liquid form to an injection valve. The injection valve provides the liquid through an orifice past which a carrier gas is provided. A pressure drop is created which causes the liquid to vaporize into gaseous form. Typically, a heater is also provided on the valve to prevent condensation of the processing gas. A typical inert carrier gas is helium. One problem encountered with such valves is the build-up of residue around the orifice, which can prevent proper seating of a cut-off plug to hinder control of the valve. Excessive build-up of residue can also block the orifice itself, or severely restrict the flow of liquid through the orifice. Residue build-up on other surfaces can contaminate subsequent gases flowing across the surface or contained in the container. Accordingly, it would be desirable to have an liquid phosphorous precursor delivery system which minimizes the build-up of residue on stainless steel surfaces. SUMMARY OF THE INVENTION The present invention recognizes that the build-up of residue in a metal alloy injection valve used to inject a liquid phosphorous precursor compound is due to the nickel in the alloy affecting the liquid phosphorous precursor compound. The invention thus provides components manufactured of an alloy having a low nickel content, preferably less than 5% nickel, and more preferably less than 1%. In an additional aspect of the invention, the alloy is provided with a higher chromium content, preferably at least 15% chromium, more preferably 16-27%. The chromium appears to inhibit the leaching of the metal by the liquid phosphorous precursor compound, thus preventing the nickel being leached out of the metal to affect the liquid phosphorous precursor compound. The nickel appears to act as a catalyst for causing decomposition of the phosphorous precursor compound when heated. Preferably, the components exposed to the phosphorous precursor compound and heat are made of stainless steel alloys of standard industrial designations 430 , 440 , or 446 , which all have a nickel content of less than 1%. In one embodiment, an injection valve is made of stainless steel alloys of standard industrial designations 430 , 440 , or 446 . This alloy is preferably used for the body of the valve, but in particular for at least the portions of the valve around the injection orifice. In another embodiment, a polymides used for a plug in an injection valve instead of prior art fluoropolymers. The polymide, preferably VESPEL®(a Du Pont product) is used, and exhibits better tolerance to the liquid phosphorous precursor compound and heat. The polymide can also be used for gaskets and seals. For a fuller understanding of the nature and advantages of the invention, reference should be made to the ensuing detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram of a liquid injection system including an injection valve according to the present invention; FIG. 2 is a block diagram showing an injection system having multiple injection valves, including an injection valve for TEPO according to the present invention; FIG. 3 is a detailed diagram of the injection valve according to the present invention; and FIGS. 4 and 5 are diagrams illustrating the build-up of residue on an injection valve. DESCRIPTION OF THE PREFERRED EMBODIMENT The following description illustrates one embodiment of the present invention using an injection valve system. The invention also applies to boiler and bubbler systems, with the low nickel stainless steel alloy being used for liquid containers in such systems, or for tubing or conduit, or for any other portion that is exposed to a liquid phosphorous precursor containing compound and also to heat. FIG. 1 illustrates a basic injection valve system for providing process gases to a process chamber 12 . A liquid container 14 containing liquid TEPO 16 is pressurized using helium provided through a valve 18 . The pressurized helium in the top of container 14 forces the liquid TEPO 16 through a line 20 to a liquid mass flow meter (LFM) 22 which meters the amount of liquid provided to an injection valve 24 via an injection line 26 . The injection valve is also provided with a carrier gas, preferably helium, through a mass flow controller (MFC) 28 and a carrier gas injection line 30 . Injection valve 24 converts the liquid from injection line 26 into gaseous form, and provides it along with the carrier gas through an outlet line 32 to process chamber 12 . Process chamber 12 includes a monitoring pressure sensor 34 and a vacuum pump 36 for removing exhaust gases. FIG. 2 illustrates the application of multiple gases to chamber 12 , including the liquid TEPO provided through injection valve 24 . In FIG. 2, there is also shown a control valve 38 for liquid TEPO connected to a control valve 44 allowing purging of the gas lines with nitrogen (N 2 ). FIG. 2 shows injection valve 24 being connected to a common gas line 42 connected to process chamber 12 . Also included in gas line 42 are an injection valve 44 for liquid TEOS and an injection valve 46 for liquid TEB. Injection valve 44 has associated with it a liquid flow meter 48 and valves 50 and 52 for controlling the liquid TEOS and nitrogen purge. A degasser 51 may optionally be included to remove helium, where helium is used to pressurize the TEOS (degassers may be used in other gas lines as well). Similarly, injection valve 46 is connected to a liquid flow meter 54 and associated valves 56 and 58 for controlling the liquid TEB and nitrogen. Finally, mass flow controllers 60 and 62 connect to gas line 42 providing a low flow carrier, and high flow carrier, respectively. Preferably, helium is typically used as the carrier. FIG. 3 shows injection valve 24 in more detail. The TEPO liquid is provided through liquid mass flow meter 22 via inlet line 26 . The inlet line is connected to a chamber 64 which includes a spring 66 for biasing against a plug 68 . Plug 68 is moved in and out under processor control in order to control the amount of flow of liquid TEPO. The top of chamber 64 is a gas orifice 70 . Helium is provided as a carrier gas through an inlet line 30 , and the combination gas mixture is provided through an outlet line 32 to the process chamber. The gas flow of the helium over the orifice causes a pressure drop which causes the liquid TEPO to vaporize, and be carried with the helium through outlet line 32 to the process chamber. Necessarily, orifice 70 is small in order to aid this vaporization process, and thus is vulnerable to residue build-up. Prior art valves typically include a valve body, including the portion surrounding the orifice, made of a stainless steel alloy. For example, stainless steel alloy SST 316 is used in prior art valves manufactured by Lintec of Japan. Plug 68 in existing valves is a compressible sealer typically made of KEL-F® Du Pont fluoropolymer. We have found that KEL-F® tends to swell up and break. Accordingly, another aspect of the present invention is the use of VESPEL® (DuPont polyimide resin) for the plug. VESPEL® can also be used for gaskets and seals in any system which utilizes a liquid phosphorous precursor compound. The valve also includes a shut-off plug 72 which can be lowered to close the orifice when flow is desired to be shut off. Plug 72 is also preferably made of VESPEL®. Also included are heater elements 74 which function to heat the valve to prevent condensation of the gaseous mixture. A thermal couple 76 allows monitoring of the temperature of the valve. FIG. 4 illustrates a residue build-up 80 around orifice 70 to a level of 300μ. This build-up does not substantially affect the flow of gas out of the orifice, but 30 does impact the proper seating of shut-off plug 72 when it is desirable to stop the flow of TEPO. FIG. 5 illustrates a build-up of residue to a thickness of 1800μ, which clogs the orifice itself, as shown by residue 82 in FIG. 5 . As can be seen, orifice 70 is completely clogged at this point. Typically, the orifice itself has a diameter of 2 mm. The inventors of the present invention determined through a series of tests that the presence of nickel in the stainless steel alloy of the valve around orifice 70 was affecting the liquid TEPO, causing the residue build-up. The prior art valves using the stainless steel alloy of SST 316 would typically contain approximately 12-15% nickel, and 16-18% chromium. In an experiment, a valve made of a stainless steel alloy 430 , which contains approximately 0.15% nickel and 16-18% chromium was used. The use of such a valve allowed TEPO to flow for 189 hours (equivalent to a throughput of 11,300 wafers). The prior art valve using the 316 alloy, on the other hand, has been typically observed to have a throughput of 1800 wafers prior to clogging due to residue build-up. On the other hand, the 430 test still had no significant residue build-up after 189 hours, suggesting that a much longer lifetime was still available to the valve. The build-up of the residue which has been observed may be due to the nickel helping to decompose TEPO into phosphoric acid and ethanol. This can be avoided by limiting the amount of nickel in the alloy. In addition, the presence of chromium inhibits the leaching of the nickel out of the metal by the TEPO liquid. Alloys with a higher chromium content are preferred, but may be more expensive. Alloy 446 , for instance, has approximately 0.6% nickel and 23-27% chromium. Alloy 440 has 0.6% nickel and 16-18% chromium. In addition, by empirical observation, it was determined that a temperature of approximately 160-170° C., preferably 165° C., for the valve provided an optimum flow of the TEPO liquid, avoiding residue build-up. The TEPO liquid, used for generating phosphorous precursor gas, is typically used for the BPSG (Boronphosphosilicate glass) and PSG (phosphosilicate glass) process steps in the processing of a wafer. As will be understood by those with skill in the art, the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For example, stainless steel alloys having a higher chromium content or lower nickel content could be used. Additionally, the valve could have an appropriate alloy of stainless steel only around the sensitive orifice area of the valve. The low nickel stainless steel alloy could also be used for stainless steel gaskets. Alternately, a different type of processing system, such as a distillation system with a stainless steel column that comes in contact with a liquid phosphorous precursor compound and heat, could use the present invention. Accordingly, reference should be made to the appended claims for describing the scope of the present invention.
The present invention recognizes that the build-up of residue in a metal alloy injection valve used to inject a liquid phosphorous precursor compound is due to the nickel in the alloy affecting the liquid phosphorous precursor compound. The invention thus provides components manufactured of an alloy having a low nickel content, preferably less than 5% nickel, and more preferably less than 1%. In an additional aspect of the invention, the alloy is provided with a higher chromium content, preferably at least 15% chromium, more preferably 16-27%.
8
FIELD OF THE INVENTION [0001] This invention generally relates to an apparatus and a process for reducing a catalyst typically used in a reforming process. DESCRIPTION OF THE RELATED ART [0002] During the reforming of a hydrocarbon stream, such as naphtha, often a continuous catalyst regeneration reforming unit is utilized. In such a unit, a reduction zone may be provided to reduce the catalyst before the catalyst can enter a reforming reactor. If carbon monoxide is present in the reduction zone, higher coke may form on the catalyst in the reforming reactor. Generally, such carbon monoxide originates from the hydrogen stream used to reduce the catalyst. Typically, the hydrogen stream can contain about 5-about 20 volume parts-per-million (hereinafter may be abbreviated “vppm”), or even amounts up to about 100 vppm, particularly for hydrogen streams containing recycled hydrogen from reforming reactors operating at low pressures and high temperatures to maximize reformate yields. [0003] Increased coking can be detrimental by lowering catalytic activity and decreasing selectivity of desired products. In addition, operating conditions may need to be changed resulting in reduced capacity. As an example, the feed rate may need to be lowered in order to increase the hydrogen:hydrocarbon ratio to mitigate the coke formation, which in turn can result in product and profitability losses. Alternatively, reforming reactor temperatures may be increased to compensate for activity loss due to coking, which in turn may produce even higher coke levels. Thus, it would be beneficial to provide a reforming process and/or unit with lower coke producing tendencies to reduce activity losses and maintain the desired product selectivities. SUMMARY OF THE INVENTION [0004] One exemplary embodiment can be a process for lowering an amount of carbon monoxide in a stream rich in hydrogen. The process can include passing the stream rich in hydrogen through a carbon monoxide removal zone to produce a product stream having no more than about 10 vppm carbon monoxide and communicating the product stream to a reduction zone receiving a catalyst comprising unreduced metal species. [0005] Another exemplary embodiment can be an apparatus for removing carbon monoxide from a reducing gas stream. The apparatus can include a reduction zone for a continuous catalyst regeneration reforming unit, and a carbon monoxide removal zone in communication with the reduction zone. [0006] A further exemplary embodiment may be a continuous catalyst regeneration reforming unit. Generally, the continuous catalyst regeneration reforming unit includes a reduction zone, a carbon monoxide removal zone, a reforming reaction zone, and a regeneration zone. The carbon monoxide removal zone can be in communication with the reduction zone to provide a product stream rich in hydrogen and having no more than about 10 vppm carbon monoxide. In addition, the reforming reaction zone can also be in communication with the reduction zone to receive a reduced catalyst. Furthermore, the regeneration zone may be in communication with the reforming reaction zone to receive a spent catalyst. [0007] The embodiments disclosed herein can provide a process and an apparatus for reducing the levels of carbon monoxide in a reducing gas, such as hydrogen. As a result, coking of the catalyst can be minimized in a reforming reaction zone and thereby can improve operability. DEFINITIONS [0008] As used herein, the term “stream” can be a stream including various hydrocarbon molecules, such as straight-chain, branched, or cyclic alkanes, alkenes, alkadienes, and alkynes, and optionally other substances, such as gases, e.g., hydrogen, or impurities, such as heavy metals, and sulfur and nitrogen compounds. The stream can also include aromatic and non-aromatic hydrocarbons. Moreover, the hydrocarbon molecules may be abbreviated C1, C2, C3. . . Cn where “n” represents the number of carbon atoms in the hydrocarbon molecule. The stream can include one or more gases, liquids, and/or solids. [0009] As used herein, the term “zone” can refer to an area including one or more equipment items and/or one or more sub-zones. Equipment items can include one or more reactors or reactor vessels, heaters, exchangers, pipes, pumps, compressors, and controllers. Additionally, an equipment item, such as a reactor, dryer, or vessel, can further include one or more zones or sub-zones. [0010] As used herein, the term “rich” can mean an amount generally of at least about 50%, and preferably about 70%, by mole, of a compound or class of compounds in a stream. [0011] As used herein, the term “substantially” can mean an amount generally of at least about 90%, preferably about 95%, and optimally about 99%, by mole, of a compound or class of compounds in a stream. [0012] As used herein, the term “adsorption” can refer to the retention of a material in a bed containing an adsorbent by any chemical or physical interaction between the material in the bed, and includes, but is not limited to, adsorption and/or absorption. The removal of the material from an adsorbent may be referred to herein as “desorption.” BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 is a schematic depiction of an exemplary apparatus for removing carbon monoxide within an exemplary continuous catalytic regeneration reforming unit. [0014] FIG. 2 is a schematic depiction of the exemplary apparatus for removing carbon monoxide within an exemplary paraffin isomerization unit in conjunction with an exemplary continuous catalytic regeneration reforming unit. DETAILED DESCRIPTION [0015] Referring to FIG. 1 , an exemplary apparatus 100 for removing carbon monoxide is depicted. The apparatus 100 can include a carbon monoxide removal zone 200 and a reduction zone 310 . Generally, the apparatus 100 can be included in a continuous catalyst regeneration reforming unit 300 , which can include the carbon monoxide removal zone 200 , the reduction zone 310 , a reforming reaction zone 320 , and a regeneration zone 340 . Although only one zone for each zone 200 , 310 , 320 , and 340 is depicted, it should be understood that each zone 200 , 310 , 320 , and 340 can each, independently, include one or more zones. A first lift 330 and a second lift 350 can communicate catalyst between, respectively, the zones 320 and 340 and the zones 310 and 340 . [0016] The carbon monoxide removal zone 200 can receive a reducing stream 204 . The stream 204 can preferably include hydrogen, such as at least about 5%, by mole, preferably about 5-about 100%, by mole. In one preferred embodiment, the reducing stream 204 can be a hydrogen-containing stream 204 . Desirably, the stream 204 can be rich in hydrogen. The stream 204 can also include C1-C5 hydrocarbons. Such streams can contain carbon monoxide at levels up to about 100 vppm, and typically about 5-about 20 vppm. Generally, the carbon monoxide levels in the stream rich in hydrogen can vary. Particularly, the carbon monoxide level may spike during, e.g., a unit upset. Consequently, the carbon monoxide removal zone 200 can be beneficial for removing the carbon monoxide, reducing or lowering the carbon monoxide amounts, and producing a stream with a consistently low amount of carbon monoxide. The product stream 208 from the carbon monoxide removal zone 200 can be no more than about 10 vppm, preferably no more than about 5 vppm, and optimally no more than about 1 vppm of carbon monoxide. [0017] In one exemplary embodiment, the carbon monoxide removal zone 200 can include a modified clinoptilolite adsorbent. The modified clinoptilolite adsorbent can be ion-exchanged with a cation, such as a lithium, potassium, magnesium, calcium, sodium, or barium cation. The adsorption of carbon monoxide can be at a temperature no more than about 100° C., and preferably about −15°-about 100° C., and at a pressure of no more than about 150 kPa, preferably no more than about 100 kPa, and optimally no more than about 50 kPa. An exemplary process for removing carbon monoxide from a hydrogen stream using a modified clinoptilolite adsorbent is disclosed in US 2005/0137443 A1. Desirably, the adsorbent for removing carbon monoxide can be regenerated. However, the adsorbent can be disposable, i.e., not regenerable, in some exemplary embodiments. [0018] Alternatively, the carbon monoxide removal zone 200 can include a methanation catalyst to remove carbon monoxide by reaction with hydrogen to form methane and water under methanation conditions. Generally, the methanation catalyst includes nickel, cobalt, or ruthenium, preferably nickel, and can be provided in any suitable manner, such as a packed bed, a fluidized bed, a coated heat exchanger tube, or a slurry catalyst mixture. Methanation conditions can include a temperature of about 200-about 400° C. and a pressure of about 600-about 4,500 kPa. Exemplary methanation processes are disclosed in, e.g., U.S. Pat. No. 3,970,435 and U.S. Pat. No. 6,379,645 B1. [0019] The product stream 208 can be split. A first portion 230 can enter the lift 350 before the regenerated catalyst may enter the reduction zone 310 . A second portion 240 can enter a heater 250 before entering the reduction zone 310 . [0020] The reduction zone 310 can receive regenerated catalyst from the regeneration zone 340 via a lift 350 . Generally, the reduction zone 310 reduces metal, such as platinum, present on the regenerated catalyst in an atmosphere rich in a reducing gas, such as hydrogen. The reduction zone 310 can be at a temperature of about 140-about 700° C., preferably about 370-about 570° C., and a pressure of about 450-about 1,500 kPa. Generally, it is preferred to operate the reduction zone at about 550-about 700° C. Moreover, the reduction time can be from about 2-about 20 hours, preferably about 10-about 20 hours. Exemplary reduction zone conditions are disclosed in U.S. Pat. No. 6,881,391 B1. Also, the reduction zone can contain single or multiple sub-zones and flow configurations. [0021] The reduction zone 310 can provide the reduced catalyst to the reforming reaction zone 320 , which can include one or more reforming reactors. The reforming reaction zone 320 can communicate with the regeneration zone 340 via the first lift 330 , which in turn can communicate with the reduction zone 310 via the second lift 350 . [0022] Particularly in the reforming reaction zone 320 , a feedstock can be admixed with a stream including hydrogen and contacted with the reduced catalyst. The usual feedstock for catalytic reforming is a petroleum fraction known as naphtha and having an initial boiling point of about 80° C. and an end boiling point of about 205° C. The reactor inlet temperatures can range from about 450-about 560° C. The catalytic reforming process can be particularly applicable to the treatment of variously derived naphthas comprised of relatively large concentrations of naphthenic and substantially straight chain paraffinic hydrocarbons, which can be subject to aromatization through dehydrogenation and/or cyclization reactions. The naphthas can contain various amounts of aromatic components as well. [0023] Reforming may be defined as the dehydrogenation of cyclohexanes and dehydroisomerization of alkylcyclopentanes to yield aromatics, dehydrogenation of paraffins to yield olefins, dehydrocyclization of paraffins and olefins to yield aromatics, isomerization of n-paraffins, isomerization of alkylcycloparaffins to yield cyclohexanes, isomerization of substituted aromatics, and hydrocracking of paraffins. An exemplary reforming process may be found in U.S. Pat. No. 4,409,095. [0024] A catalytic reforming reaction is normally effected in the presence of catalyst particles having one or more Group VIII noble metals (e.g., platinum, iridium, rhodium, and palladium) and a halogen combined with a porous carrier, such as an alumina. Optionally, the catalyst may also contain a group IVA element, such as tin, and other catalytically effective components. An exemplary catalyst is disclosed in U.S. Pat. No. 6,034,018. The catalyst may pass through the reforming reaction zone 320 to the regeneration zone 340 via the lift 330 . Exemplary reaction and regeneration zones 320 and 340 are disclosed in, e.g., U.S. Pat. No. 6,881,391 B1 and U.S. Pat. No. 6,034,018. [0025] Alternatively, as depicted in FIG. 2 , a carbon monoxide removal zone 200 can be in a second unit, such as a paraffin isomerization unit 400 . An advantage of using an existing unit can be reducing capital expenditures. Typically the paraffin isomerization unit 400 can include an isomerization reaction zone 410 producing a product stream 414 . The isomerization reaction zone 410 can isomerize any suitable paraffin hydrocarbon, such as at least one of a C4-C6 hydrocarbon, such as an exemplary zone disclosed in, e.g., Nelson A. Cusher, UOP Butamer Process and UOP Penex Process of the Handbook of Petroleum Refining Processes, Third Edition, Robert A. Meyers, Editor, 2004, pp. 9.7-9.27. Although a paraffin isomerization unit 400 has been disclosed, it should be understood that any suitable unit can include the carbon monoxide removal zone 200 . [0026] Generally, the reducing stream 204 passes through the carbon monoxide removal zone 200 , as described above. The resulting product stream 208 can include a first part 218 , and a second part 222 . The first part 218 can be routed to a continuous catalyst regeneration reforming unit 500 , and the second part 222 can be routed to the isomerization reaction zone 410 . [0027] The continuous catalyst regeneration reforming unit 500 can include a reduction zone 510 , a reforming reaction zone 520 , a first lift 530 , a regeneration zone 540 , a second lift 550 , and a heater 650 . The first part 218 can be split into the first portion 230 and the second portion 240 . The first portion 230 can be routed to the lift 550 , and the second portion 240 can be routed to the heater 650 before entering the reduction zone 510 , similarly as described above for the unit 300 . The reduction zone 510 , the reforming reaction zone 520 , the first lift 530 , the regeneration zone 540 , and the second lift 550 can operate and communicate as the reduction zone 310 , the reforming reaction zone 320 , the first lift 330 , the regeneration zone 340 , and the second lift 350 , as described above. Illustrative Embodiments [0028] The following examples are intended to further illustrate the subject embodiments. These illustrations of embodiments of the invention are not meant to limit the claims of this invention to the particular details of these examples. These examples are based on engineering calculations and actual operating experience with similar processes. EXAMPLE 1 [0029] Two catalysts are prepared with a spherical alumina support. The first catalyst has a final composition of 0.25%, by weight, platinum (Pt) and 0.30%, by weight, tin (Sn) (catalyst A) while a second catalyst has a final composition of 0.30%, by weight, Pt and 0.30%, by weight, Sn (catalyst B). Each catalyst is exychlorinated to disperse the platinum and achieve a chloride level of about 0.9-about 1%, by weight, chloride (Cl) on the catalyst. [0030] Each catalyst is then exposed to different reduction conditions in a reforming pilot plant using naphtha feed of 55.5% paraffins, 31.7% naphthenes, and 12.8% aromatics (all percents by weight) at a hydrogen:hydrocarbon mole ratio of 2, a liquid hourly space velocity (LHSV) of 1.7 hr −1 , and a pressure of 620 kPa. Catalyst activity is determined by the temperature needed to maintain a target octane. Yields are calculated based on on-line gas and liquid effluent chromatography analysis. Runs are equal in length of time and spent catalyst is dumped in separate beds after each run. A sample from each bed is submitted for a carbon burn and the results are weight-averaged to calculate the average carbon. Results are depicted in Table 1. [0000] TABLE 1 Yield and Activity Results of 56 m 3 of Naphtha Feed Per m 3 of Catalyst H2 Reduction Pilot Plant Results Conditions Activity Average Cl Time Temp. CO C5 + Temp. Carbon Catalyst (wt. %) (hour) (° C.) (vppm) (wt. %) (° C.) (g/100 cc) Delta % A 0.98 4 565 10 86.6 517 1.74 Base A 0.94 2 565 0 86.3 516 1.42 −18.4% B 0.99 4 565 10 86.8 518 2.15 Base B 0.95 2 565 0 86.5 517 1.77 −17.7% Table Abbreviations: temperature: Temp. gram: g chloride weight percent: Cl wt. % centimeter cubed: cc As depicted above, a run having 0 vppm of CO in the reducing gas decreases coking by about 18% for both catalysts A and B. The C5 + yields and activity remain relatively constant. EXAMPLE 2 [0031] Similar experiments are conducted as in Example 1 using a commercially manufactured continuous catalyst regeneration catalyst (catalyst C) containing 0.25% Pt, 0.3% Sn, and 0.94% Cl (all percentages by weight). Catalyst C is split into two portions for reduction at temperatures of 399° C. and 566° C. in the presence of 0 vppm carbon monoxide. Results are depicted in Table 2. [0000] TABLE 2 Yield and Activity Results of 56 m 3 of Naphtha Feed Per m 3 of Catalyst H2 Reduction Pilot Plant Results Conditions Activity Average Cl Time Temp. CO C5 + Temp. Carbon Catalyst (wt. %) (hour) (° C.) (vppm) (wt. %) (° C.) (g/100 cc) Delta % C 0.90 2 399 0 86.2 519 2.44 Base C 0.78 2 566 0 86.3 519 2.03 −16.8% Results indicate that higher reduction temperatures produce about 17% less coke for catalyst C. The C5 + yields and activity remain relatively constant. EXAMPLE 3 [0032] Further experiments with catalyst A and B are conducted for up to 10 hours, in the presence of 0 vppm of carbon monoxide with samples analyzed at 2, 4 and 10 hours. The data at 4 hours is from Table 1. Results are depicted in Table 3. [0000] TABLE 3 Yield and Activity Results of 56 m 3 of Naphtha Feed Per m 3 of Catalyst H2 Reduction Pilot Plant Results Conditions Activity Average Cl Time Temp. CO C5 + Temp. Carbon Catalyst (wt. %) (hour) (° C.) (vppm) (wt. %) (° C.) (g/100 cc) Delta % A 0.98 4 565 10 86.6 517 1.74 Base A 0.94 2 565 0 86.3 516 1.42 −18.4% A 0.87 10 565 0 86.1 518 1.34 −23.0% B 0.99 4 565 10 86.8 518 2.15 Base B 0.95 2 565 0 86.5 517 1.77 −17.7% B 0.87 10 565 0 86.8 518 1.56 −27.4% As depicted, extended reduction time in substantially carbon monoxide free hydrogen gas results in further coke reduction ranging from about 23-about 27% reduction, as compared to the base condition of 4 hours, as depicted in Table 1. [0033] Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. [0034] In the foregoing, all temperatures are set forth uncorrected in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated. [0035] From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
One exemplary embodiment can be a process for lowering an amount of carbon monoxide in a stream rich in hydrogen. The process can include passing the stream rich in hydrogen through a carbon monoxide removal zone to produce a product stream having no more than about 10 vppm carbon monoxide and communicating the product stream to a reduction zone receiving a catalyst comprising unreduced metal species.
1
CROSS REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/570,650 filed Dec. 14, 2011, the contents of which are incorporated herein by reference in its entirety. FIELD This patent specification generally relates to the field of wave stimulation in subterranean rock formations. This patent specification relates more specifically to the generation of vibrations in the formation using tools positioned within a borehole. BACKGROUND Wave stimulation is a known technique for enhancing oil recovery from oil-bearing formations. For example, known techniques include generating shock waves by releasing a compressed liquid or by fluidic oscillation within the borehole. Strong vibrations are known to cause oil droplets to coalesce and form larger bulbs of oil that can move and be produced. These vibrations may also change the wettability of the rock. These effects can help increase fluid production from oil wells. SUMMARY This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor intended to be used as an aid in limiting the scope of the claimed subject matter. According to some embodiments, a system is described for generating vibrations in a subterranean rock formation. The system includes: a tool body adapted to be deployable in a wellbore; a translatable mass member mounted to the tool body such that the mass member is able to translate along a first direction towards an interior surface of the wellbore when the tool body is deployed in the wellbore; a contacting surface oriented to contact the interior surface of a wellbore (e.g., either the borehole wall or a casing); and an actuator subsystem mounted within the tool body and fixed to the mass member and configured to translationally accelerate in said first direction towards the interior surface of the wellbore such that the contacting surface imparts energy into the interior surface of the wellbore when the tool body is deployed in the wellbore thereby generating vibrations within a subterranean rock formation surrounding the wellbore so as to stimulate production from the formation. According to some embodiments, the subterranean rock formation is hydrocarbon bearing, and the flow of a hydrocarbon bearing fluid is improved by the generated vibrations in the formation, for example by facilitating coalescence of oil droplets into larger bulbs and/or altering wettability of surfaces within the rock formation. According to some embodiments the actuator subsystem uses one or more pistons to convert gas or hydraulic pressure into motion of the mass member. According to some other embodiments an electric motor can be used in the actuator subsystem. According to some embodiments, the contacting surface is configured to strike the interior surface of the wellbore and the contacting surface forms part of the translatable mass member. According to some other embodiments, the contacting surface is on a contacting mass member that is separate from the translatable mass member; and the translatable mass member strikes the contacting mass member. According to some embodiments, one or more anchoring members are moveably mounted on the tool body so as to facilitate stable positioning of the tool body within the wellbore when the mass member strikes the interior surface of the wellbore. The contacting surface of the mass member can have a curvature that is substantially the same to an expected curvature of the interior surface of a wellbore. According to some embodiments more than one translatable mass member can be used which can be actuated simultaneously or in sequence. According to some embodiments, the tool body can be configured for short-term application and can be deployed in the wellbore via a wireline cable, coiled tubing, or on a drilling bottom hole assembly during a drilling process. According to some embodiments a method for generating vibrations in a subterranean rock formation is described. The method includes: deploying a tool body into a wellbore at a depth within the subterranean rock formation; and linearly accelerating a mass member from the tool body such that the mass member translates towards an interior surface of the wellbore so as to cause a contacting surface to impart energy into the interior surface of the wellbore, thereby generating vibrations within the subterranean rock formation According to some embodiments where the tool body is configured for short-term deployment the tool body can be re-positioned at second depth within the wellbore and the accelerating of the mass member can be repeated so as to cause to strike the interior surface of the wellbore at a second location, prior to retrieving the tool body from the wellbore to an above-ground location. According to some embodiments, the tool body is configured for long-term deployment in the wellbore. In some cases the tool body is configured to be deployed prior to insertion of production tubing within the wellbore, and in other cases the production tubing is removed from the wellbore prior to deploying of the tool body, and the production tubing is reinstalled following deployment of the tool body. According to some embodiments, the tool body is configured for long-term downhole deployment via a slim tool deployment technique. According to some embodiments, an apparatus is described that can be used to generate strong vibrations in the formation. In some embodiments, the apparatus translationally accelerates a mass using mechanisms built into the tool and causes the mass to strike the borehole wall. The mechanisms can control the mass acceleration, and the frequency of strikes. In some embodiments, the apparatus is designed for use in the field of petroleum recovery where the vibrations are used to create or re-establish a flow pass for the fluids in the formation. Further features and advantages of the subject disclosure will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS The subject disclosure is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of embodiments of the subject disclosure, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein: FIG. 1 is a diagram illustrating an apparatus that uses an accelerating mass to strike the borehole wall, thereby generating vibrations in the formation and achieving wave stimulation, according to some embodiments; FIGS. 2-1 , 2 - 2 and 2 - 3 show cross sections of an apparatus for generating vibrations for stimulation purposes, according to some embodiments; FIG. 3-1 shows an apparatus for generating vibrations in which air pressure is converted in to mass motion, according to some embodiments; FIG. 3-2 shows an apparatus for generating vibrations for stimulation purposes, according to some other embodiments; FIG. 4 is a cross-section of an apparatus for generating vibrations for stimulation purposes, according to some embodiments; FIG. 5 shows an apparatus for generating vibrations in which an electric motor is used to move a mass for striking a borehole wall, according to some embodiments; and FIG. 6 shows a wellsite in which a borehole tool is being deployed for generating vibrations in a subterranean formation for stimulation purposes, according to some embodiments. DETAILED DESCRIPTION The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the subject disclosure only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the subject disclosure. In this regard, no attempt is made to show structural details in more detail than is necessary for the fundamental understanding of the subject disclosure, the description taken with the drawings making apparent to those skilled in the art how the several forms of the subject disclosure may be embodied in practice. Furthermore, like reference numbers and designations in the various drawings indicate like elements. As used herein, the terms acoustic wave or vibrations refer to the vibrations induced into the subject formation and may be of frequencies generally referred to as seismic, sonic, or ultrasonic. FIG. 1 is a diagram illustrating an apparatus that uses an accelerating mass to strike the borehole wall, thereby generating acoustic waves in the formation and achieving wave stimulation, according to some embodiments. Tool 124 is shown deployed in a borehole 110 formed within formation 100 . A section of borehole wall 122 is shown where tool 124 is disposed at a particular depth. The tool 124 is equipped with a mass 126 that can be projected out of the tool body and strike the borehole wall 122 . The tool 124 is also equipped with one or more anchors 128 and 130 to position the tool 124 . According to some embodiments, the accelerated mass 126 is a piece of metal projected from the downhole tool 124 . The tool 124 has a cylindrical structure, and in some cases more than one mass may be projected from its surface to strike the borehole wall 122 . FIGS. 2-1 , 2 - 2 and 2 - 3 show cross sections of an apparatus for generating acoustic waves for stimulation purposes, according to some embodiments. Tool 124 is shown suspended in borehole 110 having borehole wall 100 . In the case of FIG. 2-1 , when the mass 126 strikes the borehole wall 122 , the force associated with the mass 126 and its acceleration is partially transferred to the formation 100 creating an acoustic wave traveling in the formation 100 . The area of the strike zone depends on the surface area of the mass 126 and the curvature of the mass 126 relative to that of the borehole wall 122 . The shape of mass surface 126 may be chosen to have substantially the same curvature as the borehole wall 122 if maximum area of acoustic excitation is desired. When the area is reduced the exerting force is concentrated in a small area and can generate higher-pressure waves in the formation 100 . In an extreme case, when the mass surface is reduced to a point, such as shown by mass 127 in the example of FIG. 2-2 , the borehole wall 122 can be indented or permanently damaged. The damage can lead to perforation or microcracks in the rock structure for formation 100 . According to some embodiments, both of the cases (shown in FIG. 2-1 and FIG. 2-2 ) have useful applications in the field of oil well production. FIG. 2-3 shows a case where the stimulation tool 124 is being deployed in a region of borehole 110 that is cased with a casing 210 . In such embodiments, the mass 126 can strike the casing 210 transmitting some of the vibrations to the formation 100 immediately behind the casing 210 . Some of the energy will also be transmitted through the casing 210 and excite areas of formation 100 above and below the strike point depth shown in FIG. 2-3 . According to some embodiments, the mechanism of projecting the mass towards the borehole wall can use air (or other gas), liquid (hydraulic), or an electric motor. In the case where air is used, it is provided from the earth surface according to some embodiments. FIG. 3-1 shows an apparatus for generating acoustic waves in which air pressure is converted in to mass motion, according to some embodiments. In the embodiments of FIG. 3-1 , a cylinder 312 having an inner cross sectional area=A 1 is equipped with a piston 310 , and is located inside the tool 124 . An O-ring 332 is positioned within a groove of piston 310 as shown to form a seal with the inner wall of cylinder 310 . The cylinder 310 is filled with air to a pressure P 1 . The piston 310 is compressed to increase the pressure inside the piston to a pressure P 2 >=P 1 . Those skilled in the art will recognize that this structure is a so-called accumulator. Depending on the available air pressure there may or may not be a need for the accumulator. Once the desired pressure P 2 is reached a three way valve 320 is opened to deliver the pressurized air to a second cylinder 314 having a second piston 316 with cross sectional area A 2 <A 1 . As in the case of piston 310 , piston 316 has an O-ring 334 for sealing. The rush of air into the second cylinder accelerates the second piston to a linear motion. The second piston is directly or indirectly connected to the mass 126 , which is then projected out of the tool body and strikes the borehole wall (not shown). If the second piston 316 is not directly connected to the mass 126 , the piston 316 can be arranged to strike the back of the mass 126 , which is of interest in some applications. Note that valve 320 can be used to reciprocate the mass for the next cycle. As a result, in this embodiment, valve 320 is an important component that controls the frequencies achievable by the described apparatus. According to some embodiments, the gas source is on the surface, and the gas is supplied via a gas supply tube 308 . When the source of compressed air (or other gas) is at the surface, the tool can be made simpler than the case where the source is downhole. The drawback, however, is that one has to have high pressure tube 308 running along the length of the well. According to some embodiments, an alternative approach provides an air tank and a pump within the tool. In this case, the gas supply tube 308 runs to another section of the tool string where the tank and pump are positioned (not shown). According to some embodiments, other fluids, such as hydraulic fluid for example, can also be used for driving the piston and the mass, instead of air. In this case, a small reservoir of hydraulic fluid 330 is provided in the tool and there is no need for high pressure tubing to run along the length of the well, unless that is desired. FIG. 3-2 shows an apparatus for generating vibrations for stimulation purposes, according to some other embodiments. In this case the mass 328 is applied to the borehole wall 122 using springs 340 and 342 , which are independent of the second piston 316 . The second piston 316 in this case is fixed to an intermediate mass 326 . The piston 316 accelerates mass 326 to strike mass 328 , thereby imparting energy into mass 328 to generate waves in formation 100 . The arrangement as shown in FIG. 3-2 has been found to help to stabilize the tool 124 within the borehole. It has been found that by linearly accelerating the moving mass (e.g., mass 126 or mass 326 ) such that it translates towards the borehole wall, such as shown and described herein can generate relatively large amplitude vibrations within the surrounding formation. The amplitudes are significantly greater than can be generated by other techniques such as by rotating or whirling a mass in a circular motion or by bending or distorting a mass such as by piezoelectric bending actuators. FIG. 4 is a cross-section of an apparatus for generating vibrations for stimulation purposes, according to some embodiments. In the case shown in FIG. 4 , symmetrically placed pistons are used to drive masses in different directions. The driving can be done simultaneously or in sequence. In the example of FIG. 4 , four pistons are used, although other numbers of pistons can be used according to other embodiments. FIG. 4 is a cross sectional view of the tool 404 at the level of cylinders 414 , 424 , 434 and 444 . Cylinder 414 houses piston 416 that applies force to mass 418 . An O-ring 412 sits within a groove of piston 416 to form a seal with the cylinder 414 . Similarly, cylinders 424 , 434 and 444 house pistons 426 , 436 and 446 respectively, which apply force to masses 428 , 438 and 448 respectively. For clarity, the mechanism and the plumbing by which the pressurizing fluid is connected to the pistons are not shown, but it is similar or identical to that shown in FIG. 3-1 , according to some embodiments. As the pressurizing fluid enters the four cylinders 414 , 424 , 434 and 444 , it pushes the pistons 416 , 426 , 436 and 446 outward which in turn causes masses 418 , 428 , 438 and 448 to accelerate and strike the borehole wall (in cases where the borehole is uncased at the location of the tool) or strike the casing 210 (in cases where the borehole is cased at the location of the tool). FIG. 5 shows an apparatus for generating vibrations in which an electric motor is used to move a mass for striking a borehole wall, according to some embodiments. According to some embodiments, a gearbox is used between the motor and the mass to control the velocity of the mass and the amount of energy imparted to the formation. In the embodiment shown in FIG. 5 , the tool 124 includes electric motor 542 that rotates the vertical shaft 544 , which is connected to the gear box 546 . The gear box 546 in this case transforms the rotational motion of shaft 544 to the translational motion of mass 518 which in turn strikes the borehole wall and generates acoustic vibrations in the formation. FIG. 6 shows a wellsite in which a borehole tool is being deployed for generating vibrations in a subterranean formation for stimulation purposes, according to some embodiments. Shown is a stimulation tool 124 being deployed in a borehole 110 formed within subterranean rock formation 100 . In the case shown in FIG. 6 , the tool 124 is being deployed in borehole 110 via a wireline 610 from wireline truck 620 . However, according to some embodiments, the mode of deploying the stimulation tool 124 depends on a number of factors including the life of the well and whether it is horizontal or vertical well. The stimulation tool 124 can be deployed using other technologies such as for example using coiled tubing, or during a drilling operation on a bottom hole assembly. According to some embodiments, as described hereinabove, an air compressor 612 can be used and connected to the tool 124 via gas tube 308 . According to some embodiments, the tool 124 can be deployed for either short-term application or long-term application. In an example of short-term application, the tool 124 is deployed in the well 110 which has just been cased. According to some embodiments, the wellbore 110 in the region of interest of formation 100 can have open hole completion, where there is direct access to the formation and the mass can strike the formation directly. According to some other embodiments, the wellbore 110 in the region of interest of formation 100 can be cased with perforations. In this case the mass (or masses) of tool 124 can strike the casing, which then transmits some of the vibrations to the formation immediately behind the casing. Some of the energy will be transmitted through the pipe and excite areas above and below the strike point. In an example of a long-term application, according to some embodiments, the tool 124 may be deployed before the production pipes are installed. In this case the connections to the tool for power, control, and possibly compressed air can go through a pipe. According to other long-term application embodiments, the well 110 is already completed and is producing, then the production pipes are removed and tool 124 is deployed, followed by a re-installation of the production pipes. According to yet other long-term application embodiments, the well 110 is already completed and is producing, then depending on the inner diameter of the pipe, a slim version of the tool 124 can be deployed. Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
According to some embodiments, a borehole deployable apparatus is described that can be used to generate strong vibrations in a subterranean rock formation. In some embodiments, the apparatus accelerates a mass using mechanisms built into the tool and causes the mass to strike the borehole wall. The mechanisms can control the mass acceleration, and the frequency of strikes. In some embodiments, the apparatus is designed for use in the field of petroleum recovery where the vibrations are used to create or re-establish a flow rate for the fluids in the formation.
4
REFERENCE TO RELATED APPLICATION [0001] This application claims priority to provisional U.S. Patent Application 61/696,760 filed Sep. 4, 2012. The disclosure of this priority patent application is incorporated herein by reference in its entirety. TECHNICAL FIELD OF INVENTION [0002] The present disclosure relates to chemical analogs and prodrugs of the loop diuretic bumetanide. Furthermore, the present disclosure relates to the use of methods and compositions of analogs and prodrugs of bumetanide for treatment of neurological and psychiatric disorders by administering these agents that modulate expression and/or activity of ion transporters of the NKCC family, and/or the KCC family, and/or GABAa-mediated synaptic signaling. BACKGROUND OF THE INVENTION [0003] General [0004] Many of the agents that are currently used to treat neurological and psychiatric disorders are thought to mediate their therapeutic effects by modulating the excitability of neurons, or some aspect of synaptic signaling between neurons, in the nervous system. Such therapeutic agents, however, affect every cell in the brain indiscriminately, regardless of whether or not the cell contributes to the neurological or psychiatric disorder. In other words, the normal functions of normal cells are affected by these treatments, as are the abnormal functions of cells that underlie the pathological condition being treated. As a consequence, treatments used to treat most neurological and psychiatric disorders elicit unwanted neurological and cognitive side effects. The methods and compositions of the present invention avoid these side effects, since they mediate their therapeutic effects by modulating ion cotransporters on neurons and glia, and do not have effects on ion channels or excitatory synaptic transmission (Hochman, Epilepsia, 2012). [0005] Anxiety [0006] Anxiety disorders are the most prevalent class of psychiatric conditions, affecting approximately 18% of adults [1]-[3]. These disorders include Panic Disorder (PD), Social Anxiety Disorder (SAD), Obsessive Compulsive Disorder (OCD), Posttraumatic Stress Disorder (PTSD), Generalized Anxiety Disorder (GAD), and Specific Phobia al. Medications currently used for treating these disorders include tricyclic antidepressants, selective serotonin reuptake inhibitors (SSRIs), serotonin norepinephrine reuptake inhibitors (SNRIs), benzodiazepines, anticonvulsants, and monoamine oxidase inhibitors. However, 20%-40% of anxiety patients remain non-responders to all available therapies [5]. Additionally, many of the anxiolytic medications can elicit central nervous system (CNS) side-effects that patients find difficult to tolerate [5], [6]. There is a need for new pharmacotherapeutic approaches to treat anxiety with greater efficacy and fewer side effects. [0007] γ-aminobutyric acid (GABA) is the primary inhibitory neurotransmitter in the CNS. The downregulation of GABA A inhibition in the brain has been hypothesized to contribute to pathophysiological anxiety [7]. Antiepileptic drugs that enhance GABA A signaling often possess anxiolytic properties and are commonly prescribed to treat anxiety. These drugs include pregabalin for GAD, pregabalin and gabapentin for SAD, and a number of benzodiazepines for GAD, SAD, and panic disorder [8]. The loop diuretics furosemide (Lasix) and bumetanide (Bumex) are also thought to be GABA A modulators with antiepileptic properties [9]-[12]. These drugs have attracted some interest from epilepsy researchers because of their antiepileptic effects over a wide variety of experimental seizure models [9], [11], [13], [14], and several clinical findings suggesting they can suppress seizures in patients with medically intractable epilepsy [15], [16]. [0008] Loop diuretics are thought to affect GABA A dependent signaling in the brain through their antagonism of cation-chloride cotransport, which is a distinctly different mechanism of action from all other known pharmacological GABA A modulators [17]. Specifically, furosemide and bumetanide antagonize the Na + —K + -2Cl − (NKCC1) cotransporter that is present on both neurons and glial cells, and the neuron-specific K + —Cl − (KCC2) cotransporter [10], [11], [18]-[20]. NKCC1 normally transports chloride from the extracellular to intracellular spaces, and KCC2 transports chloride from intracellular to extracellular spaces. Although furosemide and bumetanide are thought to antagonize both cotransporters, they both have significantly greater affinity for NKCC1 over KCC2 [10]. Hyperpolarizing inhibitory postsynaptic potentials in neurons are generated by the influx of anions (HCO 3 − and Cl −1 ) down their electrochemical gradients [21]. Since GABA A receptor-mediated current is determined, in part, by the difference between the equilibrium potential for CF and the neuronal membrane potential [22], preferential antagonism of NKCC1 with a loop diuretic would be expected to cause a hyperpolarizing shift in the GABA reversal potential, enhancing GABA A synaptic signalling. This effect can be particularly important in view of recent work showing the dominant role that NKCC1 plays at the axon initial segment of principal neurons [23], [24]. [0009] It has recently been shown the furosemide and bumetanide significantly reduce conditioned anxiety in the contextual fear-conditioning and fear-potentiated startle rat models of anxiety. Krystal et al., Loop diuretics Have Anxiolytic Effects in Rat Models of Conditioned Anxiety , PLoS ONE Vol. 7 Issue 4 e35417, April 2012. [0010] Epilepsy [0011] It has long been hypothesized that volume and ion changes in the extracellular space (ECS) can modulate the excitability and epileptogenicity of tissue (Andrew, 1991; Jefferys, 1995; Dudek et al., 1998). Neuronal networks interact with the surrounding ECS in a dynamic, feedback-loop manner. Action potential firing can change the ion concentrations and volume of the ECS, and likewise these changes in the ECS are thought to modulate synaptic transmission and neuronal excitability (Hochman, 2009). The proportion of a volume of brain tissue that is composed of the ECS is called the extracellular volume fraction (EVF). The EVF is a dynamic entity that can change within localized microscopic regions in response to neuronal activity. Action potential firing and synaptic activity generate localized increases in extracellular potassium and chloride. These ion gradients are dispersed, in part, via movement into glial cells through membrane-bound ion transporters and channels (Sontheimer, 1994; Chen & Nicholson, 2000; Emmi et al., 2000; Simard & Nedergaard, 2004). These changing ion concentrations generate osmotic gradients between extracellular and intracellular compartments, causing the diffusion of water into hypertonic spaces. The end result is an activity-driven movement of water from intracellular compartments into glial cells, mediating a transient reduction of the EVF through glial cell swelling (Simard & Nedergaard, 2004; Østby et al., 2009). These considerations suggest that the microscopic organization of glial cell processes could potentially contribute significantly to the ionic and volume changes of the ECS. An electron microscopy study showed that glial cell processes proliferate within specific microdomains in response to increases in neuronal activity during the induction of long-term potentiation (LTP) (Wenzel et al., 1991). It may be that epileptiform activity also alters the distribution of astrocytic processes in ways that are important in epileptogenesis. [0012] The loop diuretics are known to modulate ion cotransporters on neurons and glia in the brain, including a neuronal isoform of the KCC2 and the Na+—K-2Cl cotransporter (NKCC1) that is present on both neurons and glia (Russel, 2000; Blaesse et al., 2009). Under normal physiologic conditions, KCC2 transports K+ and Cl— from the intracellular spaces of neurons into the ECS, and NKCC1 transports Na+, K+, and Cl— from the ECS into the intracellular spaces of neurons and glia. The loop diuretics, furosemide (Lasix) and bumetanide (Bumex) are classic NKCC1 antagonists, with bumetanide being a more potent and specific antagonist than furosemide (Russel, 2000). Reduction of extracellular chloride (low-[Cl − ] o ) by equimolar substitution with impermeant anions such as gluconate, also antagonizes NKCC1. Furosemide antagonizes KCC2 in addition to NKCC1, and can thus reduce γ-aminobutyric acid receptor A (GABA A ) inhibition in adult neurons by reducing the neuronal transmembrane chloride gradient (Thompson et al., 1988). Both furosemide and low-[Cl − ] o treatments have been shown to block activity-driven glial cell swelling (Kimelberg & Frangakis, 1985; Ransom et al., 1985; Walz & Hinks, 1985). [0013] Furosemide has been shown to block epileptiform activity in many standard laboratory seizure models tested. In rat hippocampal slices, these include (1) afterdischarge activity in CA1 elicited by tetanic Schaffer collateral stimulation, high potassium (high-K + ) (10 mm), both acute and prolonged bathing of slices in zero-magnesium medium, 4-aminopyridine (4-AP) (300 μm), bicuculline (100 μm), and zero-calcium (0-Ca+) (Hochman et al., 1995; Gutschmidt et al., 1999). Whole animal studies in rats showed that furosemide blocks kainic acid status in rats (Hochman et al., 1995; Schwartzkroin et al., 1998) and prevented sound-triggered seizures in audiogenic seizure-prone animals (Reid et al., 2000). Furosemide has also been shown to have antiepileptic effects in several studies on human subjects. Intravenously administered furosemide blocked spontaneously occurring interictal spiking and stimulation-evoked afterdischarges of the neocortex during intraoperative studies in patients with medically intractable seizures (Haglund & Hochman, 2005). In those studies, furosemide elicited profound antiepileptic effects on each subject regardless of their specific seizure type. A small clinical trial showed that furosemide significantly reduced seizure frequency in adults with refractory epilepsy (Ahmad et al., 1976). Bumetanide, a more potent and specific antagonist of NKCC1 than furosemide, has also been studied in models of animal seizures. Bumetanide was found to be more potent than furosemide in blocking kainic acid-induced status in rats (Schwartzkroin et al., 1998), and in preventing sound-triggered seizures in audiogenic seizure-prone rats (Reid et al., 2000). Bumetanide was also found to be more potent than furosemide in blocking epileptiform activity generated by focal application of bicuculline or 4-AP to the primate cortex, as well as in blocking stimulation-evoked afterdischarges in primate cortex (Haglund & Hochman, 2009). SUMMARY [0014] The treatment compositions and methods of the present invention are useful for treating psychiatric and neurological disorders, including the anxiety disorders (posttraumatic stress disorder, generalized anxiety disorder, panic disorder, obsessive compulsive disorder, specific phobia), epilepsy, and seizure disorders (American Psychiatric Association, Diagnostic and Statistical Manual of Mental Disorders, 4 th edtion—Text Revision, 2000), as well as migraine, sleep disorders, obesity, eating disorders, autism, depression, edema, glaucoma, stroke, ischemia, neuropathic pain, tinnitus, addictive disorders, schizophrenia, psychosis, and tinnitus. The inventive compositions and methods may be employed to treat these, as well as other neurological and psychiatric disorders, while avoiding the unwanted cognitive and neurological side effects often associated with agents currently employed for the treatment of these disorders. The methods and compositions disclosed herein generally involve the cation-chloride cotransporter families NKCC and/or KCC. [0015] Analogs and prodrugs of CNS-targeted NKCC co-transporter antagonist bumetanide include those provided below as formulas I-VI. The inventors believe that such analogs have increased lipophilicity and reduced diuretic effects compared to the loop diuretics from which they are derived, and thus result in fewer undesirable side effects when employed in the inventive treatment methods. [0016] In one embodiment, the level of diuresis that occurs following administration of an effective amount of analog or prodrug as provided below as Formulas I-V is less than 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, or 10% of that which occurs following administration of an effective amount of bumetanide, from which the analog or prodrug is derived. For example, the analog or prodrug may be less diuretic than the standard loop diuretic molecule (i.e. bumetanide), when administered at the same mg/kg dose. Alternatively or additionally, the analog or prodrug may be more potent than the standard loop diuretic molecule from which it is derived, so that a smaller dose of the analog or prodrug is required for effective relief of symptoms, thereby eliciting less of a diuretic effect. For some treatments and for some molecules, the analog or prodrug may have a longer duration of action of its therapeutic effects for treating disorders than the standard loop diuretic molecule from which it is derived, so that the analog or prodrug may be administered less frequently than the standard loop diuretic molecule, thus leading to a lower total diuretic effect within any given period of time. [0017] The inventive treatment agents may be administered in combination with other known treatment agents, such as those presently used in the treatment of psychiatric disorders and/or epilepsy. One with skill in the art will appreciate that the combination of a treatment agent of the present invention with other known treatment agent(s) will positively affect a wider spectrum of therapeutic targets, thus providing a more efficacious therapeutic effect than would otherwise be possible. [0018] In general, the treatment compositions and methods of the present invention may be used therapeutically and episodically following the onset of symptoms, or prophylactically prior to the onset of symptoms. For example, treatment agents of the present invention can be used to treat existing anxiety disorders, or to prevent the development of specific anxiety disorders, such as Post Traumatic Stress Disorder, in individuals entering or undergoing stressful situations that are known to trigger the development of such disorders (such as a soldier entering the battle field). The above-mentioned and additional features of the present invention, together with the manner of obtaining them, will be best understood by reference to the following more detailed description. All references disclosed herein are hereby incorporated by reference in their entirety as if each was incorporated individually. BRIEF DESCRIPTIONS OF DRAWINGS [0019] FIGS. 1A and 1B (Working example) show the effects of furosemide and bumetanide on suppressing anxiety in two different rat models of anxiety. FIG. 1A shows experimental results using the fear potentiated startle anxiety model, and FIG. 1B shows experimental results using the contextual fear conditioning anxiety model. DETAILED DESCRIPTION [0020] Several classes of compounds that are analogs and prodrugs of the loop diuretic bumetanide and that are believed to be novel are disclosed below. A first class of compounds, identified by Formula I below, includes 5-ester derivatives of loop diuretics, which are anticipated to act as prodrugs of bumetanide. The synthetic methods for the preparation of these compounds would be considered standard to those skilled in the art. Formula I compounds are as follows: [0000] [0000] In various aspects, the present invention provides a compound having a structure according to formula I, or a pharmaceutically acceptable salt, solvate or hydrate thereof, wherein R1 is a member selected from substituted or unsubstituted cycloalkyl alkyl, substituted or unsubstituted alkylcarboxy alkyl, substituted or unsubstituted alkyldioxolone, substituted or unsubstituted alkylcarbonate alkyl, substituted or unsubstituted arylcarbonate alkyl, substituted or unsubstituted alkyloxycarbonyl alkyl, substituted or unsubstituted aryloxycarbonyl alkyl, alkyl acyl, aryl acyl, cycloalkyl acyl, heterocycloalkyl acyl, substituted or unsubstituted alkylphosphate alkyl, substituted or unsubstituted arylphosphate alkyl, substituted or unsubstituted aminoacid alkyl, substituted or unsubstituted cyclicaminoacid alkyl, and substituted or unsubstituted bumetanide alkyl. [0021] A second class of compounds, identified by Formula II below, are 5-amido and 5-keto bumetanide derivatives in which the 5-ester has been replaced by either a ketone or an amide. Formula II: [0000] [0022] In various aspects, the present invention provides a compound having a structure according to the formula II, or a pharmaceutically acceptable salt, solvate or hydrate thereof, wherein: [0023] R2 and R3 are independently: [0024] R2 is a member selected from hydrogen, OR4, substituted or unsubstituted alkyl trifluoromethyl, substituted or unsubstituted alkynyl, substituted or unsubstituted alkynyl alkyl, substituted or unsubstituted amine dialkyl cycloalkyl alkyl, acyl, substituted or unsubstituted alkyl acyl, substituted or unsubstituted cycloalkyl acyl, substituted or unsubstituted amine dialkyl cycloalkyl acyl, substituted or unsubstituted heterocycloalkyl acyl, substituted or unsubstituted aryl acyl, substituted or unsubstituted heteroaryl acyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkyl alkyl, substituted or unsubstituted heterocycloalkyl alkyl, substituted or unsubstituted alkyloxy alkyl, substituted or unsubstituted aryloxy alkyl, substituted or unsubstituted heteroaryloxy alkyl, substituted or unsubstituted cyclolalkyloxy alkyl, substituted or unsubstituted heterocycloalkyloxy alkyl, substituted or unsubstituted alkylthio alkyl, substituted or unsubstituted arylthio alkyl, substituted or unsubstituted heteroarylthio alkyl, substituted or unsubstituted cyclolalkylthio alkyl, or substituted or unsubstituted heterocycloalkylthio alkyl; [0025] R3 is a member selected from hydrogen, OR4, substituted or unsubstituted alkyl trifluoromethyl, substituted or unsubstituted alkynyl, substituted or unsubstituted alkynyl alkyl, substituted or unsubstituted amine dialkyl cycloalkyl alkyl, acyl, substituted or unsubstituted alkyl acyl, substituted or unsubstituted cycloalkyl acyl, substituted or unsubstituted amine dialkyl cycloalkyl acyl, substituted or unsubstituted heterocycloalkyl acyl, substituted or unsubstituted aryl acyl, substituted or unsubstituted heteroaryl acyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted cycloalkyl alkyl, substituted or unsubstituted heterocycloalkyl alkyl, substituted or unsubstituted alkyloxy alkyl, substituted or unsubstituted aryloxy alkyl, substituted or unsubstituted heteroaryloxy alkyl, substituted or unsubstituted cyclolalkyloxy alkyl, substituted or unsubstituted heterocycloalkyloxy alkyl, substituted or unsubstituted alkylthio alkyl, substituted or unsubstituted arylthio alkyl, substituted or unsubstituted heteroarylthio alkyl, substituted or unsubstituted cyclolalkylthio alkyl, or substituted or unsubstituted heterocycloalkylthio alkyl; [0026] R2 and R3, together with the nitrogen to which they are attached, form a saturated or unsaturated optionally substituted or unsubstituted bicyclic heterocyclic ring which may contain further heteroatoms, selected from oxygen, nitrogen or sulfur atoms, and [0027] R4 is a member selected from hydrogen, substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl, substituted or unsubstituted arylalkyl, and substituted or unsubstituted heteroarylalkyl. [0028] A third class of compounds is identified by Formula III below. [0000] [0029] In various aspects, the present invention provides a compound having a structure according to the formula III, or a pharmaceutically acceptable salt, solvate or hydrate thereof, wherein: [0030] R5 is a member selected from substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted arylalkyl, substituted or unsubstituted aryl, substituted or unsubstituted alkyloxyalkyl, substituted or unsubstituted alkyloxyaryl, substituted or unsubstituted alkyloxycycloalkyl, substituted or unsubstituted alkyloxyheteroaryl, substituted or unsubstituted alkylthioalkyl, substituted or unsubstituted alkylthioaryl, substituted or unsubstituted alkylthiocycloalkyl, substituted or unsubstituted alkylthioheteroaryl, substituted or unsubstituted alkylaminoalkyl, substituted or unsubstituted alkylaminoaryl, substituted or unsubstituted alkylaminocycloalkyl, substituted or unsubstituted alkylaminoheteroaryl, substituted or unsubstituted alkylcarboxyalkyl, substituted or unsubstituted alkylcarboxyaryl, substituted or unsubstituted alkylcarboxycycloalkyl, substituted or unsubstituted alkylcarboxyheteroaryl, substituted or unsubstituted alkyloxycarbonylalkyl, substituted or unsubstituted alkoxycarbonylaryl, substituted or unsubstituted alkoxycarbonylcycloalkyl, substituted or unsubstituted alkoxycarbonylheteroaryl, substituted or unsubstituted alkyltrifluoromethyl, and substituted or unsubstituted heteroarylalkyl. [0031] A fourth class of compounds is identified by Formula IV below. [0000] [0032] In yet additional aspects, the present invention provides a compound having a structure according to the formula IV, or a pharmaceutically acceptable salt, solvate or hydrate thereof, wherein: [0033] n=1, 2; [0034] Y is a member selected from nitrogen and CR12; and Q is a member selected from oxygen, sulfur, nitrogen and CR13; [0035] R12 is hydrogen or alkyl; and [0036] R6, R7, R8, R9, R10, R11, and R13 are each independently selected from the group consisting of: hydrogen, halogen, cyano, substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocyclicalkyl, substituted or unsubstituted arylalkyl, and substituted or unsubstituted heteroarylalkyl. [0037] A fifth class of compounds is identified by Formula V, below. [0000] [0038] In yet additional aspects, the present invention provides a compound having a structure according to the formula V, or a pharmaceutically acceptable salt, solvate or hydrate thereof, wherein: [0039] n=1, 2, 3, 4; [0040] Y is a member selected from nitrogen and CR12; and Q is a member selected from oxygen, sulfur, nitrogen and CR13; [0041] R12 is hydrogen or alkyl; and [0042] R14, R15, R16, R17, R18, R19, R20, R21, R22, R23, R24, R25 and R13 are each independently selected from the group consisting of: hydrogen, halogen, cyano, substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocyclicalkyl, substituted or unsubstituted arylalkyl, and substituted or unsubstituted heteroarylalkyl. [0043] A sixth class of compounds is identified by Formula VI, below. [0000] [0044] In still additional aspects, the present inventions provide a compound having a structure according to the formula VI, or a pharmaceutically acceptable salt, solvate or hydrate thereof, wherein: [0045] Z is a member selected from oxygen, sulfur, nitrogen and CR27; A is a member selected from oxygen, sulfur, nitrogen and CR28, B is a member selected from oxygen, sulfur, nitrogen and CR29; and [0046] R26, R27, R28, and R29 are each independently selected from the group consisting of: hydrogen, halogen, cyano, substituted or unsubstituted alkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocyclicalkyl, substituted or unsubstituted arylalkyl, and substituted or unsubstituted heteroarylalkyl. [0047] In general, the compounds described in this invention can be synthesized using traditional synthesis techniques well known to those skilled in the art. More specific synthesis routes are outlined below. [0048] Various ester-containing prodrugs such as compounds according to formula I can be synthesized according to the schemes below: [0000] [0049] The Amide analogs can be synthesized according to the scheme below: [0000] [0050] For the corresponding ketone analogs (Formula III), the target compounds can be prepared in two steps from 3-(butylamino)-5-methyl-4-phenoxybenzaldehyde as follows: [0000] [0051] For the corresponding ketone analogs with the formulas IV and V; they can be prepared according to the following schemes: [0000] [0052] Synthetic preparation of the heterocyclic target compounds (Formula VI) can be achieved in three steps from 3-(butylamino)-5-methyl-4-phenoxybenzaldehyde as follows: [0000] [0053] For many uses to treat diseases and conditions in humans, the above inventive analogs and prodrugs may be formulated in a capsule or gel-tabulate for oral delivery. The dose for inventive analogs and prodrugs would begin at ½ the dose of the common loop diuretic from which it is derived, and the dose could be increased to 10× beyond the standard dose, if necessary, since the inventive molecules would be substantially free from undesired side effects. For example, the inventive prodrugs and analogs of bumetanide could be administered to adults in 0.25 mg doses, 2× per day, and increased up to 10 mg doses delivered 2× per day. [0054] Pharmaceutical compositions of the present invention may be formulated, as is well known in the art, for oral, rectal, topical, nasal, inhalation (e.g, via an aerosol), vaginal, topical, transdermal and parenteral administration. Formulation of combinations of one or more active compounds with suitable carriers, stabilizers, and the like, to provide pharmaceutical compositions is within the skill in the art. In some applications, treatment compositions may be delivered in liposome formulations, for example, that cross the blood brain barrier, or may be co-administered with other agents that cross the blood brain barrier. Example 1 The Effects of Standard Loop Diuretics (Furosemide and Bumetanide) on Rat Models of Anxiety [0055] Methods: [0056] Animal Handling and Drug Delivery [0057] Ninety-six male, adult (3-4 months old) Long-Evans rats, housed in the University of Lethbridge vivarium, were used for these studies. Rat housing consisted of Plexiglas cages with sawdust bedding shared with two or three individuals. The colony room was temperature-controlled (20-21° C.) with a 12 h light/12 h dark cycle, beginning each day at 07:00. Food and water were provided ad libitum. Seventy-two hours prior to the experiment, rats were anaesthetized with isoflurane, and a cannula was implanted into the right external jugular vein of each rat for the purpose of administration of drugs [41]. Rats were thereafter kept in independent cages, and the cannulas were flushed daily to ensure patency. Bumetanide and furosemide were dissolved in DMSO (vehicle), and all drugs were administered I.V. via a cannulated jugular vein. Test drugs were administered 30 min prior to testing. All behavioural testing was conducted during the light cycle (7:00 am-7:00 pm). Testing occurred between the hours of 9:00 am and 3:00 pm. Different, randomly selected rats were used for each group (i.e. no rat was retested in more than one group). All testing was done under ambient room light. [0058] Contextual Fear-Conditioning [0059] Contextual Fear-Conditioning, following a previously described standard protocol, was performed on 24 rats [42]. The testing chamber consisted of a rectangular box (40 cm×56 cm×28 cm) with a stainless steel rod floor. All aspects of the timing of events were under microcomputer control (MedPC, MedAssociates Inc, Vermont, USA). Measurement of freezing was accomplished through an overhead video camera connected to a microcomputer and was automatically scored using a specialty piece of software, FreezeFrame. In Phase 1, rats were placed individually into the chambers for 5 minutes. Phase 2 occurred 24 hr later, when again rats were placed individually into the same chambers, they received an immediate (within 3 s of being placed into the chamber) foot shock (1 mA for 2 s). Thirty seconds later they were removed from the chambers. During phase 3, 24 hr later, the rats were returned to the chambers for 5 min. This session was video recorded and the amount of time spent freezing was assessed using FreezeFrame software. Freezing was defined as the total lack of body movement except for movement related to respiration. The percentage time spent freezing during each minute was entered into Excel spreadsheets and was analyzed using SPSS statistical software. One-way analysis of variance (ANOVA) was used to evaluate treatment effects. [0060] Fear-Potentiated Startle [0061] A Fear-Potentiated Startle protocol, following a previously described protocol, was used to test 23 rats [43]. Animals were trained and tested in four identical stabilimeter devices (Med-Associates). Each rat was placed in a small Plexiglas cylinder. The floor of each stabilimeter consisted of four 6-mm-diameter stainless steel bars spaced 18 mm apart through which shock can be delivered. Cylinder movements result in displacement of an accelerometer where the resultant voltage is proportional to the velocity of the cage displacement. Startle amplitude was defined as the maximum accelerometer voltage that occurs during the first 0.25 sec after the startle stimulus was delivered. The analog output of the accelerometer was amplified, digitized on a scale of 0-4096 units and stored on a microcomputer. Each stabilimeter was enclosed in a ventilated, light-, and sound-attenuating box. All sound level measurements were made with a Precision Sound Level Meter. The noise of a ventilating fan attached to a sidewall of each wooden box produces an overall background noise level of 64 dB. The startle stimulus was a 50 ms burst of white noise (5 ms rise-decay time) generated by a white noise generator. The visual conditioned stimulus was the illumination of a light bulb adjacent to the white noise source. The unconditioned stimulus was a 0.6 mA foot shock with duration of 0.5 s, generated by four constant-current shockers located outside the chamber. The presentation and sequencing of all stimuli were controlled by computer. FPS procedures consist of 5 days of testing; during days 1 and 2 baseline startle responses were collected, days 3 and 4 light/shock pairings were delivered, day 5 testing for fear potentiated startle was conducted. Animals received treatment with compound or vehicle on days 3, 4, and 5. [0062] Matching. [0063] On days 1 and 2 rats were placed individually into the Plexiglas cylinders and 3 min later presented with 30 startle stimuli at a 30 sec interstimulus interval. An intensity of 105 dB was used. The mean startle amplitude across the 30 startle stimuli on the second day was used to assign rats into treatment groups with similar means. [0064] Training. [0065] On days 3 and 4, rats were placed individually into the Plexiglas cylinders. During the first 3 min in the chamber the rats were allowed to acclimate then 10 CS-shock pairings were delivered. The shock was delivered during the last 0.5 sec of the 3.7 sec CSs at an average intertrial interval of 4 min (range, 3-5 min). [0066] Testing. [0067] On the 5th day, rats were placed in the same startle boxes where they were trained and after 3 min acclimation were presented with 18 startle-eliciting stimuli (all at 105 dB). These initial startle stimuli were used to again habituate the rats to the acoustic startle stimuli. Thirty seconds after the last of these stimuli, each animal receives 60 startle stimuli with half of the stimuli presented alone (startle alone trials) and the other half presented 3.2 sec after the onset of the 3.7 sec CS(CS-startle trials). All startle stimuli were presented at a mean 30 sec interstimulus interval, randomly varying between 20 and 40 sec. Data were entered into Excel spreadsheets and SPSS for data analysis. Independent sample t-tests are used to compare each treatment groups. [0068] Contextual Fear-Conditioning [0069] The rats treated with bumetanide (N=8) and furosemide (N=8) spent a significantly smaller percentage of the test period freezing compared to the rats treated with vehicle alone (N=8) (vehicle mean=66.914 [SE=7.04]; bumetanide mean=24.3 [SE=6.80]; furosemide mean=30.12 [SE=4.91]) (df=2; F=13.382; p<0.0001). FIG. 1A. Contextual Fear-Conditioning Results. [0070] FIG. 1A shows the percentage of time during the contextual fear-conditioning test period during which rats were freezing, following intravenous injections of vehicle (N=8), bumetanide (N=8), and furosemide (N=8). Note: Error bars indicate standard errors. [0071] Fear-Potentiated Startle [0072] The rats treated with bumetanide (N=8) and furosemide (N=7) had significantly less increase in startle amplitude with the shock-conditioned stimulus than rats treated with vehicle alone (N=8) (vehicle mean=78.22 [SE=21.10]; bumetanide mean=−8.75 [SE=13.03]; furosemide mean=−8.42 [SE=10.82]) (df=2; F=9.99; p<0.001). FIG. 1B. Fear-Potentiated Startle Test Results. [0073] FIG. 1B shows the startle amplitudes for rats receiving intravenous injections of vehicle (N=7), rats receiving furosemide (N=8), and rats receiving bumetanide (N=8). (A) Percent amount of fear-potentiated startle, and (B) amplitude of startle to the noise alone. Note: Error bars indicate standard errors.
Novel analogs and prodrugs of the loop diuretic bumetanide are described. Pharmaceutical compositions containing bumetanide analogs and prodrugs are also described. These analogs and prodrugs are particularly useful for the treatment and/or prophylaxis of conditions that involve the NKCC cotransporter family (NKCC1 and NKCC2), or the KCC cotransporter family (KCC1, KCC2, KCC3, KCC4), or GABAa receptors. Such conditions include, but are not limited to anxiety disorders, epilepsy, migraine, non-epileptic seizures, sleep disorders, obesity, eating disorders, autism, depression, edema, glaucoma, stroke, ischemia, neuropathic pain, addictive disorders, schizophrenia, psychosis, and tinnitus.
2
BACKGROUND OF THE INVENTION The invention relates to an automatic machine for forming and distributing bakery products of various shapes in baking tins, in particular what are known in Italy as "piped" and "poured in" biscuits. DESCRIPTION OF THE PRIOR ART Machines are already known that carry out the above mentioned operations, and these comprise a conveyor that supplies baking tins in succession to an overhead sweetened paste kneading device in which is included an extrusion group that supplies ropes of paste which, under the action of a cutting device, are subdivided into many pieces of a length adjustable constantly up to the formation of which are called "piped" biscuits whose length corresponds to the maximum dimension of the baking tin. The various operating parts of the machine, that is to say, the paste kneading device, the conveyor supplying the baking tins, and the cutting device for subdividing the ropes of paste, are each driven by a geared motor group, each of which is independent of the others and is interlocked to electrical operating means tripped by cams or mechanical devices. With the cutting device rendered inoperative, the said machines are utilized to create what are called "poured in" biscuits. The separation of the "poured in" biscuits from the extrusion group is brought about mainly through a traction action applied to the ropes of paste located in proximity of the extrusion group, caused by the baking tins moving forward one step. In many cases, the breaking (tearing) of the ropes does not take place in an optimal fashion, thereby giving rise to all the consequential problems this involves. With the above mentioned machines, the formation is not possible of "poured in" biscuits in which there are external helical lines (for example of the sugary type known in Italy as "spumini"), and this undoubtedly represents a limitation in the possibilities of the said machines. SUMMARY OF THE INVENTION The object of the invention is to make available an extremely versatile improved machine with which one can create biscuits of both the "piped" and the "poured in" type without, in respect of the former, any limitation in length and contour and, as regards the latter, any limitation in thickness and contour, and to do so in a fully optimal fashion both insofar as the separation of the ropes of paste from the extrusion group and compliance with the dimension/contour specifications for the biscuits are concerned, with everything being achieved through simple regulations and/or operating action on a control panel and the aid of electromechanical and mechanical means that are simple yet reliable on a long term basis. A further object of the invention is to make provision for sweetened paste of any hardness to be kneaded in an extremely simple and compact machine which, compared with the results achievable therewith, is not at all complicated to construct and is easy to maintain. The foregoing objects are indeed attained with the automatic machine according to the invention, for forming and distributing bakery products of various shapes in baking tins, of the type that comprises: a sweetened paste kneading device, operated by a first geared motor, provided to supply the said paste to an extrusion group connected thereto; a conveyor, driven by a second geared motor, for supplying baking tins in succession to the overhead said extrusion group; means for the oscillating rotation of the said conveyor, at an adjustable angle, operated by a third geared motor; and a cutter device, operated by the said third geared motor, placed at the side of the said extrusion group and operating underneath this in order to cut the extruded ropes of sweetened paste into a number of products of predetermined length; the said extrusion group being constituted by two vertical tubular blocks, coupled telescopically one to the other, with the first tubular block placed beneath and integral with the frame of the said kneading device, and with the second tubular block sliding axially with respect to the first, in contrast with elastic means, under the action of corresponding control means, the said second tubular block being closed at the bottom by an extrusion plate provided with a plurality of molds and defining, with the said two tubular blocks, a variable volume chamber; electrical means being connected to the said cutter device, to the said conveyor, and to the said means for the oscillating rotation of the latter, for operating contemporaneously or alternately the said conveyor and the said paste kneading device, and for operating alternately the said cutter device and the said means for the oscillating rotation of the said conveyor. BRIEF DESCRIPTION OF THE DRAWINGS Characteristics of the invention that are not immediately apparent from the description given above, are emphasized hereinafter, with particular reference to the accompanying table of drawings, in which: FIGS. 1 and 2 each show, in a perspective view, the machine according to the invention with certain parts removed in order to render others more visible; FIG. 3 shows, in a perspective view in a larger scale than in FIGS. 1 and 2, the cutter device plus the means for the operation thereof, and, in part, the means for the rotating operation of the molds of the extrusion group; FIG. 4 shows, in a perspective view, the means for the oscillating rotation of the conveyor; FIGS. 5 and 6 show, in a head-on perspective view and in a bottom to top view, respectively, the extrusion group together with the remaining elements of the said means for the rotating operation of the molds; FIG. 7 shows, in a lateral diagrammatic view, the control means of the extrusion group; FIG. 8 shows, diagrammatically in a perspective view, part of the electromechanical means with which the machine is provided; FIGS. 9a, 9b and 9c each show, diagrammatically, one moment in the creation of "poured in" biscuits conducted in what is called the "chamber full condition"; FIGS. 10a, 10b, 10c and 10d show, diagrammatically, four different moments in the creation of "poured in" biscuits conducted in which is called the "chamber empty condition"; FIGS. 11a, 11b and 11c show, diagrammatically and qualitatively, phase graphs, the ones in FIGS. 11a and 11b relating to the creation of "piped" and "poured in" biscuits conducted with the machine in the said "chamber full condition", and that in FIG. 11c relating to the creation of "poured in" biscuit conducted with the machine in the said "chamber empty condition". DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to the accompanying figures, at 1 is shown a base frame above which is placed a device 2 for kneading sweetened paste 15. The said device 2 is constituted by three forming cylinders, 3, 4a and 4b, one of which, namely cylinder 3, rotates in the opposite direction to the other two identical cylinders. The cylinders 4a and 4b are turned by means of gears, 5a and 5b, fixedly mounted thereon, which mesh with one and the same gear 6 that is carried in rotation by known means 7 that terminate at a corresponding geared motor 12. Above the containment body 8 of the said cylinders is placed a hopper 9 for receiving the paste 15, while underneath, integral with the said body 8, an extrusion group 14 is provided and more about this will be said below. The body 8 is able to rotate with respect to a transverse pin 8a, thereby facilitating the cleaning of the device 2 and of the extrusion group 14. Placed beneath the group 14, virtually in the region of the top plane of the frame 1 and pivotally connected thereto at 55, there is a structure 16 substantially in the form of a "U" that serves as a support (with a surface 16a) and guide for the baking tins 17. From the commencement point to way past the group 14, the support surface 16a has in it two longitudinal grooves 117 inside which slide corresponding continuous conveyor chains 18 provided with a plurality of suitably spaced projections 19 that are destined to thrust the baking tins 17 (in direction T shown in FIG. 3) resting on the structure 16. The chains 18 are wound endlessly around drive pinions 20 (both of which keyed to a shaft 22 pivoted to the base frame 1 and, in turn, carried in rotation, through a chain 24, by a geared motor 13 that is independent of the previously mentioned geared motor 12) and around corresponding driven pinions 26 (in particular three per chain) rotatably supported by the structure 16. One extremity of the shaft 22 is connected to an electromechanical group 50, more about which will be said in due course. At 11 is shown a third and last geared motor, independent of the two previously mentioned geared motors 12 and 13, onto the shaft of which at one side is keyed a first cam 30 (FIG. 4), and at the other, a second cam 31 and a disk 51 (FIG. 3). The first cam 30 exerts an action, via a roller 32, on a rocker arm 33 pivoted at 34 to the base frame 1 and thus able to oscillate in both the directions indicated by the arrow 35 (FIG. 4). The said rocker arm 33 is provided longitudinally with a seat 36 along which is able to slide, controlled by an endless screw-knob assembly 37, the extremity 38a of a connecting rod 38 whose upper extremity is pivoted to the underneath of the said structure 16, in proximity of the end part of this (FIG. 4). It ensues that the rotation of the cam 30 causes an intermittent oscillation of the structure 16 (in the directions shown by the arrow 39 in FIG. 4) around the fulcrum 55. The value of the said oscillation, determined by regulating the pivoting point of the extremity 38a (using the knob 37), can vary from a maximum in which the baking tin is in the immediate vicinity of the extrusion group 14 to a minimum in which the structure is no longer subjected to any oscillation; by means of a knob 38b for regulating the length of the connecting rod 38, a variation is made in the distance the said extrusion group 14 and the said structure 16 are apart. The second cam 31 exerts an action, via a roller 40 maintained in contact there with through a spring 41, on an articulated parallelogram 42 fastened to two transverse shafts 43a and 43b rotatably supported by the frame 1. Fixedly mounted on the shaft 43a are two identical arms 44 that point, one parallel with the other, upwards way past the structure 16. To the upper extremity of the arms 44 is pivoted, at 47, the rear part of a cutter device 45 (FIG. 3) which, at the front rests, by means of brackets 46, on two cams 48. The said cams are keyed to a transverse shaft 49 (rotatably supported by the said body 8) onto which is fixedly mounted a driven pinion 52 operated by means of a chain 53 that meshes with a drive pinion (not illustrated) keyed to the shaft of the geared motor 11. The extreme front part of the device 45 is provided with a cutting edge 54 that extends transversely and is given the task of cutting the bakery products exiting from the extrusion group 14 in cases when, as will be explained below, determinate conditions of operation of the machine occur. The rotation of the cam 31 causes a to-and-fro movement of the device 45 in the direction T, while the rotation of the cams 48 causes the said device to oscillate around the fulcrum 47 in the direction S. The phase relationship between the cam 31 and the cams 48 is such as to position the cutting edge 54 at the maximum height thereof (almost shaving the underneath side of the extrusion group 14) when the device 45 is displaced in the downstream direction, and subsequently to position the cutting edge 54 at the minimum height thereof in synchrony with the return of the said device in the upstream direction. This is advantageous since the cutting edge 54, after having cut the bakery products, does not come into contact with the ropes of sweetened paste exiting from the extrusion group 14. Between the said body 8 and upstream of the furthermost retracted position adopted by the device 45, a vertical magazine 90 integral with the structure 16 is provided, and this is destined to receive a stack P of baking tins 17. The said magazine is constituted by four vertical angular elements 91 integral with the longitudinal sides of the structure 16, the two front ones of which each have at the bottom a recess 92 destined to allow the longitudinal sides of the bottom baking tin 17 in the stack P to pass freely there through when the said baking tin is intercepted by a pair of the said projections 19. The outside face of the said disk 51 is provided with an annular groove 51a, eccentric with respect to the axis of the said disk, with which engages a roller 56 cantilever supported by the lower extremity of an arm 57. The center of the said arm is pivoted to the frame 1, while the upper part thereof is pivotally connected to a tie rod 58 which, in turn, is pivoted to a bracket 59 which, centrally and vertically, is pivotally connected to the frame 1. Integral with the said bracket 59 there is a vertical pin 60 to the top of which can be connected, with the aid of a knob 61, a cross bar 21 more about which will be said below. Downstream of the extrusion group 14, bilaterally to the structure 16, are placed two levers 62, each of which pivoted to a transverse pin coaxial with the other pin and integral with the longitudinal sides of the structure 16. The extremity 62a of each lever is pivotally connected to a corresponding vertical rod 63 freely inserted in a vertical tubular block 64 integral with the corresponding longitudinal side of the structure 16, and the upper part of each rod is rendered integral with a vertical cylinder 65 to which further reference will be made. The other extremity 62b of each lever 62 is subjected (through elastic means 130) to the action of a cam 66 fixedly mounted on a transverse shaft 67 rotatably supported by the structure 16 (or more precisely, underneath this). Also keyed to the said shaft is a second cam 66a that acts in conjunction with the extremity 62b of the second lever 62 placed on the opposite side, with respect to the structure 16, to the first lever 62. The said cams 66 and 66a are spatially positioned in an identical fashion, by means of a regulating device 68 constituted by a collar 69 keyed to one extremity of the said shaft 67, with which is integral a radial arm 70 whose outer extremity is integral with a transverse bush 71 inside which slides axially a rod 72 (subjected to non illustrated elastic means and operated by a knob 72a), the inner extremity of which protrudes out of the said bush so that it can be inserted in one of a plurality of suitably spaced holes 73 machined in a vertical disk 74 integral with one longitudinal side of the structure 16. From what has been stated above, it follows that through the device 68 it is possible to regulate the projecting part of the upper extremity of each of the cylinders 65 with respect to the surface 16a supporting the baking tins 17. The said extrusion group 14 (see FIGS. 5, 6, 9 and 10) is constituted by a first tubular block 75, integral with the bottom part of the body 8, and by a second tubular block 76 placed underneath the first, with which it is telescopically and externally coupled. The vertical sliding motion of the second block 76 is guided by vertical rods 77 enshrouded by corresponding helical springs 78 that support the second block 76 and, at the same time, elastically contrast the raising of this. The base part of the block 76 is provided with transverse guides 79 destined to receive, coupled thereto, the transverse edges of an extrusion plate 80 of a suitable type (able to be locked to the block 76 in a known fashion by means of the knobs 101) provided with a plurality of molds 81 (having a predetermined profile) aligned transversely, with the axis thereof spaced away from the recesses in the magazine 90 at a distance practically equal to the length of the baking tins. In one particular application for the machine in question (more about which will be said) the said molds 81 (for example of a star shaped profile) are externally enshrouded by tightly fitted rings 81a provided externally with axially extending straight toothing that meshes with a transverse rack 109 integral with a longitudinal rod 110 pivotally connectible to the said transverse bar 21. Jointly with the plate 80, the said tubular blocks 75 and 76 defined a chamber 82 whose volume varies from a maximum to a minimum value set by the extreme lowered position and by the maximum uplift, respectively, of the second tubular block 76. The raising of the block 76 is consequential to contact there with being made by the cylinders 65, this resulting from the uplifting of these when the structure 16 rotates upwards. The electromechanical group 50 with which the machine is provided (see FIG. 8) consists of a disk 83 fixedly mounted on the shaft 22, provided with a radial projecting part 84 that is destined to trip a microswitch RS (connected to a control panel 100). Starting at the said projecting part 84 and working, for example, counter clockwise, the said disk 83 is provided with a plurality of axial projections 86a, . . . 86n (for example: with n=18) that are angularly equidistant and are destined to trip a microswitch M 1 connected to the panel 100. It should be noted that the angular displacement between the first projection 86a and the final projection 86n is greater than the angular displacement between any two of the said projections considered in the stated order. Between the projections 86a and 86n, in an internal position with respect to the radial projecting part 84, fashioned in the disk 83 there is a face cam 85 destined to intercept a microswitch C 1 connected to the panel 100. Furthermore, the machine forming the subject of the invention is provided with two more microswitches M 2 and M 3 (FIG. 4) destined to be tripped by corresponding cams 87 and 88 fixedly mounted on the shaft of the said geared motor 11. The said control panel is, among other things, provided on the outside with a master switch I G , two keys T M and T A for operating the machine manually and automatically, respectively, a meter C, a changeover switch SCR, and three timers T R , T i and T' R . A description will now be given of the operation of the machine assuming that it is wished to create what are known as "piped" biscuits B. First of all it is necessary to prepare the machine for use, that is to say, to position a baking tin 17 underneath the extrusion group 14 and to fill the chamber 82 with the paste 15. For the formation of "piped" biscuits, the cutter device 45 is rendered operative and the rocker arm 33 inoperative (in other words, it is not made to oscillate the structure 16) and the bar 21 is not used. For this form of operation, the changeover switch SCR is placed in position H 1 , the meter is set at value n=18 (corresponding to the number of projections 86) and the key T M is depressed. All this does is to set in operation the geared motor 13 for displacing (direction T) the baking tins until the microswitch M 1 is tripped by the projection 86n (the eighteenth tripping operation): graph D 1 in FIG. 11a. The bottom baking tin in the stack P is, in consequence, carried in the direction T and with the halting of the geared motor 13, the front transverse edge of the said tin is one step to the rear with respect to the overhead molds 81. Subsequently, the operator sets the timer T' R which, for a t' R time, allows the geared motor 12 to operate (see graph D 2 in FIG. 11a), and in this way the chamber 82 is filled with paste 15. At this point, the operator sets on the meter C an n number that is a submultiple of n (in this way the n/n ratio defines the number of transverse rows of biscuits in each baking tin), sets a t R time on the timer T R (with t R less than or equal to the time needed for the disk 83 to rotate by the angle existing between two projections 86 in the order considered), and then, by means of the timer T i , sets a t i time with t R +t i lesser than or equal to the time needed for the disk 83 to cover the angle existing between the projections 86a and 86n. The operator, at this juncture, depresses the key T A and this causes the undermentioned succession of events: the operation of the geared motor 13 (graph D 1 ); the tripping by the cam 55 of the microswitch C 1 whereby the timer T i is switched in and the timer T R is switched out; in this way for the t i time the geared motor 12 is inactive (graph D 2 ); upon the expiry of the said t i time, a changeover occurs between T R and T i , that is to say, the timer T i is switched out and the timer T R is switched in: this brings about the operation of the geared motor 12 (with the consequent discharge from the orifices of the molds 81 of ropes of biscuits of the predetermined contour) for a t R time (graph D 2 ); the tripping (at the t* time) by the projection 86a of the microswitch M 1 with the taking out of operation of the geared motor 13 and of the geared motor 12 (if not already rendered inactive by T R ), and the operation of the geared motor 11; the operation of the cutter device 45 with the shearing, by means of the cutting edge 54, of the said ropes at a point corresponding to the underneath of the extrusion group 14 (graph D 3 , FIG. 11a); the tripping by the cam 87 of the microswitch M 2 , with the device 45 in the furthermost retracted position, the consequence of this being the taking out of operation of the geared motor 11 and the synchronous running of the geared motors 12 and 13. At this stage the geared motor 12 remains in operation for the t R time, while the geared motor 13 drops out in consequence of the n number of times the projections 86 have been set to trip the microswitch M 1 . The procedure then continues automatically until the considered baking tin has been filled, that is to say, up until the projection 86n at which point the microswitch C 1 comes back into operation and by changing over T R with T i and subsequently T i with T R , makes possible the optimal positioning of the next baking tin beneath the molds 81, as stated previously. As regards the operation of the RESET microswitch RS, it is stressed that with this, upon completion of one cycle (a complete revolution of the disk 83), it is possible to vary the previously set n number, thereby enabling, in consequence, the number of transverse rows of biscuits for the subsequent baking tins to be varied. The above operating configuration (pertinent to the state K 1 or chamber 82 full condition) enables "piped" biscuits to be created, the profile of which is dependent on the profile of the orifices of the molds, and the length of which is a function of t R . With the above mentioned K 1 state, biscuits of what is called the "poured in" type are also possible, for example sugary type products known in Italy as "spumini", in which there are external helical lines or longitudinal lines. For "poured in" products to be created, the cutter device 45 has to be rendered inoperative, the rocker arm 33 has to be so set as to obtain a predetermined oscillation of the structure 16 and, to conclude, it is necessary to regulate the projection of the vertical cylinders 65 with respect to the corresponding tubular blocks 64 (done by means of the device 68) in such a way that the contact the cylinders make with the said second tubular block 76 obliges the latter to undergo a predetermined displacement with respect to the first tubular block 75. The procedure for getting the machine ready to operate, as also the necessary operations for positioning the first baking tin underneath the extrusion group 14, are the same as previously stated for "piped" biscuits. In this situation the t R time set with the timer T R is of a value such as solely to allow the chamber 82 to be filled with the paste 15 (FIG. 9a); see also graph D 5 in FIG. 11b. When the microswitch M 1 has been tripped the number of times corresponding to the n number set on the meter C, the geared motor 13 ceases operating (the geared motor 12 is already at a standstill since t R is certainly less than the operating time of the geared motor 13) and this causes the geared motor 11 to be set in operation (see graphs D 4 and D 6 in FIG. 11b in respect of the operation of the geared motors 13 and 11, respectively). What has just been said involves the raising of the structure 16 with interception of the second block 76 on the part of the cylinders 65; the uplift of the second block brings about a gradual decrease in the volume of the chamber 82; the paste, compressed in this way, consequently spills out of the orifices of the molds 81 and thus the paste is "poured in" onto the underneath baking tin 17 (see FIG. 9b). The said flow ceases once the structure 16 reaches the top dead center point, and the subsequent downward displacement of the structure 16 causes the volume of the chamber 82 to increase and this has the effect of decompressing the paste and of the ropes of paste breaking spontaneously, as a consequence, in the region of the said orifices (see FIG. 9c). When the structure 16 has completed one full oscillation, that is to say, when it has returned to the bottom dead center point, the cam 87 trips the microswitch M 2 and this causes the geared motor 11 to drop out and the other two geared motors 12 and 13 to be set contemporaneously in operation. The geared motor 12 remains in operation for the t R time needed to fill completely the chamber 82 with paste, while the geared motor 13 remains in operation for the time needed to cause the baking tin 17 to move forward by an amount equal to the predetermined distance between two consecutive transverse rows of biscuits B. The thickness of the "poured in" biscuits created in accordance with the foregoing description is dependent on the spacing in between the blocks 76 and 75, while the contour of the biscuits depends on the profile of the orifices of the molds. With star shaped orifices (FIG. 6), the sugary products known in Italy as "spumini", in which there are longitudinal lines, are formed. If, instead, it is wished to create "spumini" with helical lines, it is necessary to use molds 81 coupled to the said rings 81a provided externally with straight toothing, to mesh the said toothing with the rack 109 and, lastly, to connect the rod 110 to the transverse bar 21. In this way, on a time relationship basis with the "pouring in" of the biscuits (graph D 7 in FIG. 11b), the said molds are made to rotate in a predetermined direction whereby it is possible to produce "poured in" biscuits in which there are external helical lines. The machine according to the invention enables "poured in" biscuits to be created in an operating condition, or K 2 state that is different from the previously mentioned K 1 state, in which the chamber 82 is empty. In the K 2 state, the cutter device 45 is rendered inoperative, the bar 21 is not utilized and nor is the timer T i . As regards the preparation for use of the machine and also the positioning of the first baking tin beneath the extrusion group 14, the information given previously is applicable: the one thing that needs to be stressed is that the microswitch C 1 serves solely for halting the geared motor 13. In the K 2 state (changeover switch SCR in the H 2 position), when the key T A is depressed, the chamber 82 is empty (FIG. 10a). All that the operation of the key T A does is to set in motion the geared motor 13 which, after the microswitch M 1 has been tripped an n number of times (graph D 8 in FIG. 11c), comes to a halt (the n value being set on the meter C). With the dropping out of the geared motor 13, the operation occurs of the geared motor 11 (graph D 9 in FIG. 11c), and in this way the structure 16 is raised and the cylinders 65 cause the block 76 to be displaced upwards: the volume of the chamber 82 decreases (FIG. 10b). When the structure 16 is at top dead center, the cam 88 trips the microswitch M 3 , and this causes the halting of the geared motor 11 (baking tin at a standstill upwards), and the operation of the geared motor 12 (graph D 10 in FIG. 11c). The operation of the geared motor 12 causes paste to be sent into the chamber 82 and subsequently to be "poured in" through the orifices of the molds (FIG. 10c). The geared motor 12 remains in operation for a t R time suited to the thickness of the "poured in" biscuits being placed in the baking tin. Once the t R time has elapsed, the geared motor 12 drops out and the geared motor 11 resumes operation (graph D 9 in FIG. 11c). The downward displacement of the tubular block 76 causes the decompression of the chamber 82 with the consequent spontaneous breaking of the ropes of paste in the region of the orifices of the molds (FIG. 10d). With the structure 16 at bottom dead center, the cam 87 trips the microswitch M 2 and this brings about the halting of the geared motor 11 and the operation of the geared motor 13, and thus a fresh cycle, identical to the preceding one, is commenced. To conclude, with the machine according to the invention it is possible to create "piped" and "poured in" biscuits, the former of predetermined length and contour, the latter of a thickness and contour also predetermined. The special conformation of the extrustion group 14 makes simple and optimal, the regulation of the thichness of "poured in" biscuits and of the contour thereof and, furthermore, the separation of the ropes of paste from the extrusion plate 80 takes place in a reliable way as a consequence of the decompression of the chamber 82. It is understood that the foregoing description has been given purely as an example and thus that any variations in the constructional details are understood to fall within the framework of protection afforded to the invention as described above and claimed below.
Disclosed herein is a machine comprising a sweetened paste kneading device that supplies an extrusion group constituted by two telescopically coupled, vertical tubular blocks, namely a first fixed tubular block and a second movable tubular block closed at the bottom by an extrusion plate which, with the said tubular blocks, defines a variable volume chamber; and a conveyor that supplies baking tins in succession to the overhead said extrusion group. When the variable volume chamber is full of paste, "piped" or "poured in" biscuits are created with, in the first instance, the volume of the said chamber maintained constant and, in the latter, firstly a decrease and then a volumetric increase. When the paste is "piped", the separation from the said extrusion plate of the ropes of extruded paste is achieved with the use of cutting means, while for "poured in" paste, it occurs through breakage caused by the decompression of the paste in the said chamber. When no paste is in the chamber, "poured in" biscuits are created through, in this order, a reduction in the volume of the chamber, the operation of the kneading device, with the consequent extrusion of the paste, and then an increase in the volume of the chamber with the breakage, through decompression, of the ropes of extruded paste.
0
BACKGROUND OF THE INVENTION This application is a continuation-in-part application of co-pending Ser. No. 028,525 filed Apr. 9, 1979 now abandoned. While the practice varies somewhat from place to place, and with the type of business involved, conventional bookkeeping practice has generally involved a substantial number of separate account books generally called journals or ledgers. Frequently, separate account books are kept for cash receipts, cash disbursements, purchases, sales, a general ledger, etc., as well as a volume in which journal entries are made. Generally, these books are bulky, are spread about the accounting department of a business and are cumbersome. This practice persists frequently in small businesses, probably because of general bookkeeping tradition and practice. Over the years, there has been a significant amount of inventive activities directed to bookkeeping and intended to simplify comparisions, prevent errors in transcribing figures, simplify the comparision of figures, to eliminate labor in copying over column headings, and the like. Examples include Schuessler, U.S. Pat. No. 3,081,112 which provides for folding of pages for comparison, and involved the use of correlator sheets, carbon paper and additional entries. Similarly, Lilly, U.S. Pat. No. 1,885,928 involves a comparison means involving repeated folding over sheets in a shingled fashion to expose a series of similar columns. Sterling, U.S. Pat. No. 1,625,105 involves using sheets of different sizes and with corresponding columns for much the same purpose. Using sheets of different sizes has also been employed in DeRham, et al, U.S. Pat. No. 3,269,975, which also employs pressure sensitive strips affixed to the column headings. Matthews, U.S. Pat. No. 1,478,975, uses such strips of paper to actually make the entries which are intended by the inventor to be attached to the appropriate columns in the account book. In Engelberg, U.S. Pat. No. 1,252,333, the column headings are actually made a part of the book cover and raised. Davis, et al., U.S. Pat. No. 2,046,151, also utilizes a shingled configuration of pages for the comparison of columns in a configuration that would undoubtedly prove to be of substantial size. Finally, Kalada, U.S. Pat. No. 1,761,078, also utilizes a folding method to compare figures on one page with the figures on the following page as a means of improving upon the accuracy in transcribing figures from one page to another. However, none of this inventive activity is directed to the area of combining a number of different accounts into the single modular unit that many of the smaller businesses would find convenient, inexpensive and entirely appropriate to their needs, whether that bookkeeping is done manually, with the aid of bookkeeping machines, or utilizing the printouts of computers. Moreover, the separate columns generally contain figures for a series of years. In such figures were kept in a single modular unit, with a new module initiated for each fiscal year, all figures necessary for the preparation of annual or other quarterly reports to officers, directors and shareholders, would be in a single place with out irrelevant figures from preceding years, and the records for the year would also be in a single place for purposes of producing same for an Internal Revenue Service (IRS) audit of a given year's operations. SUMMARY OF THE INVENTION With the foregoing in mind, it is a principal object to provide a modular fiscal year account book which will be suitable to keep a great many of the accounts now separately kept in conventional bookkeeping practice, but will allow the entries to be made in a single convenient annual or other periodic modular unit. Another object of the invention is to maintain the periodic records of a business in a modular unit of manageable size for small and medium sized businesses, to eliminate the substantial expense of purchasing multiple volumes. A further object of the invention is to maintain current periodic records together and eliminate the bulk and inconvenience of carrying around in an accounting department, records from prior periods that are irrelevant to present operations. Another object of the invention is to maintain records for a given fiscal period in one place to be able to produce same for an IRS audit without the necessity of producing records from other years which have not been requested for the audit, thereby limiting the audit to the specific periods requested Still another object of the invention is to provide a completely flexible modular fiscal year accout book which, through the use of a unique construction and cooperation between the individual sheets, will be flexible, expandable and adaptable to any different type of business without significent expense, and which will further provide a complete bound record when the fiscal period has elasped. Other objects and advantages will become apparent to those skilled in the art upon reading the following descriptions of the invention and upon reference to the drawings. In accordance with the invention there is provided a durable binder of appropriate size, generally having hinged covers with a post construction that may be expanded to accommodate additional sheets or separating means as needed. Contained therein will be the modular unit comprising a plurality of sheets having lines and columns appropriate to various bookkeeping functions as hereinafter described. The sheets of paper will generally be of substantially the same size as the binding and cover, but may be ruled or lined in accordance with the differing bookkeeping accounts intended. The invention further incorporates a series of separators having tabs or other means to identify the contents of the various divisions within the module, each of which can be identified with a different account. These tabs may be marked with such headings as "cash received", "disbursements", "sales", "liabilities", "general journal", and the like. As noted above, each of the accounts will include paper ruled appropriately for that type of account, but will preferably be of uniform size with paper utilized for the other accounts. In addition, since the binder will preferably be of the type that opens for the insertion or removal of papers, each of the sheets which comprise the module will be punched to accommodate the binder retaining means. The invention will be better understood after reading the following detailed description of the embodiments thereof with reference to the appended drawings, in which: DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the modular fiscal year account book as it would appear inserted within a typical binder. FIG. 2 is a plan view of the invention opened to the first page of one of the accounts contained therein showing the index tab and separator and the ruled bookkeeping paper appropriate to that account. FIG. 3 is an enlarged fragmentary view of the upper right corner of FIG. 2 showing typical index tabs with inscriptions for some of the accounts contained in the book. FIG. 4 is a typical sheet employed in the module showing the unique cooperation and positioning of adhesive strips, which initially create the module, allow expansion of the module during the accounting period, and which further are adapted to form the module into a bound volume at the conclusion of the accounting period. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Turning to FIG. 1, a typical binder which would normally be employed with this invention is designated generally as 20, and comprises a pair of durable hard covers 22 and 24 connected by hinges 26 to upper 28 and lower 30 halves of the binder 20. The lower portion of the binder 30 includes posts 32 and 34 which penetrate the upper portion of the binder 28, and further includes a slidable locking means 36. The module 38 comprises a multiplicity of uniform sized sheets 48 and separators 44 having a plurality of apertures 70 adapted to receive the posts 32 and 34 to secure the module 38 within the binder 20. The pages 48 and separators 44 will generally be shorter than the covers at 40 to make room for index tabs 42 within the covers 22 and 24, thereby protecting said index tabs 42. Turning to FIG. 2, the Multiple Account Bookkeeping Book is opened to the beginning of one of the accounts near the middle of the book. A separator 44 has affixed a specific index tab 46 which is positioned in a staggered position with regard to the remainder of the index tabs 42 so that an inscription placed thereon regarding the type of account will be visible when the book is opened. A representative sheet of paper 48 having columns 50 and rows 52 appropriate to a particular account is depicted; however, it should be appreciated that the arrangement of rows 52 and columns 50 will vary according to the particular accounts employed in the module. FIG. 3 showing an enlarged fragmentary view of the upper right corner of FIG. 2 shows more clearly index tabs 42 at various points within pages 48 as well as rows 52 and columns 50 of the page to which the book is opened in FIG. 2. FIG. 3 further illustrates a number of the typical tabs with inscriptions showing accounts likely to be included in the modular unit, however the invention is not limited to these accounts depicted. In fact, some of them may be subdivided, such as "assets", may be divided into "current assets" and "fixed assets", and "accounts receivable" or "accounts payable" could also be included. Additionally, within each account there would be column headings which could be pre-printed. Referring now particularly to FIGS. 1 and 4, it can be seen that the module 38 comprises a plurality of apertured sheets 48 and separators 44 having two distinct strips of adhesive material coated on the portion of the module 38 which is clamped by the binder 20. A strip of thermo-setting or heat actuated adhesive 80 is coated on the captive edge of the individual sheets and separators which comprise the module 38, and a strip of pressure sensitive adhesive 90 is coated intermediate the thermo-setting adhesive 80 and the apertures 70. The purpose for this arrangement is twofold; the pressure sensitive adhesive 90 is intended to loosely bind the sheets and separators together to form the module core before and after insertion into the binder, and during the entry of items into the individual accounts; and the heat actuated adhesive is intended to form a permanent binding for the module after all of the entries have been made for a given accounting period. By choosing a pressure sensitive adhesive, which will only loosely bind the adjacent sheets and separators, allows the module to be expanded when necessary to accommodate additional sheets 48. The weak temporary bond afforded by the pressure sensitive adhesive between adjacent sheets allows the module to be manually separated into upper and lower loosely bound components. The upper component is removed from the posts 32 and 34 as a unit, and the additional sheets or plurality of sheets are inserted onto the posts 32 and 34. The cooperation of the posts 32 and 34 with the apertures 70 aligns the adhesive strips 80 and 90 of the additional sheets with the upper and lower module components when the module is re-assembled in the binder. The clamping force of the binder 20 re-establishes the loose bond created by the pressure sensitive adhesive strip 90 and the module is once again a cohesive unit. After all the entries have been made in the module for a given fiscal period, the edge of the module 38 is exposed to heat and the thermo-setting adhesive strip 80 is liquified and penetrates the adjacent sheets 48 and separators 40 to form a permanent binding for the modular fiscal year account book of the instant invention. The pressure sensitive adhesive affords a temporary bond for the module which maintains the alignment of the sheets when the module is being inserted into the binder, and also provides the expansion capability for the module while maintaining the alignment of the sheets which comprise the upper and lower components respectively during the insertion of additional sheets. In FIGS. 1 and 4 the adhesive strips 80 and 90 are shown as coated on only one side of the sheets and separators; however, both sides of the sheets and separators may be coated in keeping with the breadth and scope of this invention. Having described the preferred embodiment of the invention, it should be understood that various changes in construction and arrangement would be apparent to those skilled in the art, and are fully contemplated here without departing from the true spirit of the invention. Accordingly, there are covered all alternatives, modifications, and equivalents as may be included in the spirit and scope of the invention as defined solely by the appended claims.
This invention relates to the field of bookkeeping equipment and specifically to the area of modular fiscal year account books, wherein the user is provided with a self contained account ledger insert, which will accommodate all of the entries for a fiscal year, and will contain a complete record of business transactions for auditing and accounting purposes.
1
The invention relates to improvements in methods of making fiber reinforced plastic pipe, and is more particularly directed to improvements in methods of continuously making pipe of the type utilizing a conveyor tube which becomes an integral part of the completed pipe assembly. BACKGROUND OF THE INVENTION As disclosed in my U.S. Pat. Nos. 3,507,412; Apr. 21, 1970 and 3,700,519; Oct. 24, 1972, the use of an air impervious conveyor tube which becomes an integrated part of the completed pipe assembly of resin and fiber in a continuous method of making the pipe assembly is known. In continuous methods of making fiber reinforced plastic pipe it has been the practice to use mandrels. Some provision must be made to prevent the conveyor tube from sticking to the mandrel. As disclosed in the aforementioned patents, a belt system has been used wherein the belts are coated with a mold release material. Also, and particularly where the conveyor tube will be made to provide a resin-rich surface on the interior of the pipe, or will be saturated with a resin composition, a cellophane casing has been used for contact with the mandrel. The cellophane acts as a release material, and must be subsequently stripped from within the finished pipe assembly. A primary object of the present invention is to provide a method of continuously making fiber reinforced plastic pipe of the type having a resin-saturated conveyor tube which becomes an integrated part of the finished pipe assembly wherein it is unnecessary to resort to a stripping step, or to remove release material from within the finished product. Further, the conveyor tube preferably is made so that it has a resin-rich inner surface or liner. Nevertheless, it is unnecessary to use a belt assembly or a like mechanism in order to enable the manufacture of the product. As will hereinafter appear, the method of the invention is simple. The equipment used to fabricate the pipe is of simple construction, and the steps involved to produce the product are minimal in number, particularly in that it is not necessary to resort to a final stripping step though the finished product includes a resin-rich liner. SUMMARY OF THE INVENTION To produce fiber reinforced plastic pipe in which the conveyor tube is made an integrated part of the pipe and in which the conveyor tube is formed to provide a resin-rich inner surface for the completed pipe, a mandrel is used which comprises a first mandrel section and second mandrel section in alignment therewith and longitudinally spaced therefrom by a gap. A tube of resin-absorbent material is applied to the first mandrel section. The tube is continuously advanced across the gap and over the second mandrel section. As the tube passes over the gap a thermosetting resin is applied in an amount sufficient to saturate the tube. Prior to the arrival of the advancing resin-saturated tube onto the second mandrel section, the resin is at least partially cured to thereby provide a tube which may serve as a means to convey the subsequently applied wrappings or layers or bands of material applied thereto. Then the plurality of bands of thermosetting composition coated continuous fiber elements such as glass rovings are applied to the conveyor tube, and the thermosetting resin is cured to provide the fiber reinforced assembly having the conveyor tube integral therewith. Preferably, when the thermosetting resin is applied to the tube as it passes over the gap it is applied in an amount which is also sufficient to provide a coating on the inner side to thereby furnish a conveyor tube having a resin-rich inner liner. Also, the resin saturant for the tube is preferably cured prior to the application thereto of the plurality of bands of thermosetting resin composition coated continuous fiber elements. Also, it is preferred that the tube of resin-absorbent material applied or formed upon the first mandrel section be reinforced prior to the application of the thermosetting resin saturant thereto as it passes over the gap. For this purpose, a strip of reinforcing strands coated with a substantially dry, partially gelled thermosetting resin is wrapped around the tube while the tube is on the first mandrel section and heat is applied to cause the strands to be bonded to the tube. Since the heat is applied while the advancing tube is still on the first mandrel section, the heat is applied in an amount to cause the strands to be bonded to the tube while inhibiting the flow of resin to the inner side of the tube. The advantages and improved results furnished by the methods of the invention will be apparent from the following detailed description, taken in conjunction with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1, 1A and 1B together are a schematic showing of a continuous system for making pipe in accordance with the invention; FIG. 2 is a more detailed showing of the means for forming a conveyor tube from strips of material withdrawn from rolls; FIG. 3 is an elevational view partly in cross-section, showing a guide plate for the strips; FIG. 4 is an enlarged partial elevational view partly in cross-section showing the formation of the conveyor tube; FIG. 5 is a partial vertical cross-sectional view taken approximately in the plane of line 5--5 of FIG. 1A; FIG. 6 is a detailed showing, in vertical cross-section, of means for supplying air under compression to a conduit extruding through the mandrel, the conduit terminating in the pipe assembly being fabricated; and FIG. 7 is a detailed showing of a floating piston positioned within the advancing pipe assembly. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIGS. 1 1A and 1B, the method of the invention generally comprises providing an air impervious tube T on axially fixed, hollow, rotatable mandrel A. The conveyor tube is made to become an integral part of the pipe assembly P. Referring to FIG. 4, the mandrel A comprises a first mandrel section 10 and a second mandrel section 12 which is in alignment therewith and longitudinally spaced therefrom by a gap 14 having a diameter less than the diameter of the mandrel sections. The tube T of absorbent or permeable material is applied over the first mandrel section. More specifically, the tube is formed upon the first mandrel section from strips of absorbent material such as kraft paper. As shown in FIGS. 2 and 3, strips of paper, four in number in the illustrated form of the invention, and unwound from rolls 16, and applied longitudinally to the mandrel. The rolls are supported by welding brackets 18 to the mandrel. The brackets support spindles 20 for the rolls of paper strip. The advancing pipe assembly P of which the conveyor tube T becomes an integral part serves to draw the paper strips off the rolls so that the longitudinal edges of the strips are in slightly overlapping relationship. The longitudinally applied strips are guided to assume such relationship by a guide member 22 provided with slots 24 extended therethrough as shown in FIG. 3. The guide member, which is provided with a central aperture to allow the mandrel to extend therethrough, is suspended from longitudinally extending rods having their rearward ends fastened or welded to a pair of the roll holder brackets as shown in the aforementioned patents. After the plurality of longitudinally extending paper strips have been laid on to the first mandrel section with their edges overlapped, the strips are reinforced by applying reinforcing strands coated with a substantially dry, partially gelled thermosetting resin while the strips are on the first mandrel section. As shown in FIGS. 1 and 4, a plurality of rolls 26, preferably two, comprising strands 30 coated or impregnated with resin which is B-staged to a partial gel and cooled are unwound from the rolls and applied circumferentially about the longitudinally extending strips 16 of paper on the mandrel. Heat is applied by the heater 32 in an amount sufficient to cause the strands to be bonded to the paper tube while inhibiting the flow of resin to the inner side of the tube. Preferably, infrared heat is used. The resin flows sufficiently to bond the strands to the paper. It is important that the resin flow only enough to accomplish the bonding; the resin must not flow through the paper tube, for otherwise there will be adhesion to the underlying first mandrel section thereby stopping the line. A strip 31 of porous material such as tissue paper may be wound circumferentially about the strand reinforced tube before applying heat to effect bonding of the strands to the tube. The strand reinforced tube is then pulled over the gap 14 and impregnated with resin from the metering pump 34. The gap is a reduction in mandrel diameter so that the resin which soaks through the tube will not bond to the mandrel. The resin applied at this point fully saturates the reinforced conveyor tube, flows completely through the permeable tube, saturates it, and preferably provides an inner coating or resin-rich liner 36 (FIG. 4). While still in the gap 14 or the area between the mandrel sections, heat, preferably in the form of infra-red heating, is applied at 38 while the resin saturated tube is traversing the gap to at least partially cure the resin. The resin impregnated tube having the resin-rich liner then continues onto the second mandrel section 12 which properly sizes and rounds up the tube for the subsequent winding operations. While it might appear that the conveyor tube is rather weak during its course over the gap 14 because of the lack of mandrel support and the paper being wet, actually the tube is quite rigid because of the axial load which is applied to the advancing tube. The conveyor tube is leak proof as required for the subsequent pressurized winding operations. It has a resin-rich lining 36 for the chemical resistance which it will afford in the finished product, and the outer surface of the conveyor tube will bond well to the subsequently applied bands of continuous fiber elements coated or impregnated with a thermosetting resin. Referring to FIG. 1A, a series of resin coated glass windings are applied at 40, 42 and 44 to the reinforced conveyor tube T. These windings are applied with substantial compressive forces. To assist in resisting these forces the conveyor tube is filled with air under pressure. It is at this point or station 46 that the mandrel ends. As shown in FIG. 5, there is a sealing cup B secured to the end of the mandrel A for engagement with the interior of the pipe being fabricated. If the windings of continuous fiber elements coated or impregnated with thermosetting resin were applied where the mandrel alone is located without air under pressure in the conveyor tube or between the mandrel and tube, a binding action would result to interfere with the progress or movement of the pipe assembly through the line. To maintain air under pressure within the pipe as it is being fabricated beyond and forward of the sealing cup B, a floating piston C is secured to the end of a tie-rod 48 which is supported back at the mandrel or a mandrel stabilizer 50 (FIG. 5). The floating piston is located just beyond the puller D, and before the station where predetermined sections of the pipe assembly are cut off at E. To supply air under pressure within the pipe assembly between the sealing cup B and the floating piston C a conduit or tube 52 is provided which extends from a stationary coupling member 54 at the front end of the line to the end of the mandrel at 46. As shown in FIG. 6, the stationary coupling member is provided with a threaded opening 56 extending through the wall thereof in which there is screwed a fitting 58 connected to a source of compressed air (not shown). In order that the compressed air may have access to the hollow conduit 52, the stationary coupling member is provided with a section 60 of increased inner diameter. A rotary coupling 62 is provided with a diametrically extending channel 64 to place the central bore 66 of the coupling in communication with the air line. One end of the tube 52 is force fitted or otherwise secured within the bore of a hollow connecting member 68, the opposite end of the connecting member being suitably secured within the bore 66 of the rotary coupling. By this arrangement the air line or tube 52 is connected for rotation with the rotary coupling and with the mandrel A through which it extends. The conveyor tube T and the bands of resin coated fibrous material applied thereto are rotated and advanced by the control means or puller D having a construction as shown in the U.S. Pat. Nos. 3,507,412 and 3,700,519. The power for operating the puller D is supplied by a motor, pulley, and belt arrangement as disclosed in these patents. As also shown in FIGS. 1A and 1B, after the windings are applied at 40, 42 and 44, a strip of tissue paper 70 is wound over the assembly and adhered thereto by the resin coating just previously applied. The assembly passed through a series of ovens 72, 74, 76, 78 to cure the resin. The pipe being continuously fabricated is rotated and it is linearly advanced by the puller D, following which predetermined lengths of the finished pipe are cut off at E. Any air which may leak by the sealing cup B escapes through the openings or holes 80 in the mandrel wall (FIG. 5), and out through the end of the mandrel to the atmosphere. It will be understood that the reference to thermosetting resin preferably refers to resins of the epoxy and polyester types. The reference to continuous fiber elements preferably refers to glass filaments or rovings. The described method of manufacture enables the simple formation of a strong conveyor tube which may be integrated in the finished pipe. Pipe having a very large diameter may be made in accordance with the method of the invention. It is believed that the advantages and improved results furnished by the methods of the invention will be apparent from the foregoing description of a preferred embodiment of the invention. Various modifications and changes may be made without departing from the spirit and scope of the invention as sought to be defined in the claims.
In a continuous method of making pipe from fiber elements coated with a thermosetting resin, the coated fiber elements are wrapped around a resin saturated conveyor tube which becomes an integral part of the finished pipe assembly. The method of manufacture employs a first mandrel section and a second mandrel section in alignment therewith and longitudinally spaced therefrom by a gap. A tube of resin-absorbent material is applied to the first mandrel section, a thermosetting resin is applied to the tube as it passes over the gap in an amount sufficient to saturate the tube. The resin is at least partially cured prior to its arrival onto the second mandrel section where it provides the conveyor tube for the application thereto of a plurality of bands of continuous fiber elements coated with a thermosetting resin composition.
1
RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 13/758,866 filed on Feb. 4, 2013, which is a continuation of U.S. patent application Ser. No. 13/430,650 filed on Mar. 26, 2012, which is a continuation of U.S. patent application Ser. No. 12/699,846 filed on Feb. 3, 2010, now U.S. Pat. No. 8,149,829, which is a continuation of U.S. patent application Ser. No. 11/728,246 filed on Mar. 23, 2007, now U.S. Pat. No. 7,756,129, which is a continuation of U.S. patent application Ser. No. 10/894,406 filed on Jul. 19, 2004, now U.S. Pat. No. 7,218,633, which is a continuation of U.S. patent application Ser. No. 09/535,591 filed on Mar. 27, 2000, now U.S. Pat. No. 6,804,232, which is related to U.S. patent application Ser. No. 09/536,191 filed on Mar. 27, 2000, now U.S. Pat. No. 7,386,003, all of which are incorporated herein by reference in their entirety for all purposes. BACKGROUND AND FIELD OF THE INVENTION A. Field of the Invention The present invention relates to network protocols and, more particularly, to attachment protocols for use in a network. B. Description of Related Art Over the last decade, the size and power consumption of digital electronic devices has been progressively reduced. For example, personal computers have evolved from laptops and notebooks into hand-held or belt-carriable devices commonly referred to as personal digital assistants (PDAs). One area of carriable devices that has remained troublesome, however, is the coupling of peripheral devices or sensors to the main processing unit of the PDA. Generally, such coupling is performed through the use of connecting cables. The connecting cables restrict the handling of a peripheral in such a manner as to lose many of the advantages inherent in the PDA's small size and light weight. For a sensor, for example, that occasionally comes into contact with the PDA, the use of cables is particularly undesirable. While some conventional systems have proposed linking a keyboard or a mouse to a main processing unit using infrared or radio frequency (RF) communications, such systems have typically been limited to a single peripheral unit with a dedicated channel of low capacity. Based on the foregoing, it is desirable to develop a low power data network that provides highly reliable bidirectional data communication between a host or server processor unit and a varying number of peripheral units and/or sensors while avoiding interference from nearby similar systems. SUMMARY OF THE INVENTION Systems and methods consistent with the present invention address this need by providing a wireless personal area network that permits a host unit to communicate with peripheral units with minimal interference from neighboring systems. A system consistent with the present invention includes a hub device and at least one unattached peripheral device. The unattached peripheral device transmits an attach request to the hub device with a selected address, receives a new address from the hub device to identify the unattached peripheral device, and communicates with the hub device using the new address. In another implementation consistent with the present invention, a method for attaching an unattached peripheral device to a network having a hub device connected to multiple peripheral devices, includes receiving an attach request from the unattached peripheral device, the attach request identifying the unattached peripheral device to the hub device; generating a new address to identify the unattached peripheral device in response to the received attach request; sending the new address to the unattached peripheral device; and sending a confirmation message to the unattached peripheral device using the new address to attach the unattached peripheral device. In yet another implementation consistent with the present invention, a method for attaching an unattached peripheral device to a network having a hub device connected to a set of peripheral devices, includes transmitting an attach request with a selected address to the hub device; receiving a new address from the hub device to identify the unattached peripheral device; and attaching to the network using the new address. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, explain the invention. In the drawings: FIG. 1 is a diagram of a personal area network (PAN) in which systems and methods consistent with the present invention may be implemented; FIG. 2 is a simplified block diagram of the Hub of FIG. 1 ; FIG. 3 is a simplified block diagram of a PEA of FIG. 1 ; FIG. 4 is a block diagram of a software architecture of a Hub or PEA in an implementation consistent with the present invention; FIG. 5 is an exemplary diagram of communication processing by the layers of the software architecture of FIG. 4 ; FIG. 6 is an exemplary diagram of a data block architecture within the DCL of the Hub and PEA in an implementation consistent with the present invention; FIG. 7A is a detailed diagram of an exemplary stream usage plan in an implementation consistent with the present invention; FIG. 7B is a detailed diagram of an exemplary stream usage assignment in an implementation consistent with the present invention; FIG. 8 is an exemplary diagram of a time division multiple access (TDMA) frame structure in an implementation consistent with the present invention; FIG. 9A is a detailed diagram of activity within the Hub and PEA according to a TDMA plan consistent with the present invention; FIG. 9B is a flowchart of the Hub activity of FIG. 9A ; FIG. 9C is a flowchart of the PEA activity of FIG. 9A ; FIGS. 10A and 10B are high-level diagrams of states that the Hub and PEA traverse during a data transfer in an implementation consistent with the present invention; FIGS. 11 and 12 are flowcharts of Hub and PEA attachment processing, respectively, consistent with the present invention; and FIG. 13 is a flowchart of PEA detachment and reattachment processing consistent with the present invention. DETAILED DESCRIPTION The following detailed description of the invention refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. Systems and methods consistent with the present invention provide a wireless personal area network that permits a host device to communicate with a varying number of peripheral devices with minimal interference from neighboring networks. The host device uses tokens to manage all of the communication in the network, and automatic attachment and detachment mechanisms to communicate with the peripheral devices. Network Overview A Personal Area Network (PAN) is a local network that interconnects computers with devices (e.g., peripherals, sensors, actuators) within their immediate proximity. These devices may be located nearby and may frequently or occasionally come within range and go out of range of the computer. Some devices may be embedded within an infrastructure (e.g., a building or vehicle) so that they can become part of a PAN as needed. A PAN, in an implementation consistent with the present invention, has low power consumption and small size, supports wireless communication without line-of-sight limitations, supports communication among networks of multiple devices (over 100 devices), and tolerates interference from other PAN systems operating within the vicinity. A PAN can also be easily integrated into a broad range of simple and complex devices, is low in cost, and is capable of being used worldwide. FIG. 1 is a diagram of a PAN 100 consistent with the present invention. The PAN 100 includes a single Hub device 110 surrounded by multiple Personal Electronic Accessory (PEA) devices 120 configured in a star topology. Other topologies may also be possible. Each device is identified by a Media Access (MAC) address. The Hub 110 orchestrates all communication in the PAN 100 , which consists of communication between the Hub 110 and one or more PEA(s) 120 . The Hub 110 manages the timing of the network, allocates available bandwidth among the currently attached PEAs 120 participating in the PAN 100 , and supports the attachment, detachment, and reattachment of PEAs 120 to and from the PAN 100 . The Hub 110 may be a stationary device or may reside in some sort of wearable computer, such as a simple pager-like device, that may move from peripheral to peripheral. The Hub 110 could, however, include other devices. The PEAs 120 may vary dramatically in terms of their complexity. A very simple PEA might include a movement sensor having an accelerometer, an 8-bit microcontroller, and a PAN interface. An intermediate PEA might include a bar code scanner and its microcontroller. More complex PEAs might include PDAs, cellular telephones, or even desktop PCs and workstations. The PEAs may include stationary devices located near the Hub and/or portable devices that move to and away from the Hub. The Hub 110 and PEAs 120 communicate using multiplexed communication over a predefined set of streams. Logically, a stream is a one-way communications link between one PEA 120 and its Hub 110 . Each stream has a predetermined size and direction. The Hub 110 uses stream numbers to identify communication channels for specific functions (e.g., data and control). The Hub 110 uses MAC addresses to identify itself and the PEAs 120 . The Hub 110 uses its own MAC address to broadcast to all PEAs 120 . The Hub 110 might also use MAC addresses to identify virtual PEAs within any one physical PEA 120 . The Hub 110 combines a MAC address and a stream number into a token, which it broadcasts to the PEAs 120 to control communication through the network 100 . The PEA 120 responds to the Hub 110 if it identifies its own MAC address or the Hub MAC address in the token and if the stream number in the token is active for the MAC address of the PEA 120 . Exemplary Hub Device FIG. 2 is a simplified block diagram of the Hub 110 of FIG. 1 . The Hub 110 may be a battery-powered device that includes Hub host 210 , digital control logic 220 , radio frequency (RF) transceiver 230 , and an antenna 240 . Hub host 210 may include anything from a simple microcontroller to a high performance microprocessor. The digital control logic (DCL) 220 may include a controller that maintains timing and coordinates the operations of the Hub host 210 and the RF transceiver 230 . The DCL 220 is specifically designed to minimize power consumption, cost, and size of the Hub 110 . Its design centers around a time-division multiple access (TDMA)-based network access protocol that exploits the short range nature of the PAN 100 . The Hub host 210 causes the DCL 220 to initialize the network 100 , send tokens and messages, and receive messages. Responses from the DCL 220 feed incoming messages to the Hub host 210 . The RF transceiver 230 includes a conventional RF transceiver that transmits and receives information via the antenna 240 . The RF transceiver 230 may alternatively include separate transmitter and receiver devices controlled by the DCL 220 . The antenna 240 includes a conventional antenna for transmitting and receiving information over the network. While FIG. 2 shows the exemplary Hub 110 as consisting of three separate elements, these elements may be physically implemented in one or more integrated circuits. For example, the Hub host 210 and the DCL 220 , the DCL 220 and the RF transceiver 230 , or the Hub host 210 , the DCL 220 , and the RF transceiver 230 may be implemented as a single integrated circuit or separate integrated circuits. Moreover, one skilled in the art will recognize that the Hub 110 may include additional elements that aid in the sending, receiving, and processing of data. Exemplary Pea Device FIG. 3 is a simplified block diagram of the PEA 120 . The PEA 120 may be a battery-powered device that includes a PEA host 310 , DCL 320 , RF transceiver 330 , and an antenna 340 . The PEA host 310 may include a sensor that responds to information from a user, an actuator that provides output to the user, a combination of a sensor and an actuator, or more complex circuitry, as described above. The DCL 320 may include a controller that coordinates the operations of the PEA host 310 and the RF transceiver 330 . The DCL 320 sequences the operations necessary in establishing synchronization with the Hub 110 , in data communications, in coupling received information from the RF transceiver 330 to the PEA host 310 , and in transmitting data from the PEA host 310 back to the Hub 110 through the RF transceiver 330 . The RF transceiver 330 includes a conventional RF transceiver that transmits and receives information via the antenna 340 . The RF transceiver 330 may alternatively include separate transmitter and receiver devices controlled by the DCL 320 . The antenna 340 includes a conventional antenna for transmitting and receiving information over the network. While FIG. 3 shows the exemplary PEA 120 as consisting of three separate elements, these elements may be physically implemented in one or more integrated circuits. For example, the PEA host 310 and the DCL 320 , the DCL 320 and the RF transceiver 330 , or the PEA host 310 , the DCL 320 , and the RF transceiver 330 may be implemented as a single integrated circuit or separate integrated circuits. Moreover, one skilled in the art will recognize that the PEA 120 may include additional elements that aid in the sending, receiving, and processing of data. Exemplary Software Architecture FIG. 4 is an exemplary diagram of a software architecture 400 of the Hub 110 in an implementation consistent with the present invention. The software architecture 400 in the PEA 120 has a similar structure. The software architecture 400 includes several distinct layers, each designed to serve a specific purpose, including: (1) application 410 , (2) link layer control (LLC) 420 , (3) network interface (NI) 430 , (4) link layer transport (LLT) 440 , (5) link layer driver (LLD) 450 , and (6) DCL hardware 460 . The layers have application programming interfaces (APIs) to facilitate communication with lower layers. The LLD 450 is the lowest layer of software. Each layer may communicate with the next higher layer via procedural upcalls that the higher layer registers with the lower layer. The application 410 may include any application executing on the Hub 110 , such as a communication routine. The LLC 420 performs several miscellaneous tasks, such as initialization, attachment support, bandwidth control, and token planning. The LLC 420 orchestrates device initialization, including the initialization of the other layers in the software architecture 400 , upon power-up. The LLC 420 provides attachment support by providing attachment opportunities for unattached PEAs to attach to the Hub 110 so that they can communicate, providing MAC address assignment, and initializing an NI 430 and the layers below it for communication with a PEA 120 . The LLC 420 provides bandwidth control through token planning. Through the use of tokens, the LLC 420 allocates bandwidth to permit one PEA 120 at a time to communicate with the Hub 110 . The NI 430 acts on its own behalf, or for an application 410 layer above it, to deliver data to the LLT 440 beneath it. The LLT 440 provides an ordered, reliable “snippet” (i.e., a data block) delivery service for the NI 430 through the use of encoding (e.g., 16-64 bytes of data plus a cyclic redundancy check (CRC)) and snippet retransmission. The LLT 440 accepts snippets, in order, from the NI 430 and delivers them using encoded status blocks (e.g., up to 2 bytes of status information translated through Forward Error Correction (FEC) into 6 bytes) for acknowledgments (ACKs). The LLD 450 is the lowest level of software in the software architecture 400 . The LLD 450 interacts with the DCL hardware 460 . The LLD 450 initializes and updates data transfers via the DCL hardware 460 as it delivers and receives data blocks for the LLT 440 , and processes hardware interrupts. The DCL hardware 460 is the hardware driven by the LLD 450 . FIG. 5 is an exemplary diagram of communication processing by the layers of the software architecture 400 of FIG. 4 . In FIG. 5 , the exemplary communications involve the transmission of a snippet from one node to another. This example assumes that the sending node is the Hub 110 and the receiving node is a PEA 120 . Processing begins with the NI 430 of the Hub 110 deciding to send one or more bytes (but no more than will fit) in a snippet. The NI 430 exports the semantics that only one transaction is required to transmit these bytes to their destination (denoted by “( 1 )” in the figure). The NI 430 sends a unique identifier for the destination PEA 120 of the snippet to the LLT 440 . The LLT 440 maps the PEA identifier to the MAC address assigned to the PEA 120 by the Hub 110 . The LLT 440 transmits the snippet across the network to the receiving device. To accomplish this, the LLT 440 adds header information (to indicate, for example, how many bytes in the snippet are padded bytes) and error checking information to the snippet, and employs reverse-direction status/acknowledgment messages and retransmissions. This is illustrated in FIG. 5 by the bidirectional arrow between the LLT 440 layers marked with “(n+m).” The number n of snippet transmissions and the number m of status transmissions in the reverse direction are mostly a function of the amount of noise in the wireless communication, which may be highly variable. The LLT 440 may also encrypt portions or all of the snippet using known encryption technology. The LLT 440 uses the LLD 450 to provide a basic block and stream-oriented communications service, isolating the DCL 460 interface from the potentially complex processing required of the LLT 440 . The LLT 440 uses multiple stream numbers to differentiate snippet and status blocks so that the LLD 450 need not know which blocks contain what kind of content. The LLD 450 reads and writes the hardware DCL 460 to trigger the transmission and reception of data blocks. The PEA LLT 440 , through the PEA LLD 450 , instructs the PEA DCL 460 which MAC address or addresses to respond to, and which stream numbers to respond to for each MAC address. The Hub LLT 440 , through the Hub LLD 450 , instructs the Hub DCL 460 which MAC addresses and stream numbers to combine into tokens and transmit so that the correct PEA 120 will respond. The Hub DCL 460 sends and receives (frequently in a corrupted form) the data blocks across the RF network via the Hub RF transceiver 230 ( FIG. 2 ). The Hub LLT 440 employs FEC for status, checksums and error checking for snippets, and performs retransmission control for both to ensure that each snippet is delivered reliably to its client (e.g., PEA LLT 440 ). The PEA LLT 440 delivers snippets in the same order that they were sent by the Hub NI 430 to the PEA NI 430 . The PEA NI 430 takes the one or more bytes sent in the snippets and delivers them in order to the higher-level application 410 , thereby completing the transmission. Exemplary DCL Data Block Architecture FIG. 6 is an exemplary diagram of a data block architecture 600 within the DCL of the Hub 110 and the PEA 120 . The data block 600 contains a MAC address 610 designating a receiving or sending PEA 120 , a stream number 620 for the communication, and a data buffer 630 which is full when sending and empty when receiving. As will be described later, the MAC address 610 and stream number 620 form the contents of a token 640 . When the LLD 450 reads from and writes to the hardware DCL 460 , the LLD 450 communicates the MAC address 610 and stream number 620 with the data buffer 630 . When a PEA 120 receives a data block, the DCL 460 places the MAC address 610 and stream number 620 contained in the preceding token 640 in the data block 600 to keep track of the different data flows. Exemplary Stream Architecture The LLD 450 provides a multi-stream data transfer service for the LLT 440 . While the LLT 440 is concerned with data snippets and status/acknowledgements, the LLD 450 is concerned with the size of data blocks and the direction of data transfers to and from the Hub 110 . FIG. 7A is a detailed diagram of an exemplary stream usage plan 700 in an implementation consistent with the present invention. A single stream usage plan may be predefined and used by the Hub 110 and all PEAs 120 . The PEA 120 may have a different set of active streams for each MAC address it supports, and only responds to a token that specifies a MAC address of the PEA 120 and a stream that is active for that MAC address. In an implementation consistent with the present invention, every PEA 120 may support one or more active Hub-to-PEA streams associated with the Hub's MAC address. The stream usage plan 700 includes several streams 710 - 740 , each having a predefined size and data transfer direction. The plan 700 may, of course, have more or fewer entries and may accommodate more than the two data block sizes shown in the figure. In the plan 700 , streams 0 - 2 ( 710 ) are used to transmit the contents of small data blocks from the PEA 120 to the Hub 110 . Streams 3 - 7 ( 720 ) are used to transmit the contents of larger data blocks from the PEA 120 to the Hub 110 . Streams 8 - 10 ( 730 ), on the other hand, are used to transmit the contents of small data blocks from the Hub 110 to the PEA 120 . Streams 11 - 15 ( 740 ) are used to transmit the contents of larger data blocks from the Hub 110 to the PEA 120 . To avoid collisions, some of the streams are reserved for PEAs desiring to attach to the network and the rest are reserved for PEAs already attached to the network. With such an arrangement, a PEA 120 knows whether and what type of communication is scheduled by the Hub 110 based on a combination of the MAC address 610 and the stream number 620 . FIG. 7B is a detailed diagram of an exemplary stream usage assignment by the LLT 440 in an implementation consistent with the present invention. The LLT 440 assigns different streams to different communication purposes, reserving the streams with small block size for status, and using the streams with larger block size for snippets. For example, the LLT 440 may use four streams ( 4 - 7 and 12 - 15 ) for the transmission of snippets in each direction, two for odd parity snippets and two for even parity snippets. In other implementations consistent with the present invention, the LLT 440 uses different numbers of streams of each parity and direction. The use of more than one stream for the same snippet allows a snippet to be sent in more than one form. For example, the LLT 440 may send a snippet in its actual form through one stream and in a form with bytes complemented and in reverse order through the other stream. The alternating use of different transformations of a snippet more evenly distributes transmission errors among the bits of the snippet as they are received, and hence facilitates the reconstruction of a snippet from multiple corrupted received versions. The receiver always knows which form of the snippet was transmitted based on its stream number. The LLT 440 partitions the streams into two disjoint subsets, one for use with Hub 110 assigned MAC addresses 750 and the other for use with attaching PEAs' self-selected MAC addresses (AMACs) 760 . Both the LLT 440 and the LLD 450 know the size and direction of each stream, but the LLT 450 is responsible for determining how the streams are used, how MAC numbers are assigned and used, and assuring that no two PEAs 120 respond to the same token (containing a MAC address and stream number) transmitted by the Hub 110 . One exception to this includes the Hub's use of its MAC address to broadcast its heartbeat 770 (described below) to all PEAs 120 . Exemplary Communication FIG. 8 is an exemplary diagram of a TDMA frame structure 800 of a TDMA plan consistent with the present invention. The TDMA frame 800 starts with a beacon 810 , and then alternates token broadcasts 820 and data transfers 830 . The Hub 110 broadcasts the beacon 810 at the start of each TDMA frame 800 . The PEAs 120 use the beacon 810 , which may contain a unique identifier of the Hub 110 , to synchronize to the Hub 110 . Each token 640 ( FIG. 6 ) transmitted by the Hub 110 in a token broadcast 820 includes a MAC address 610 ( FIG. 6 ) and a stream number 620 for the data buffer 630 transfer that follows. The MAC address 610 and stream number 620 in the token 640 to g ether specify a particular PEA 120 to transmit or receive data, or, in the case of the Hub's MAC address 610 , specify no, many, or all PEAs to receive data from the Hub 110 (depending on the stream number). The stream number 620 in the token 640 indicates the direction of the data transfer 830 (Hub 110 to PEA 120 or PEA 120 to Hub 110 ), the number of bytes to be transferred, and the data source (for the sender) and the appropriate empty data block (for the receiver). The TDMA plan controls the maximum number of bytes that can be sent in a data transfer 830 . Not all of the permitted bytes need to be used in the data transfer 830 , however, so the Hub 110 may schedule a status block in the initial segment of a TDMA time interval that is large enough to send a snippet. The Hub 110 and PEA 120 treat any left over bytes as no-ops to mark time. Any PEA 120 not involved in the data transfer uses all of the data transfer 830 bytes to mark time while waiting for the next token 640 . The PEA 120 may also power down non-essential circuitry at this time to reduce power consumption. FIG. 9A is an exemplary diagram of communication processing for transmitting a single data block from the Hub 110 to a PEA 120 according to the TDMA plan of FIG. 8 . FIGS. 9B and 9C are flowcharts of the Hub 110 and PEA 120 activities, respectively, of FIG. 9A . The reference numbers in FIG. 9A correspond to the flowchart steps of FIGS. 9B and 9C . With regard to the Hub activity, the Hub 110 responds to a token command in the TDMA plan [step 911 ] ( FIG. 9B ) by determining the location of the next data block 600 to send or receive [step 912 ]. The Hub 110 reads the block's MAC address 610 and stream number 620 [step 913 ] and generates a token 640 from the MAC address and stream number using FEC [step 914 ]. The Hub 110 then waits for the time for sending a token 640 in the TDMA plan (i.e., a token broadcast 820 in FIG. 8 ) [step 915 ] and broadcasts the token 640 to the PEAs 120 [step 916 ]. If the stream number 620 in the token 640 is zero (i.e., a NO-DATA-TRANSFER token), no PEA 120 will respond and the Hub 110 waits for the next token command in the TDMA plan [step 911 ]. If the stream number 620 is non-zero, however, the Hub 110 determines the size and direction of the data transmission from the stream number 620 and waits for the time for sending the data in the TDMA plan (i.e., a data transfer 830 ) [step 917 ]. Later, when instructed to do so by the TDMA plan (i.e., after the PEA 120 identified by the MAC address 610 has had enough time to prepare), the Hub 110 transmits the contents of the data buffer 630 [step 918 ]. The Hub 110 then prepares for the next token command in the TDMA plan [step 919 ]. With regard to the PEA activity, the PEA 120 reaches a token command in the TDMA plan [step 921 ] ( FIG. 9C ). The PEA 120 then listens for the forward error-corrected token 640 , having a MAC address 610 and stream number 620 , transmitted by the Hub 110 [step 922 ]. The PEA 120 decodes the MAC address from the forward error-corrected token [step 923 ] and, if it is not the PEA's 120 MAC address, sleeps through the next data transfer 830 in the TDMA plan [step 924 ]. Otherwise, the PEA 120 also decodes the stream number 620 from the token 640 . All PEAs 120 listen for the Hub heartbeat that the Hub 110 broadcasts with a token containing the Hub's MAC address 610 and the heartbeat stream 770 . During attachment (described in more detail below), the PEA 120 may have two additional active MAC addresses 610 , the one it selected for attachment and the one the Hub 110 assigned to the PEA 120 . The streams are partitioned between these three classes of MAC addresses 610 , so the PEA 120 may occasionally find that the token 640 contains a MAC address 610 that the PEA 120 supports, but that the stream number 620 in the token 640 is not one that the PEA 120 supports for this MAC address 610 . In this case, the PEA 120 sleeps through the next data transfer 830 in the TDMA plan [step 924 ]. Since the PEA 120 supports more than one MAC address 610 , the PEA 120 uses the MAC address 610 and the stream number 620 to identify a suitable empty data block [step 925 ]. The PEA 120 writes the MAC address 610 and stream number 620 it received in the token 640 from the Hub 110 into the data block [step 926 ]. The PEA 120 then determines the size and direction of the data transmission from the stream number 620 and waits for the transmission of the data buffer 630 contents from the Hub 110 during the next data transfer 830 in the TDMA plan [step 927 ]. The PEA 120 stores the data in the data block [step 928 ], and then prepares for the next token command in the TDMA plan [step 929 ]. FIGS. 9A-9C illustrate communication of a data block from the Hub 110 to a PEA 120 . When the PEA 120 transfers a data block to the Hub 110 , similar steps occur except that the Hub 110 first determines the next data block to receive (with its MAC address 610 and stream number 620 ) and the transmission of the data buffer 630 contents occurs in the opposite direction. The Hub 110 needs to arrange in advance for receiving data from PEAs 120 by populating the MAC address 610 and stream number 620 into data blocks with empty data buffers 630 , because the Hub 110 generates the tokens for receiving data as well as for transmitting data. FIGS. 10A and 10B are high-level diagrams of the states that the Hub 110 and PEA 120 LLT 440 ( FIG. 4 ) go through during a data transfer in an implementation consistent with the present invention. FIG. 10A illustrates states of a Hub-to-PEA transfer and FIG. 10B illustrates states of a PEA-to-Hub transfer. During the Hub-to-PEA transfer ( FIG. 10A ), the Hub 110 cycles through four states: fill, send even parity, fill, and send odd parity. The fill states indicate when the NI 430 ( FIG. 4 ) may fill a data snippet. The even and odd send states indicate when the Hub 110 sends even numbered and odd numbered snippets to the PEA 120 . The PEA 120 cycles through two states: want even and want odd. The two states indicate the PEA's 120 desire for data, with ‘want even’ indicating that the last snippet successfully received had odd parity. The PEA 120 communicates its current state to the Hub 110 via its status messages (i.e., the state changes serve as ACKs). The Hub 110 waits for a state change in the PEA 120 before it transitions to its next fill state. During the PEA-to-Hub transfer ( FIG. 10B ), the Hub 110 cycles through six states: wait/listen for PEA-ready-to-send-even status, read even, send ACK and listen for status, wait/listen for PEA-ready-to-send-odd status, read odd, and send ACK and listen for status. According to this transfer, the PEA 120 cannot transmit data until the Hub 110 requests data, which it will only do if it sees from the PEA's status that the PEA 120 has the next data block ready. The four listen for status states schedule when the Hub 110 asks to receive a status message from the PEA 120 . The two ‘send ACK and listen for status’ states occur after successful receipt of a data block by the Hub 110 , and in these two states the Hub 110 schedules both the sending of Hub status to the PEA 120 and receipt of the PEA status. The PEA status informs the Hub 110 when the PEA 120 has successfully received the Hub 110 status and has transitioned to the next ‘fill’ state. Once the PEA 120 has prepared its next snippet, it changes its status to ‘have even’ or ‘have odd’ as appropriate. When the Hub 110 detects that the PEA 120 has advanced to the fill state or to ‘have even/odd,’ it stops scheduling the sending of Hub status (ACK) to the PEA 120 . If the Hub 110 detects that the PEA 120 is in the ‘fill’ state, it transitions to the following ‘listen for status’ state. If the PEA 120 has already prepared a new snippet for transmission by the time the Hub 110 learns that its ACK was understood by the PEA 120 , the Hub 110 skips the ‘listen for status’ state and moves immediately to the next appropriate ‘read even/odd’ state. In this state, the Hub 110 receives the snippet from the PEA 120 . The PEA 120 cycles through four states: fill, have even, fill, and have odd (i.e., the same four states the Hub 110 cycles through when sending snippets). The fill states indicate when the NI 430 ( FIG. 4 ) can fill a data snippet. During the fill states, the PEA 110 sets its status to ‘have nothing to send.’ The PEA 120 does not transition its status to ‘have even’ or ‘have odd’ until the next snippet is filled and ready to send to the Hub 110 . These two status states indicate the parity of the snippet that the PEA 120 is ready to send to the Hub 110 . When the Hub 110 receives a status of ‘have even’ or ‘have odd’ and the last snippet it successfully received had the opposite parity, it schedules the receipt of data, which it thereafter acknowledges with a change of status that it sends to the PEA 120 . Exemplary Attachment Processing The Hub 110 communicates with only attached PEAs 120 that have an assigned MAC address 610 . An unattached PEA can attach to the Hub 110 when the Hub 110 gives it an opportunity to do so. Periodically, the Hub 110 schedules attachment opportunities for unattached PEAs that wish to attach to the Hub 110 , using a small set of attach MAC (AMAC) addresses and a small set of streams dedicated to this purpose. After selecting one of the designated AMAC addresses 610 at random to identify itself and preparing to send a small, possibly forward error-corrected, “attach-interest” message and a longer, possibly checksummed, “attach-request” message using this AMAC and the proper attach stream numbers 620 , the PEA 120 waits for the Hub 110 to successfully read the attach-interest and then the attach-request messages. Reading of a valid attach-interest message by the Hub 110 causes the Hub 110 believe that there is a PEA 120 ready to send the longer (and hence more likely corrupted) attach-request. Once a valid attach-interest is received, the Hub 110 schedules frequent receipt of the attach-request until it determines the contents of the attach-request, either by receiving the block intact with a valid checksum or by reconstructing the sent attach-request from two or more received instances of the sent attach-request. The Hub 110 then assigns a MAC address to the PEA 120 , sending the address to the PEA 120 using its AMAC address. The Hub 110 confirms receipt of the MAC address by scheduling the reading of a small, possibly forward error-corrected, attach-confirmation from the PEA 120 at its new MAC address 610 . The Hub 110 follows this by sending a small, possibly forward error-corrected, confirmation to the PEA 120 at its MAC address so that the PEA 120 knows it is attached. The PEA 120 returns a final small, possibly forward error-corrected, confirmation acknowledgement to the Hub 110 so that the Hub 110 , which is in control of all scheduled activity, has full knowledge of the state of the PEA 120 . This MAC address remains assigned to that PEA 120 for the duration of the time that the PEA 120 is attached. FIGS. 11 and 12 are flowcharts of Hub and PEA attachment processing, respectively, consistent with the present invention. When the Hub 110 establishes the network, its logic initializes the attachment process and, as long as the Hub 110 continues to function, periodically performs attachment processing. The Hub 110 periodically broadcasts heartbeats containing a Hub identifier (selecting a new heartbeat identifier value each time it reboots) and an indicator of the range of AMACs that can be selected from for the following attach opportunity [step 1110 ] ( FIG. 11 ). The Hub 110 schedules an attach-interest via a token that schedules a small PEA-to-Hub transmission for each of the designated AMACs, so unattached PEAs may request attachment. Each attaching PEA 120 selects a new AMAC at random from the indicated range when it hears the heartbeat. Because the Hub 110 may receive a garbled transmission whenever more than one PEA 120 transmits, the Hub 110 occasionally indicates a large AMAC range (especially after rebooting) so that at least one of a number of PEAs 120 may select a unique AMAC 610 and become attached. When no PEAs 120 have attached for some period of time, however, the Hub 110 may select a small range of AMACs 610 to reduce attachment overhead, assuming that PEAs 120 will arrive in its vicinity in at most small groups. The Hub 110 then listens for a valid attach-interest from an unattached PEA [step 1120 ]. The attach-interest is a PEA-to-Hub message having the AMAC address 610 selected by the unattached PEA 120 . Upon receiving a valid attach interest, the Hub 110 schedules a PEA-to-Hub attach-request token with the PEA's AMAC 610 and reads the PEA's attach-request [step 1130 ]. Due to the low-power wireless environment of the PAN 100 , the attach-request transmission may take more than one attempt and hence may require scheduling the PEA-to-Hub attach-request token more than once. When the Hub 110 successfully receives the attach-request from the PEA, it assigns a MAC address to the PEA [step 1140 ]. In some cases, the Hub 110 chooses the MAC address from the set of AMAC addresses. The Hub 110 sends the new MAC address 610 in an attach-assignment message to the now-identified PEA 120 , still using the PEA's AMAC address 610 and a stream number 620 reserved for this purpose. The Hub 110 schedules and listens for an attach-confirmation response from the PEA 120 using the newly assigned MAC address 610 [step 1150 ]. Upon receiving the confirmation from the PEA 120 , the Hub 110 sends its own confirmation, acknowledging that the PEA 120 has switched to its new MAC, to the PEA 120 and waits for a final acknowledgment from the PEA 120 [step 1160 ]. The Hub 110 continues to send the confirmation until it receives the acknowledgment from the PEA 120 or until it times out. In each of the steps above, the Hub 110 counts the number of attempts it makes to send or receive, and aborts the attachment effort if a predefined maximum number of attempts is exceeded. Upon receiving the final acknowledgment, the Hub 110 stops sending its attach confirmation, informs its NI 430 ( FIG. 4 ) that the PEA 120 is attached, and begins exchanging both data and keep-alive messages (described below) with the PEA 120 . When an unattached PEA 120 enters the network, its LLC 420 ( FIG. 4 ) instructs its LLT 440 to initialize attachment. Unlike the Hub 110 , the PEA 120 waits to be polled. The PEA 120 instructs its DCL 460 to activate and associate the heartbeat stream 770 ( FIG. 7B ) with the Hub's MAC address and waits for the heartbeat broadcast from the Hub 110 [step 1210 ] ( FIG. 12 ). The PEA 120 then selects a random AMAC address from the range indicated in the heartbeat to identify itself to the Hub 110 [step 1220 ]. The PEA 120 instructs its DCL 460 to send an attach-interest and an attach-request data block to the Hub 110 , and activate and associate the streams with its AMAC address [step 1230 ]. The PEA 120 tells its driver to activate and respond to the selected AMAC address for the attach-assignment stream. The unattached PEA 120 then waits for an attach-assignment with an assigned MAC address from the Hub 110 [step 1240 ]. Upon receiving the attach-assignment, the PEA 120 finds its Hub-assigned MAC address and tells its driver to use this MAC address to send an attach-confirmation to the Hub 110 to acknowledge receipt of its new MAC address [step 1250 ], activate all attached-PEA streams for its new MAC address, and deactivate the streams associated with its AMAC address. The PEA 120 waits for an attach confirmation from the Hub 110 using the new MAC address [step 1260 ] and, upon receiving it, sends a final acknowledgment to the Hub 110 [step 1270 ]. The PEA 120 then tells its NI 430 that it is attached. The PEA 120 , if it hears another heartbeat from the Hub 110 before it completes attachment, discards any prior communication and begins its attachment processing over again with a new AMAC. Exemplary Detachment and Reattachment Processing The Hub 110 periodically informs all attached PEAs 120 that they are attached by sending them ‘keep-alive’ messages. The Hub 110 may send the messages at least as often as it transmits heartbeats. The Hub 110 may send individual small, possibly forward error-corrected, keep-alive messages to each attached PEA 120 when few PEAs 120 are attached, or may send larger, possibly forward error-corrected, keep-alive messages to groups of PEAs 120 . Whenever the Hub 110 schedules tokens for PEA-to-Hub communications, it sets a counter to zero. The counter resets to zero each time the Hub 110 successfully receives a block (either uncorrupted or reconstructed) from the PEA 120 , and increments for unreadable blocks. If the counter exceeds a predefined threshold, the Hub 110 automatically detaches the PEA 120 without any negotiation with the PEA 120 . After this happens, the Hub 110 no longer schedules data or status transfers to or from the PEA 120 , and no longer sends it any keep-alive messages. FIG. 13 is a flowchart of PEA detachment and reattachment processing consistent with the present invention. Each attached PEA 120 listens for Hub heartbeat and keep-alive messages [step 1310 ]. When the PEA 120 first attaches, and after receiving each keep-alive message, it resets its heartbeat counter to zero [step 1320 ]. Each time the PEA 120 hears a heartbeat, it increments the heartbeat counter [step 1330 ]. If the heartbeat counter exceeds a predefined threshold, the PEA 120 automatically assumes that the Hub 110 has detached it from the network 100 [step 1340 ]. After this happens, the PEA 120 attempts to reattach to the Hub 110 [step 1350 ], using attachment processing similar to that described with respect to FIGS. 11 and 12 . If the Hub 110 had not actually detached the PEA 120 , then the attempt to reattach causes the Hub 110 to detach the PEA 120 so that the attempt to reattach can succeed. When the PEA 120 is out of range of the Hub 110 , it may not hear from the Hub 110 and, therefore, does not change state or increment its heartbeat counter. The PEA 120 has no way to determine whether the Hub 110 has detached it or how long the Hub 110 might wait before detaching it. When the PEA 120 comes back into range of the Hub 110 and hears the Hub heartbeat (and keep-alive if sent), the PEA 120 then determines whether it is attached and attempts to reattach if necessary. Conclusion Systems and methods consistent with the present invention provide a wireless personal area network that permit a host device to communicate with a varying number of peripheral devices with minimal power and minimal interference from neighboring networks by using a customized TDMA protocol. The host device uses tokens to facilitate the transmission of data blocks through the network. The foregoing description of exemplary embodiments of the present invention provides illustration and description, but is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The scope of the invention is defined by the claims and their equivalents.
A network ( 100 ) includes a hub device ( 110 ) and at least one unattached peripheral device ( 120 ). The hub device comprises circuitry and a transceiver in communication with the circuitry. In operation, the hub device is configured to cause the transceiver to i) send a message to indicate the availability of the hub device for attachment to a first peripheral device, ii) receive, from the first peripheral device, a message indicating the availability of the first peripheral device for communication with the hub device, iii) send, to the first peripheral device, a signal including a first peripheral device identifier, iv) receive, from the first peripheral device, a response, v) send a hub response to the first peripheral device, and vi) receive, from the first peripheral device, a second peripheral response including the first peripheral device identifier.
8
DEDICATORY CLAUSE The invention described herein may be manufactured, used, licensed by or for the Government for Governmental purposes without the payment to me of any royalties thereon. CROSS-REFERENCE TO RELATED APPLICATION The methyltricarboranylmethyl perchlorate used in the propellant of this invention is disclosed and claimed in my concurrently filed U.S. Patent application titled: "Organic Perchlorate Oxidizer for Ultrahigh Burning Rate Propellants." BACKGROUND OF THE INVENTION Carboranes and derivatives thereof have been and are being used as burning rate catalysts for solid propellant compositions. Normal-hexylcarborane and carboranylmethyl, -ethyl, or -propyl sulfide are typical carborane derivatives which are catalyst-plasticizer compounds that have been used for high burning rate propellants. Inorganic and organic iron and iron-containing compounds have also been employed in propellants as burning rate catalysts. Ferrocene and ferrocene derivatives are typical of the organoiron compounds which have been used as burning rate catalysts. Various theories and proposed mechanisms for the acceleration of propellant burning rates have evolved from experimentation in the field of catalysis. Apparently, the rate-controlling step for uncatalyzed propellant burning rates is determined mainly by the rate at which ammonium perchlorate undergoes decomposition. The burning rates of propellants increase as the particle size of the ammonium perchlorate is reduced. Smaller particle sizes facilitate the decomposition rate of ammonium perchlorate. Very fine particle-sized (e.g. of only a few microns average mean-weight-diameter particle size) ammonium perchlorate in conjunction with catalysts (which have been incorporated in the propellant composition as liquid plasticizers) have been responsible for achieving ultrahigh burning rates for propellant compositions. The use of the liquid-type burning rate catalysts, however, has lead to other problems which include catalyst-plasticizer migration into the liner-insulation system. The migration of liquid catalysts into the liner-insulation material can be eliminated by the use of a mixed intramolecular perchlorate salt: carboranyldiferrocenylmethyl perchlorate. The salt was disclosed and claimed in my U.S. Patent Application Ser. No. 120,682, filed Mar. 3, 1971. The activity of the compound is attributed to two different mechanisms for burning rate catalysis plus the oxidizer function which is derived from the perchlorate. Although the catalyst with both carboranyl and ferrocenyl funnctional groups has provided beneficial results, the carboranyl functional group alone has proven to be an excellent catalyst. The liquid carborane system does have, however, the undesirable feature of catalyst migration. Therefore, a solid carborane system would be highly desired since there would be no catalyst migration problem with a solid catalyst. Desirable would be a propellant composition that employs a combination catalyst-oxidizer ingredient which can be used as a partial replacement for ammonium perchlorate without reducing the perchlorate ion content in the propellant composition. Advantageous would be the propellant composition employing a catalyst-oxidizer ingredient that is a solid ingredient and that has excellent compatibility with the other propellant ingredients. A catalyst-oxidizer ingredient which can be used as a replacement for the carborane catalyst-plasticizer in a propellant composition would be advantageous. Therefore, an object of this invention is to provide a propellant composition which has improved burning rates and improved mechanical properties when the liquid catalyst-plasticizer is replaced with a catalyst-oxidizer ingredient. Another object of this invention is to provide a propellant composition which employs a catalyst-oxidizer propellant ingredient that is stable with other propellant ingredients and that does not migrate into the liner-insulation system. Still a further object of this invention is to provide a propellant composition which uses a lesser total amount of catalyst and ammonium perchlorate to thereby permit the use of a larger quantity of binder, and/or fuel, and/or oxidizer in the formulation to yield a propellant of high solids (metallic fuel, inorganic oxidizer) loading without adversely affecting the mechanical properties which is the situation which normally arises when the solids loading of a propellant is increased. SUMMARY OF THE INVENTION Methyltricarboranylmethyl perchlorate is employed as the combination catalyst-oxidizer of a propellant composition additionally comprised of hydroxyl-terminated polybutadiene, a diisocyanate crosslinking agent, an interfacial bonding agent, ammonium perchlorate oxidizer, and a metal fuel. The propellant composition of this invention has improved burning rates and improved mechanical properties. Since the methyltricarboranylmethyl perchlorate is a solid salt which contains three carboranyl functional groups and a perchlorate functional group per molecule, a gain in catalyst function and oxidizer function is achieved. The liquid carboranyl catalyst normally used can be replaced by the solid salt. Additional binder can be employed which permits the use of more oxidizer and metal fuel without a sacrifice of mechanical properties. The propellant is a high solids loading propellant with ultrahigh burning rates. DESCRIPTION OF THE PREFERRED EMBODIMENT The use of methyltricarboranylmethyl perchlorate in a composite propellant provides a means for simultaneously introducing a burning rate catalyst as part of a perchlorate-type oxidizer. This is illustrated in the following propellant compositions. Composition A depicts a propellant composition which has been especially developed as a high burning rate propellant as an alternate for the Safeguard System. Composition B depicts a comparable propellant which contains the methyltricarboranylmethyl perchlorate. The carboranyl content is maintained the same in both compositions of Table I. TABLE 1__________________________________________________________________________A COMPARISON OF PROPELLANTS CONTAININGCARBORANYL BURNING RATE PROMOTERS COMPOSITION COMPOSITION A BINGREDIENTS: (Wt %)Hydroxyl-terminated Polybutadiene Prepolymer 6.05 14.75Isophorone Diisocyanate 0.50 1.50Bonding Agent (BA-114) 0.35 0.35Normal Hexylcarborane 13.10 --Methyltricarboranylmethyl perchlorate -- 10.7Ammonium Perchlorate 70.0 62.7Aluminum (H-30) 10.0 10.BALLISTIC PROPERTIES:Isps (lbf-sec/lbm)(15° half angle) (1000/14.7 psia) 255 255Ispsd (in 6-in motor) (lbf-sec/lbm) 245 250Pressure Exponent (n) 0.65 0.57Burning Rate (at 2000 psia)(ips) 5.7 8-9MECHANICAL PROPERTIES:Specific Gravity (gm/cc) 1.63 1.64Stress/Strain (psi/%) -40° F 330/20 Not Determined +77° F 150/30 225/40 +140° F 120/35 Not DeterminedModulus (psi) 600-700 1200-1300__________________________________________________________________________ The following conclusions are possible: a. Because Composition B contains the same percentage of carboranyl moiety as Composition A, the burning rate should be nearly the same. Actually a considerable improvement in burning rate was observed. b. Because a lesser amount of methyltricarboranylmethyl perchlorate is required to produce the same catalytic content, a larger amount of the hydroxyl-terminated polybutadiene prepolymer could be used. This would mean improved mechanical properties and processing characteristics. c. If a lesser amount of hydroxyl-terminated polybutadiene prepolymer than that which is contained in Composition B were used, this would permit the use of a higher percentage of aluminum and ammonium perchlorate and result in higher performance with still better mechanical properties. d. Since the presently-used n-hexylcarborane (see Composition A) is liquid, it undergoes migration into the liner-insulation system. This migration problem does not exist in Composition B insofar as the carboranyl compound is concerned because the burning rate promoter is a solid salt. The synthesis of methyltricarboranylmethyl perchlorate can be accomplished by the following series of chemical steps, similar to the procedure described by A. N. Nesmeyanov, E. G. Perevalora, L. I. Leont'eva and Yu. A. Ustynyuk, Izvestia Akademii Nauk USSR, Scriya Khimcheskaya No. 3, pp 556-558, March 1966. It can be summarized by the following series of chemical equations: ##SPC1## Synthesis of methyltricarboranylmethyl perchlorate involves the following: Decaborane is converted to carboranylcarbonitrile by reaction with acetonitrile. The carboranylcarbonitrile is reacted with carboranyllithium (which is prepared by the reaction of decaborane with acetylene, followed by lithiation) to form the methyldicarboranylketone which is reacted with an additional quantity of carboranyllithium to form the methyltricarboranylmethyl alcohol after hydrolysis. The alcohol is reacted with perchloric acid to form the methyltricarboranylmethyl perchlorate. The bonding agent employed in the propellant compositions of Table I is added for the purpose of improving the mechanical properties of the cured propellant. The bonding agent functions as an interfacial bonding agent because it interacts with the ammonium perchlorate and the binder to form a chemical bond. When the propellant is then cured, a highly crosslinked network is produced among the AP, the binder and other propellant ingredients. The interfacial bonding agents (BA-114) employed in the propellant formulations of this invention may be derived from di- or tri-functional aziridinylphosphine oxides or their derivatives reacted with polyfunctional carboxylic acids as specifically set forth in a commonly assigned Patent Application Ser. No. 851,137, filed July 30, 1969, now U.S. Pat. No. 3,762,972. The Nominal structure of the reaction product may be represented by the following general formula: ##STR1## Where X 1 represents an aziridinyl group of the structure: ##STR2## and Q 1 and Q 2 are either hydrogen or alkyl groups of one to four carbon atoms (Q 1 and Q 2 may be the same or different), X 2 may be the same as X 1 or may be an organic radical such as phenyl, benzyl, ethyl, etc., R is an alkyl that contains at least one active hydrogen atom or an organic entity or molecules that contain one or more hydroxyl groups, and n is 2, 3, or 4. The reaction product described above, is produced by dissolving the reactants in a suitable inert organic solvent such as methanol, ethanol, methylene chloride, tetrahydrofuran, diethyl ether, or mixtures of these. It has been found to be preferable that methanol or ethanol comprise at least a part of the solvent. Reaction temperature is not critical, and may range from 70° F to 200° F for such time as is needed for essentially all carboxyl groups to be reacted. The solvent is then removed by any suitable means, such as, evaporation under reduced pressure at elevated temperatures. The residue is the reaction product, an interfacial bonding agent, which is usually straw-colored and quite viscous. The perchlorate salt of this invention may be used in a propellant composition in amounts from about 5 to about 20 weight percent of the propellant composition. The salt is easily blended, utilizing standard mixing equipment and procedures. Other propellant ingredients include an additional oxidizer, preferably ammonium perchlorate, in amounts from about 60-72 weight percent, metal fuel (e.g. powdered aluminum, magnesium, titanium, zirconium, and boron) in amounts from about 5 to about 20 weight percent, a binder in amounts from about 6 to about 16 weight percent, a crosslinking agent in amounts from about 0.5 to about 1.0 weight percent, and additives for specific functions desired (e.g. ballistic modifiers, stabilizers, bonding agents etc.) in trace amounts from about 0.2 to 2.0 weight percent. Hydroxyl-terminated polybutadiene prepolymer serves as a binder after curing. The prepolymers are available with different functional groups and curatives or stabilizers. Appropriate crosslinking agents may be added. An appropriate crosslinking agent, isophorone diisocynate, is used with hydroxyl functional prepolymers to provide the necessary strength by crosslinking the binder for the propellant system. Additionally, the physical properties and stability of the propellant is enhanced by the use of from about 0.2 to about 0.4 weight percent of an interfacial bonding agent of the type described earlier herein. The combination burning rate catalyst and oxidizer salt, methyltricarboranylmethyl, is compatible with a large number of propellant ingredients and can be advantageously utilized in propellant formulations which require higher burning rates than that which are presently derivable from the available burning rate catalysts of the organometallic type. Methyltricarboranylmethyl perchlorate is particularly suited for use with a propellant utilizing a high solids loading (e.g. high total percent of inorganic oxidizer, metal fuel, and a relatively small amount of a binder).
A solid propellant composition that employs methyltricarboranylmethyl perorate as a replacement for some of the ammonium perchlorate and for all of the carboranyl plasticizer achieves both improved burning rate and improved mechanical properties. In addition to methyltricarboranylmethyl perchlorate, the propellant of this invention comprises a diisocyanate crosslinking agent, hydroxyl-terminated polybutadiene binder, an interfacial bonding agent and aluminum metal fuel.
2
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to Japanese Patent Application No. 2007-82799, filed Mar. 27, 2007, which is incorporated by reference herein in the entirety. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a combustion control system for an internal combustion engine that uses a plurality of fuels having different octane numbers. 2. Description of Related Art A related art combustion control system for an internal combustion engine includes fuel injection valves that, respectively, inject a low octane fuel and a high octane fuel into a combustion chamber. During the compression stroke, fuel injection is performed such that the low and high octane fuels substantially do not overlap one another in the combustion chamber. The concentration of the gaseous mixture in the combustion chamber is prevented from being over-concentrated, fuel distributions different in octane number can be generated, and stable ignition and suppression of nitrogen oxide and smoke in compressed self ignition are compatibly implemented. Nevertheless, problems described below still remain unresolved. In the event that distribution of the plurality of fuels having different octane numbers is generated, while preventing the fuels from substantially overlapping one another, fuel ignition is initiated with the low octane fuel. More specifically, compression self-ignition combustion is performed. Since the plurality of fuels having different octane numbers from one another are combusted independently of one another, ignition is facilitated. On the other hand, however, from the viewpoint of controlling combustion, there is a difficulty similar to other conventional cases of conventional compression self-ignition combustion. More specifically, when there is a change in operation conditions, and in particular, when the engine load is high, difficulties in combustion control are known. More specifically, when control is performed only to start ignition with the ignition of the low octane fuel regardless of the engine load, it is difficult to compatibly accomplish high thermal efficiency and output in a wide range of operation conditions. BRIEF SUMMARY OF THE INVENTION In view of the problems described above, an object of the present invention is to compatibly accomplish a low fuel consumption cost and a high output when combustion is performed by distributing a plurality of fuels having different octane numbers from one another to different portions of a combustion chamber. In an embodiment, the invention provides an internal combustion engine, including a first fuel injector that supplies a first fuel to a first predetermined region in a combustion chamber, and a second fuel injector that supplies a second fuel to a second predetermined region in the combustion chamber. The second fuel has an octane number that is different than an octane number of the first fuel, and the second predetermined region is different from the first predetermined region. An ignition device is configured to start ignition of one of the first and second fuels based on an ignition signal. An operation condition detector detects at least one engine operating condition. A controller is configured to provide the ignition signal to the ignition device and to determine which one of the first and second fuels to ignite by the ignition device based on the engine operation condition. In another embodiment, the invention provides a fuel control method for an internal combustion engine, including distributing a first fuel to a first predetermined region in a combustion chamber, distributing a second fuel to a second predetermined region in the combustion chamber, the second fuel having an octane number different than an octane number of the first fuel, the second predetermined region being different from the first predetermined region, detecting an operation condition of the engine, determining in accordance with the operation condition of the engine whether to start ignition of one of the first or second fuels, and igniting the determined fuel. According to the present invention, switching between ignition start portions is performed corresponding to the engine operation condition. Consequently, combustion can be executed from a portion of fuel having an octane number suited for the operation condition, and hence optimal combustion can be implemented. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate preferred embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain features of the invention. FIG. 1 is a configuration diagram showing an internal combustion engine in a first embodiment of the present invention; FIG. 2 is a diagram showing a system from a fuel tank to the combustion control system in the first embodiment; FIG. 3 is an explanatory diagram of a gaseous mixture forming method in the first embodiment; FIG. 4 is an explanatory diagram of a combustion method to be executed in the first embodiment; FIG. 5 is configuration diagram showing an internal combustion engine in a second embodiment of the present invention; FIG. 6 is an explanatory diagram of a gaseous mixture forming method to be executed in the second embodiment; FIG. 7 is an explanatory diagram of a combustion method to be executed in the second embodiment; FIG. 8 is a configuration diagram showing an internal combustion engine in a third embodiment of the present invention; FIG. 9 is an explanatory diagram of a gaseous mixture forming method to be executed in the third embodiment; FIG. 10 is an explanatory diagram of a combustion method to be executed in the third embodiment; FIG. 11 is a configuration diagram showing an internal combustion engine in a fourth embodiment of the present invention; FIG. 12 is a detail view of a spark plug in an auxiliary chamber in the fourth embodiment; FIG. 13 is a flow diagram representing a combination control example (1); FIG. 14 is a flow diagram representing a combination control example (2); and FIGS. 15A to 15C are diagrams showing stratified patterns. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a diagram showing an internal combustion engine according to a first embodiment of the present invention. A combustion chamber 1 , working as a main combustion chamber includes a cylinder head, a cylinder block and a piston. The combustion chamber 1 communicates with an intake port 5 and an exhaust port 6 via an intake valve 3 and an exhaust valve 4 , respectively. The intake valve 3 and the exhaust valve 4 are opened and closed in operative association with an intake valve driving cam 7 and an exhaust valve driving cam 8 , respectively. A cavity 9 or piston cavity is formed in a surface of a piston crown. The intake port 5 is provided with a first fuel injection valve 11 for supplying a high octane fuel. A lower surface of the cylinder head includes a second fuel injection valve 12 for supplying a low octane fuel and a third fuel injection valve 13 that works as an ignition trigger device for supplying an initial ignition fuel. The fuel to be sprayed from the first fuel injection valve 11 is directed to a peripheral area of the combustion chamber 1 in the form of an annulus, for example, via the intake valve 3 . The first fuel injection valve 11 injects the high octane fuel during a relatively late timing of an intake stroke. The fuel sprayed from the second fuel injection valve 12 is directed to the piston cavity 9 from the lower surface of the cylinder head in the center of the combustion chamber 1 . The second fuel injection valve 12 injects the low octane fuel in the latter half of a compression stroke. The fuel sprayed from the third fuel injection valve 13 is directed to the peripheral area of the combustion chamber 1 from the lower surface of the cylinder head in the center of the combustion chamber 1 . More specifically, the low octane fuel, which serves as an initial ignition fuel in an area close to a compression top dead center, or TDC, is injected into the combustion chamber 1 in a dispersive manner. The low octane fuel thus being injected from the third fuel injection valve 13 preferably has a lower octane number or a higher cetane number than the low octane fuel being injected from the second fuel injection valve 12 , but the fuels may be the same. As used in the Figures, RON refers to research octane number, or more generally—octane number. Fuel injection from the third fuel injection valve 13 is performed at a timing directly before the timing when the in-cylinder pressure increases to be readily ignitable, in which the density of the fuel spray mass is high. As such, although the fuel has the same octane number, the fuel can easily be usable as the initial ignition fuel. Further, the intake port 5 has a swirl control valve 14 that works as a swirl generating device capable of generating swirl in the combustion chamber 1 . FIG. 2 is a diagram showing a system including a fuel tank and the respective fuel injection valves 11 to 13 . A primary fuel tank 31 preliminarily stores fuel supplied from an external source. The fuel is supplied by a fuel pump 32 a , 32 b to respective fuel reformers 33 a , 33 b. The fuel reformer 33 a performs reformation of the fuel by utilizing exhaust air heat and a reforming catalyst to increase the octane number of the fuel supplied from the primary fuel tank 31 . The fuel reformer 33 b performs reformation of the fuel by utilizing exhaust air heat to reduce the octane number of the fuel supplied from the primary fuel tank 31 . A high octane fuel obtained through the reformation performed in the fuel reformer 33 a is stored into a secondary fuel tank 34 a . A low octane fuel obtained through the reformation performed in the fuel reformer 33 b is stored into a secondary fuel tank 34 b . The secondary fuel tank 34 a includes a sensor 35 a for detecting the amount of the high octane fuel. Similarly, the secondary fuel tank 34 b includes a sensor 35 b for detecting the amount of the low octane fuel. Methods for generating the reformed fuel and storing the fuel in the fuel tank may be similar to those described in U.S. Pat. No. 7,263,967. The high and low octane fuels stored in the respective secondary fuel tanks 34 a and 34 b are supplied by booster pumps to the fuel injection valves 11 , 12 , and 13 . By controlling the amount of the fuel to the respective fuel injection valves 11 , 12 , and 13 , the high and low octane fuels can be supplied to the engine from the respective fuel injection valves 11 , 12 , and 13 at determined rates. Signals from, for example, a crank angle sensor 54 , a coolant temperature sensor 55 , and an acceleration sensor 56 may be inputted into an engine control unit, or ECU 50 . In accordance with the signals, the ECU 50 performs control of the fuel injection valves 11 , 12 , and 13 . In the first embodiment, gaseous mixture formation is performed in a manner described below. The high octane fuel is distributed to a peripheral area of the combustion chamber 1 , generally defined as an area near the cylinder wall of the combustion chamber 1 , and the low octane fuel is distributed to a central area of the combustion chamber 1 , generally defined as an area spaced inward from cylinder wall of the combustion chamber 1 , as shown in FIG. 3 . First, during the latter portion of the intake stroke, the high octane fuel is injected from the first fuel injection valve 11 , which is configured and arranged for communication with the intake port 5 . The fuel from the first fuel injection valve 11 is injected in the intake port 5 and flows into the combustion chamber 1 , through the intake valve 3 . The fuel flows into the combustion chamber 1 , is swirled by the swirl stream generated during the intake stroke, and is distributed to the peripheral area of the combustion chamber 1 . Subsequently, in the latter half of the compression stroke, the low octane fuel is injected from the second fuel injection valve 12 into the cylinder. The fuel injection is aimed toward the piston cavity 9 , whereby the gaseous mixture of the low octane fuel is distributed to an upper portion of the cavity 9 . In the manner described above, fuel distributions different in octane number can be generated. That is, the high octane fuel is distributed to the peripheral area of the combustion chamber 1 , and the low octane fuel is distributed to the central area of the combustion chamber 1 . Combustion according to the first embodiment is performed in a manner described below and in FIG. 4 . The fuel ignition is performed as follows. The low octane fuel, which is used as the initial ignition fuel, is discretely injected into the combustion chamber 1 from the third fuel injection valve 13 . In the gaseous mixture distribution described above, ignition is started with the high octane fuel on the peripheral area of the combustion chamber 1 in a low load state, whereas ignition is started with the low octane fuel on the central area of the combustion chamber 1 in a high load state. For this reason, a fuel injection timing of the third fuel injection valve 13 may be advanced in the low load state, or retarded in the high load state. When the injection timing of injection valve 13 is advanced, the in-cylinder pressure is relatively low, so the fuel can be dispersed to a larger volume, toward the peripheral area. Concurrently, the in-cylinder temperature also is low, and hence an ignition retardation time period is increased, so that ignition is started after the fuel has dispersed toward the cylinder wall. Conversely, when the injection timing is retarded, ignition is advanced to initialize in the central area of the combustion chamber 1 . Thus, a fuel ignition position can be controlled through control of the injection timing. In the low load state, the injection timing of the third fuel injection valve 13 is advanced to cause the low octane fuel, which is used as the initial ignition fuel, to reach into the high octane fuel on the peripheral area of the combustion chamber 1 . Thereby, ignition is started with the high octane fuel on the peripheral area of the combustion chamber 1 , and combustion is executed. In the high load state, the injection timing of the third fuel injection valve 13 is retarded to cause the low octane fuel, which is used as the initial ignition fuel, to stay in the area of the low octane fuel on the central area of the combustion chamber 1 . Thereby, ignition is started with the low octane fuel on the central area of the combustion chamber 1 , and the combustion is executed. According to the first embodiment, switching control is performed by the ignition trigger device to set the area where the initial ignition is started to be the portion for distribution of the high octane fuel in the low load state, or the portion for distribution of the low octane fuel in the high load state. Thereby, effects and advantages as described below can be obtained. In the low load state, combustion is started with fuel that is likely to remain uncombusted as uncombusted hydrocarbons (HC), thereby improving the combustion efficiency. On the other hand, in the high load state, by combusting the low octane fuel earlier, knocking induced by adiabatic compression due to a combustion flame in an end gas portion can be prevented. Further, according to the first embodiment, among the fuels having different octane number to be supplied into the combustion chamber 1 , the fuel having high octane number is distributed to the peripheral area of the combustion chamber 1 , and the fuel having low octane number is distributed to the central area of the combustion chamber 1 . The fuels are supplied in the manner described above to the combustion chamber 1 , thereby, combustion is executed by starting combustion with the high octane fuel in the low load state, and with the low octane fuel in the high load state. Thereby, effects and advantages as described below can be obtained. In the low load state, combustion is started from the peripheral area of the combustion chamber 1 . In this case, a near-wall surface region where the combustion temperature increases is set as an initial combustion portion, and the fuel near the wall, which is prone to be uncombusted because of flame quenching, is securely combusted. Thereby, the combustion efficiency can be improved. In particular, the combustion efficiency improvement can be advantageously implemented in engines of the type in which a significant dilution of the gaseous mixture is performed. Alternatively, in the event of lean combustion being performed in a low load region, the combustion temperature is dependant on a combustion air-to-fuel ratio, and hence does not relatively increase, such that the heat loss is not greatly exacerbated even by combustion in the near-wall surface region. However, it is contemplated that, in operations being performed with an air-to-fuel ratio close to a theoretical or stoichiometric air-to-fuel ratio in the high load region, when combustion is started from the near-wall surface region, the heat loss is increased. As such, in the high load state, combustion is started from a central area of the combustion chamber 1 , thereby preventing such a heat loss increase associated with the combustion in the near-wall surface region. Further, the first embodiment has an advantage in that, for example, a spark plug for ignition does not have to be provided in the combustion chamber 1 , and hence limitations regarding the valve opening area size are reduced. FIG. 5 is diagram showing an internal combustion engine according to a second embodiment of the present invention. The same numerals designate portions of configurations common to those of the internal combustion engine in the first embodiment. The second embodiment includes a pair of air injection valves 15 as a device for distributing fuels having different octane numbers to different areas in the combustion chamber 1 . The respective air injection valves 15 are directed towards the interior of the combustion chamber 1 so as to inject air or exhaust gas recirculation (EGR) along a tangential direction of the cylinder bore. In the present embodiment, the respective air injection valves 15 are controlled by a signal supplied from the ECU 50 . The first fuel injection valve 11 for supplying the high octane fuel is directed towards the central area in the combustion chamber 1 via the intake valve 3 . The second fuel injection valve 12 for supplying the low octane fuel is directed from the lower surface of the cylinder head towards the peripheral area in the combustion chamber 1 . Other configurations are substantially the same as those of the first embodiment. The gaseous mixture is formed in the second embodiment in a manner described below. The high octane fuel is distributed to the central area of the combustion chamber 1 , and the low octane fuel is distributed to the peripheral area of the combustion chamber 1 (see FIG. 6 ). First, the high octane fuel is injected from the first fuel injection valve 11 mounted to the intake port 5 to flow into the cylinder in the intake stroke. While the fuel is injected to the intake port 5 similarly as in the first embodiment, fuel injection directed to the peripheral area of the combustion chamber 1 is not specifically performed. Consequently, the gaseous mixture of the fuel and air once drawn in the combustion chamber 1 is substantially uniformly generated. In addition to the gaseous mixture, air or EGR is injected and supplied from the air injection valve 15 during the transition from a late phase of the intake stroke to a near-midway phase of the compression stroke. Thereby, the high octane fuel is compressed towards the central area of the combustion chamber 1 , and the air is distributed towards the peripheral area of the combustion chamber 1 . Then, the low octane fuel is injected from the second fuel injection valve 12 and distributed towards the peripheral area of the combustion chamber 1 . In the manner described above, fuel distributions different in octane number can be generated. That is, the high octane fuel is distributed to the central area of the combustion chamber 1 , and the low octane fuel is distributed to the peripheral area of the combustion chamber 1 . Ignition or combustion in the second embodiment is performed in a manner described below, and as illustrated in FIG. 7 . The fuel ignition is performed in the manner that the low octane fuel, which is used as the initial ignition fuel, is discretely injected into the combustion chamber 1 from the third fuel injection valve 13 mounted in the combustion chamber 1 . In the gaseous mixture distribution described above, ignition is started with the high octane fuel on the central area of the combustion chamber 1 in the low load state, whereas ignition is started with the low octane fuel on the peripheral area of the combustion chamber 1 in the high load state. For this reason, the fuel injection timing of the third fuel injection valve 13 is set to be retarded in the low load state, but is set to be advanced in the high load state. In the low load state, the injection timing of the third fuel injection valve 13 is retarded to thereby cause the low octane fuel, which is used as the initial ignition fuel, to stay in the area of the high octane fuel in the central area of the combustion chamber 1 . Thereby, ignition is started with the high octane fuel on the central area of the combustion chamber 1 , and combustion is executed. In the high load state, the injection timing of the third fuel injection valve 13 is advanced to thereby cause the low octane fuel, which is used as the initial ignition fuel, to reach the area of the low octane fuel in the peripheral area of the combustion chamber 1 . Thereby, ignition is started with the low octane fuel on the peripheral area of the combustion chamber 1 , and combustion is fully executed. According to the second embodiment, among the fuels having different octane number to be supplied into the combustion chamber 1 , the fuel having a high octane number is distributed to the central area of the combustion chamber 1 , and the fuel having a low octane number is distributed to the peripheral area of the combustion chamber 1 . The fuels are supplied in the manner described above into the combustion chamber 1 , thereby, combustion is executed by starting combustion with the high octane fuel in the low load state, and with the low octane fuel in the high load state. Thereby, effects and advantages can be obtained as described below. In the low load state, combustion is started from the central area of the combustion chamber 1 with the high octane fuel. In the event that the combustion air-to-fuel ratio is close to the theoretical or stoichiometric air-to-fuel ratio in the low load state, when combustion is started from the peripheral area, there is a concern that the heat loss is increased. So, preferably, combustion is started from the central area of the combustion chamber 1 , and self-ignition combustion is performed in the peripheral area of the combustion chamber 1 , sequentially. In contrast, combustion is started from the peripheral area of the combustion chamber 1 with the low octane fuel. In the event that a large or sufficient amount of the high octane fuel cannot be supplied in the high load state, when ignition is started in the state wherein the low octane fuel is disposed on the central area of the combustion chamber 1 , it is contemplated that knocking occurs in association with self-ignition of the low octane fuel before combustion of the low octane fuel is completed and combustion of the high octane fuel is initiated. In such an event, the low octane fuel is preferably combusted at an early timing from many ignition points to thereby prevent such self-ignition. In order to effectively reduce the flame propagation distance, it is advantageous that the low octane fuel is disposed on the peripheral area and combustion is started from the peripheral area. Accordingly, the manner described above is advantageous when a large or sufficient amount of the high octane fuel cannot be supplied and when the combustion air-to-fuel ratio is set to the near-theoretical or stoichiometric air-to-fuel ratio while controlling the engine load to be reduced by use of, for example, a throttling or variable valve mechanism. A modified example of the second embodiment will be described below. As described above, in the second embodiment, the ignition start portion is variable in the manner that the injection timing of the third fuel injection valve 13 for supplying the initial ignition fuel is regulated, and the distribution position of the initial ignition fuel is thereby differentiated. In a configuration including a variable compression ratio setting mechanism capable varying the compression ratio of the engine, the distribution position of the initial ignition fuel can be differentiated in a manner that the compression ratio is regulated by the variable compression ratio setting mechanism to thereby regulate an in-combustion chamber atmospheric pressure in the event of fuel injection of the third fuel injection valve 13 for supplying the initial ignition fuel. This manner is adaptable because the dispersion of the fuel injected from the third fuel injection valve 13 varies with the in-cylinder pressure in the event of fuel injection. For the variable compression ratio setting mechanism, the mechanism such as disclosed in U.S. Pat. No. 6,505,582, for example, may be used. More specifically, in the low load state, with the compression ratio being increased, the low octane fuel, which is injected from the third fuel injection valve 13 and is used as the initial ignition, is led to stay in the area of the high octane fuel in the central area of the combustion chamber 1 . Then, ignition is started with the high octane fuel in the central area of the combustion chamber 1 , and combustion is fully executed. In the high load state, with the compression ratio being reduced, the low octane fuel, which is injected from the third fuel injection valve 13 and is used as the initial ignition fuel, is led to reach into the area of the low octane fuel on the peripheral area of the combustion chamber 1 . Then, ignition is started with the low octane fuel on the peripheral area of the combustion chamber 1 , and combustion is fully executed. The increase in the compression ratio in the low load state leads to an improvement in output power, the reduction in the compression ratio in the high load state leads to knocking suppression. Accordingly, from this viewpoint as well, the manner of ignition and combustion is effective. Thus, since the distribution of the low octane fuel, which is used as the initial ignition fuel, is controlled to be varied, the compression ratio control (output power/knocking control) corresponding to the engine load and the ignition position control can be synchronously performed, and excellent combustion can be executed in many operating conditions. FIG. 8 is a configuration diagram showing an internal combustion engine according to a third embodiment of the present invention. The same numerals designate portions of configurations common to those of the internal combustion engine in the first embodiment. The third embodiment includes, as ignition trigger devices, a spark plug 16 in place of the third fuel injection valve 13 and a pair of spark plugs 17 . More specifically, the spark plug 16 is provided in the central area of the combustion chamber 1 , and the pair of spark plugs 17 are provided in peripheral areas of the combustion chamber 1 . The spark plugs 16 and 17 are selectively used corresponding to engine operation conditions. The first fuel injection valve 11 supplying the high octane fuel is directed towards the central area in the combustion chamber 1 via the intake valve 3 . The second fuel injection valve 12 supplying the low octane fuel is directed from the lower surface of the cylinder head in the center of the combustion chamber 1 towards the peripheral area in the combustion chamber 1 . Other configurations are substantially the same as those of the first embodiment. The gaseous mixture is formed in the third embodiment in a manner described below. Similarly as in the second embodiment, the high octane fuel is distributed to the central area of the combustion chamber 1 , and the low octane fuel is distributed to the peripheral area of the combustion chamber 1 , as shown in FIG. 9 . First, during a relatively late timing of the intake stroke, the high octane fuel is injected from the first fuel injection valve 11 , which is mounted to be in fluid communication with the intake port 5 . The fuel from the first fuel injection valve 11 is injected towards the central area of the combustion chamber 1 via the intake valve 3 and flows into the combustion chamber 1 . When, similarly as in the first embodiment, a swirl stream has been generated in the combustion chamber 1 , since a large amount of the fuel is not mixed along the peripheral area of the cylinder, the fuel stays on the central area of the combustion chamber 1 . In the latter half of the compression stroke, the low octane fuel is injected from the second fuel injection valve 12 towards the peripheral area of the combustion chamber 1 so that the low octane fuel is distributed to the peripheral area of the combustion chamber 1 . In the manner described above, the fuel distributions different in octane number can be generated. That is, the high octane fuel is distributed to the central area of the combustion chamber 1 , and the low octane fuel is distributed to the peripheral area of the combustion chamber 1 . Ignition (combustion) in the third embodiment is performed in a manner described below and in FIG. 10 . In the gaseous mixture distribution described above, in the low load state, the spark plug 16 on the central area of the combustion chamber 1 is used to initialize ignition of the high octane fuel in the central area of the combustion chamber 1 , and the fuel is combusted. In contrast, in the high load state, the two spark plugs 17 on the peripheral area of the combustion chamber 1 are used to initialize ignition of the low octane fuel in the peripheral area of the combustion chamber 1 , and combustion is executed. According to the third embodiment, the plurality of spark plugs 16 and 17 , respectively provided corresponding to the ignition start areas, are used as an ignition trigger device and are selectively operated corresponding to the engine operation conditions. Thereby, operations, such as the ignition timing and position, can be securely controlled without being influenced by the operation states. FIG. 11 is a diagram showing an internal combustion engine according to a fourth embodiment of the present invention. The same numerals designate portions of configurations common to those of the internal combustion engine in the first embodiment. The fourth embodiment includes a torch-type ignition that works as an ignition trigger device. The torch-type ignition includes an auxiliary chamber 22 provided in bi-directional communication with the combustion chamber 1 through an opening 21 , and a spark plug 23 for igniting fuel filled in the auxiliary chamber 22 , in place of the third fuel injection valve 13 and the spark plugs 16 and 17 . The torch-type ignition provides a flame dispersively through the opening 21 . The gaseous mixture is formed in the combustion chamber 1 in one of the following two manners. In one manner, similarly as in the first embodiment, the high octane fuel is distributed to the peripheral area of the combustion chamber 1 and the low octane fuel is distributed to the central area of the combustion chamber 1 . In the other manner, as in the second and third embodiments, the high octane fuel is distributed to the central area of the combustion chamber 1 and the low octane fuel is distributed to the peripheral area of the combustion chamber 1 . For fuel supply into the auxiliary chamber 22 , the fuel in the combustion chamber 1 may be compressed during the compression stroke and directed into the auxiliary chamber 22 . Alternatively, a fuel injection valve may be provided to directly supply the fuel into the auxiliary chamber 22 . For starting ignition in the combustion chamber 1 , the flame exiting from the auxiliary chamber 22 including the spark plug 23 is used. A propagation force of the flame is controllable in accordance with an ignition position in the auxiliary chamber 22 and the concentration of the gaseous mixture in the auxiliary chamber 22 . For example, when the ignition position in the auxiliary chamber 22 is moved close to the opening 21 , the flame exits before the pressure in the auxiliary chamber 22 sufficiently increases, and the propagation force is reduced. Alternatively, when ignition is performed at an upper portion of the auxiliary chamber 22 , the pressure in the auxiliary chamber 22 sufficiently increases before the flame exits the opening 21 . Consequently, the propagation force of the torch-shaped flame is increased. FIG. 12 shows a practical example of how the ignition position of the spark plug 23 is changed. More specifically, two lateral electrodes 25 a and 25 b are provided in different positions on a single central electrode 24 protruding from a leading edge of the spark plug 23 . In this case, when ignition is executed on the side of the leading edge of the central electrode 24 by use of the one lateral electrode 25 a , the propagation force of the flame can be reduced. However, when ignition is executed on the side of the base end of the central electrode 24 by use of the other lateral electrode 25 b , the propagation force of the flame can be increased. In the case where the concentration of the gaseous mixture has been changed, the energy of combustion is proportionally higher as the concentration of the gaseous mixture is increased, and also the flame propagation force of the flame is increased. Accordingly, the flame propagation force can be reduced by reducing the concentration of the gaseous mixture, so that control of the position for starting ignition can be controlled. As described above, according to the present embodiment, similarly as in the first embodiment, when the high octane fuel has been distributed to the peripheral area of the combustion chamber 1 , and the low octane fuel has been distributed to the central area of the combustion chamber 1 , the propagation force of the flame is increased in the low load state, and ignition is started with the high octane fuel on the peripheral area of the combustion chamber 1 . On the other hand, in the high load state, the propagation force of the flame is reduced, and ignition is started with the low octane fuel on the central area of the combustion chamber 1 . In contrast, similarly as in the second and third embodiments, when the high octane fuel has been distributed to the central area of the combustion chamber 1 , and the low octane fuel has been distributed to the peripheral area of the combustion chamber 1 , the propagation force of the torch-shaped flame is reduced in the low load state, and ignition is started with the high octane fuel on the central area of the combustion chamber 1 . On the other hand, in the high load state, the propagation force of the flame is increased, and ignition is started with the low octane fuel on the peripheral area of the combustion chamber 1 . According to the fourth embodiment, the torch-type ignition is used as the ignition trigger device. The torch-type ignition includes the auxiliary chamber 22 provided in fluid communication with the combustion chamber 1 through the opening 21 , and the spark plug 23 for igniting fuel in the auxiliary chamber 22 . The torch-type ignition expels out a flame dispersively from the opening 21 . With the torch-type ignition being used, the propagation force of the flame is regulated to thereby control the position for starting ignition. Consequently, a lean combustion limit can be significantly increased, so that the thermal efficiency of partial load combustion can be improved, and rapid combustion of the low octane fuel under high load can be implemented. The gaseous mixture forming methods and ignition methods in the first to fourth embodiments can be carried out in combination. A control example for a combination will be described below with reference to flow diagrams shown in FIGS. 13 and 14 . The control example shown in the flow diagram of FIG. 13 is a case in which, as in the first embodiment, processing is performed in the manner that, at step S 11 , the gaseous mixture of the high octane fuel is formed in the peripheral area of the combustion chamber 1 and the gaseous mixture of the low octane fuel is formed in the central area of the combustion chamber 1 . In this case, the processing proceeds to either step S 13 or step S 14 in accordance with a determination of whether the load state is a low load or high load state. In the low load state, the processing proceeds to step S 13 , and the high octane fuel is ignited on the peripheral area of the combustion chamber 1 in accordance with any one of processes (1) to (3) described below. (1) Process using an advanced injection timing or IT: Similarly as in the first and second embodiments, the third fuel injection valve 13 for supplying the initial ignition fuel is used, and the IT is advanced, thereby to execute ignition on the peripheral area of the combustion chamber 1 . (2) Process using the outer spark plugs: Similarly as in the third embodiment, the outer spark plugs 17 are used, and ignition is executed on the peripheral area of the combustion chamber 1 . (3) Process with the increased propagation force of the flame: Similarly as in the fourth embodiment, the flame generated by the auxiliary chamber 22 and the spark plug 23 are used, and the flame propagation force is increased, thereby to execute ignition on the peripheral area of the combustion chamber 1 . In the high load state, the processing proceeds to S 14 , and the low octane fuel is ignited on the central area of the combustion chamber 1 in accordance with any one of processes (1) to (3) described below. (1) Process using a retarded IT: Similarly as in the first and second embodiments, the third fuel injection valve 13 for supplying the initial ignition fuel is used, and the IT is retarded, thereby to execute ignition on the central area of the combustion chamber 1 . (2) Process using the inner spark plug: Similarly as in the third embodiment, the inner spark plug 16 is used, and ignition is executed on the central area of the combustion chamber 1 . (3) Process with the reduced propagation force of the flame: Similarly as in the fourth embodiment, the flame generated by the auxiliary chamber 22 and the spark plug 23 are used, and the flame propagation force is reduced, thereby to execute ignition on the central area of the combustion chamber 1 . The reach position of the initial ignition fuel can be controlled in the manner that the third fuel injection valve 13 for supplying the initial ignition fuel is used in combination with the variable compression ratio setting mechanism. In this case, however, since the compression ratio is reduced in the low load state and is increased in the high load state, the manner is not realistic from the viewpoint of knocking suppression. The control example shown in the flow diagram of FIG. 14 is a case in which, as in the second and third embodiments, processing is performed in the manner that, at step S 21 , the gaseous mixture of the high octane fuel is formed in the central area of the combustion chamber 1 , and the gaseous mixture of the low octane fuel is formed in the peripheral area of the combustion chamber 1 . In this case, the processing proceeds to either step S 23 or step S 24 in accordance with a determination of whether the load state is a low load or high load state. In the low load state, the processing proceeds to step S 23 , and the high octane fuel is ignited on the central area of the combustion chamber 1 in accordance with any one of processes (1) to (4) described below. (1) Process using a retarded IT: Similarly as in the first and second embodiments, the third fuel injection valve 13 for supplying the initial ignition fuel is used, and the IT is retarded, thereby to execute ignition on the central area of the combustion chamber 1 . (2) Process with the reduced compression ratio of the shotgun: Similarly as in the first and second embodiments, the third fuel injection valve 13 for supplying the initial ignition fuel is used, and the variable compression ratio setting mechanism are used to increase the compression ratio thereof, thereby to execute ignition on the central area of the combustion chamber 1 . (3) Process using the inner spark plug: Similarly as in the third embodiment, the inner spark plug 16 is used, and ignition is executed on the central area of the combustion chamber 1 . (4) Process with the reduced propagation force of the flame: Similarly as in the fourth embodiment, the flame generated by the auxiliary chamber 22 and the spark plug 23 are used, and the flame propagation force is reduced, thereby to execute ignition in the central area of the combustion chamber 1 . In the high load state, the processing proceeds to S 24 , and the low octane fuel is ignited on the peripheral area of the combustion chamber 1 in accordance with any one of processes (1) to (4) described hereinbelow. (1) Process using an advance IT: Similarly as in the first and second embodiments, the third fuel injection valve 13 for supplying the initial ignition fuel is used, and the IT is advanced, thereby to execute ignition on the peripheral area of the combustion chamber 1 . (2) Process with the increased compression ratio of the shotgun: Similarly as in the first and second embodiments, the third fuel injection valve 13 for supplying the initial ignition fuel is used, and the variable compression ratio setting mechanism is used to reduce the compression ratio thereof, thereby to execute ignition on the peripheral area of the combustion chamber 1 . (3) Process using the outer spark plugs: Similarly as in the third embodiment, the outer spark plugs 17 are used, and ignition is executed on the peripheral area of the combustion chamber 1 . (4) Process with the increased propagation force of the torch-shaped flame: Similarly as in the fourth embodiment, the flame generated by the auxiliary chamber 22 and the spark plug 23 are used, and the flame propagation force is increased, thereby to execute ignition on the peripheral area of the combustion chamber 1 . The gaseous mixture distribution control is inclusive of the following. The low and high octane fuels are not required to be distributed to the central and peripheral areas of the combustion chamber 1 , in stratified patterns formed in the concentric radial direction. For example, as shown in FIG. 15A , the pattern may be a first dimensional pattern or disposition, such as in an engine intake-exhaust direction or front-rear direction. In addition, as shown in FIGS. 15B and 15C , the respective gaseous mixture concentration distributions include uniform and non-uniform distributions. Further, the control of the distributions of the low and high octane fuels to the central and peripheral areas of the combustion chamber 1 corresponding to the operation conditions does not deny or exclude the case of operation in a so-called “uniform mixture state” in which the low octane fuel and the high octane fuel are mixed together in a low load region, high load region, or intermediate region. In other words, the present invention can be adapted to engines of the type in which a plurality of fuels different in octane number are supplied to a combustion chamber under at least a part of operation conditions, and combustion is executed by distributing the fuels into different portions of the combustion chamber. While the invention has been disclosed with reference to certain preferred embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the invention, as defined in the appended claims and equivalents thereof. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims.
In an embodiment, the invention provides an internal combustion engine, including a first fuel injector that supplies a first fuel to a first predetermined region in a combustion chamber, and a second fuel injector that supplies a second fuel to a second predetermined region in the combustion chamber. The second fuel has an octane number that is different than an octane number of the first fuel, and the second predetermined region is different from the first predetermined region. An ignition device is configured to start ignition of one of the first and second fuels based on an ignition signal. An operation condition detector detects at least one engine operating condition. A controller is configured to provide the ignition signal to the ignition device and to determine which one of the first and second fuels to ignite by the ignition device based on the engine operation condition.
5
FIELD OF THE INVENTION [0001] The invention relates to a method and system for testing, particularly but not exclusively for software testing. BACKGROUND ART [0002] The test phase of a software product, one of the fundamental steps in the production of the document, is often referred to as a “test design” which describes a set of test scenarios needed to certify the quality of the software being tested. During this activity, the test designer must create appropriate test scenarios based on a use case model created by a development team. Use cases artifacts needed to communicate with the customer, developer, technical writer and/or tester are in accordance with a rational unified process (RUP). A use case typically describes how a software product under development may interact with a person or other system to satisfy the specific requirement. The design work needed to be created by the tester defines test scenarios starting from a use case and following a well-defined procedure is called a use case base test (UCBT). [0003] Once the list of scenarios has been created by the tester, the tester will classify them using an orthogonal defect classification (ODC) trigger. The tester must then prioritize and assign an execution cost to each scenario. This is carried out manually and is time-consuming, error prone and has a high maintenance cost. [0004] There have been a number of solutions proposed to solve the first part of the above identified problem, namely the generation of test scenarios. But the solutions do not solve other problems or address the methodology of classification of scenarios and simple execution cost analysis. [0005] US2005/0144529A1 discloses a method for deriving software tests from use cases which are represented in an activity diagram. The test case scenarios are derived by applying coverage metrics on the activity diagram so that the activities can be matched with an appropriate test. A test idea document is then generated along with system test scenarios which are created by concatenating the test case scenarios with a system walk-through. The system test scenarios are then augmented if possible and used to vary the test case scenarios result before a final test design document is produced. This solution still suffers from many of the disadvantages identified above. SUMMARY OF THE INVENTION [0006] The present invention is directed to a method, computer program product and system as defined in the independent claims. [0007] More particularly, the present invention discloses a method of evaluating a cost associated with a test scenario, which test scenario comprises one or more branches making up a use case, the method comprising the steps of: determining a first parameter based on the complexity of the use case; determining a second parameter which indicates the criticality of the use case; determining a third parameter which indicates an execution cost of each action and decision point of the use case; determining a fourth parameter which indicates the priority of each branch of the use case; determining a fifth parameter which indicates the classification of each test parameter for each branch of the use case; determining a cost associated with the test scenario, based on a predetermined calculation using two or more of the first, second, third, fourth and fifth parameters. [0008] The present invention further discloses apparatus for evaluating a cost, associated with a test scenario, which test scenario comprises one or more branches making up a use case, the apparatus comprising: a first module for determining a first parameter based on the complexity of the use case; a second module for determining a second parameter which indicates the criticality of the use case; a third module for determining a third parameter which indicates an execution cost of each action and decision point of the use case; a fourth module for determining a fourth parameter which indicates the priority of each branch of the use case; a fifth module for determining a fifth parameter which indicates the classification of each test parameter for each branch of the use case; a cost determination module for determining a cost associated with the test scenario, based on a predetermined calculation using two or more of the first, second, third, fourth and fifth parameters. [0009] Other aspects of the invention can be seen in the appended dependent claims. BRIEF DESCRIPTION OF THE DRAWINGS [0010] Reference will now be made by way of example to the accompanying drawings, in which: — [0011] FIG. 1 is a diagram showing an overview of the system for testing, in accordance with an embodiment of the invention, by way of example. [0012] FIG. 2 is a flowchart of the method steps, in accordance with an embodiment of the invention, by way of example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0013] In order to classify the test scenarios, the following summary of definitions of the classification will be employed herein. The ODC triggers are defined as the following: coverage, variation, sequencing, interaction, backward compatibility and rare. Each of these triggers has a guideline defined for an ODC scenario classification. These guidelines are as follows; [0014] A simple basic flow is defined as coverage (C). [0015] A simple alternative flow is defined as variation (V). [0016] A complex flow where the final expected result depends on the previous results is defined as sequencing (S). In this situation, it is not possible to reach the final expected result without success of a previous result. [0017] A complex flow where there is an interaction between different functions or difference instances of the same function is defined as interaction (I) [0018] A flow that deals with backward compatibility issues is defined as backward compatibility (B). [0019] flow that is an alternative and that can only be achieved in rare and unusual conditions is defined as rare (R). [0020] By referring initially to FIG. 1 , a system overview diagram is shown. An activity diagram 100 is used to define the behavior of a use case 102 which has been built in accordance with a predefined naming convention (NC) 104 . This is indicated by Arrow A. The same naming convention is also used in a test best practice knowledge base (TBPKB) 106 to define a set of decision point actions. The decision point actions will define the cost for the execution of the action and the ODC classification attribute that is dependent on each alternative test pattern for the specific action (happy paths, error condition, variation and/or boundary condition). An example is an INSTALL_LOCATION decision point to test an installation use case. The test pattern available for this decision point includes path missing (e.g., wrong path), valid (e.g., existing path) and with special characters (e.g., with spaces). When an installation of a product is tested, it is necessary to test different values in the field “INSTALLATION_LOCATION” to be sure that the installation works well. To do this, different tests (variation) of the same installation are carried out thereby changing the “INSTALLATION_LOCATION” field using different test patterns such as missing path, valid path and path with special characters such as spaces. This step is indicated by arrow B. [0021] The activity diagram is then used as an input to a test generator engine (TGE) 108 as illustrated by arrow C. The test generator engine can form part of a workbench 110 in the form of a plug-in, or can be a stand-alone process. Data from the test best practice knowledge base is also input into the test generator engine as is shown by arrow D. The test generator engine uses the information from the TBPKB to produce a set of test data which includes cost, ODC classification, test pattern and so on. The test data may then be added to the activity diagram as notes as indicated by arrow E. Any user can optionally validate the test data (see arrow F), for example in an enhanced activity diagram, which is enriched with test information. In an alternative embodiment, the test data may be manually added into the activity diagram by a user. [0022] The test generator engine 108 then uses the new tagged activity diagram to generate a test design document 112 , as illustrated by arrow G. The test design document includes a test case matrix and test case procedure. As indicated by arrow H, the test generator engine may select a test script from the test script template knowledge base, 114 . The script template may be matched with the test pattern defined as indicated by arrow B above. The script template is started and actual data extracted from the TBPKB inserted in order to generate test scripts for test execution. An example could be a script template based on the ISMP response file used to test an installation use case. In general, the template is filled with actual data extracted from the TBPKB. [0023] The system thus enables a tester to be supported in the complex analysis of use case diagrams including the ability to classify with ODC trigger, priority and execution cost the tests in scenarios generated by the UCBT procedure. In addition, an estimate of test effort is also dynamically generated. [0024] The method in accordance with the present invention is composed of two main phases. These main phases are the data insertion phase and the test generation phase, each will be described in detail below. [0025] The data insertion phase will be described with reference to FIG. 2 . Initially the use case description is analyzed as shown in step 200 in order to add test data to an activity diagram as shown in step 202 . The use case description may be derived from a UML activity diagram. The test data must be applied to each branch or event of the activity diagram in order to generate a set of test scenarios. This is then the input value used in carrying out the use case flows. In accordance with the present invention, it is also required that the activity diagram be supplemented with information needed to support the classification of the generated scenarios (for example, ODC trigger, priority and execution costs). In order for this to be carried out, the following processes takes place. [0026] At step 204 , a parameter (CX) is generated which gives an indication of the complexity of the whole use case. For example, if there is some type of interaction with complex middleware or other equipment then this may imply that the use case is complex. [0027] At step 206 , a parameter (CR) is generated in order to describe if the whole use case is critical or not. For example, traffic control software would be critical and the parameter CR would have an high value. Similarly, other software may not be critical and as such this parameter would have a low value. [0028] At step 208 , a parameter (E) is generated to give an estimation of the execution cost. This execution cost must be applied to each actual action nodes and decision point in the activity diagram. [0029] At step 210 , a parameter (P) is used to estimate the priority of the use case. It is used in such a way that it is applied to each branch of the activity diagram. [0030] At step 212 , parameter (T) is used to estimate the ODC trigger classification. This is applied to each test data in each branch of the activity diagram. [0031] Finally, a determination of cost, priority and classification (e.g., ODC scenario classification) is made at step 216 as described in the second phase below: [0032] The apparatus of FIG. 1 includes modules associated with each step of the process as described in FIG. 2 , though they may not be called this with respect to FIG. 1 . [0033] The second phase of the method relates to test generation. In this part of the invention, the system applies the following method in order to combine the input parameters (CX, CR, E, P and T) so as to classify the generated scenarios (for example, ODC trigger, priority or execution cost). The system generates a scenarios matrix and for each scenario a set of parameters is determined. The set of parameters may include a step-by-step procedure, an ODC trigger, a priority and an execution cost. The above-mentioned parameter CX is used together with E to estimate the execution cost of the generated scenarios. In addition, the parameter CR is used together with P to estimate the priority of each generated scenario. Finally, parameter T is used to estimate the ODC trigger of each generated scenario. [0034] Execution cost is determined as follows: [0000] Execution Cost= CX *SUM( E for each step) [0035] Execution cost is determined by considering that a test scenario is a list of step to be executed including a number of action or decision points. The sum of all execution costs (E) in each step of the list of steps is then determined. A multiplication of this sum with the complexity (CX) of the use case is determined. Typically, the value of CX various between 0 and 2, for example a CX values of 1 is normal, 1.5 is high and 2 is very high. It should be noted that cost need not relate just to monetary cost, but can extend to the cost in another characteristic such as in respect of anything for example time, effort, processing, power, capacity, etc. or any combination of things. [0000] The priority can be calculated in a similar manner as defined below: [0000] Priority= CR *SUM( P for each branch) [0036] In this situation, a branch in a test scenario is considered as the path traversed after a decision point. The list of all priorities (P) in each branch carried out or crossed by the list of steps is determined. As above, the value of P can vary; where 1 is low, 2 is medium and 3 is high. A multiplication of the sum of P and critical value (CR) of the use case is determined. CR values are generally; 1 is normal, 1.5 is critical and 2 is very critical. [0037] The classification (ODC trigger) can be calculated as follows: [0000] ODC Trigger=( C if all T=C ) or ( V if exist T=V and not S,I,B,R ) or ( S if exist T=S and not I,B,R ) or ( I if exist T=I and not B,R ) or ( B if exist T=B and not R ) or ( R if exist T=R ) [0038] In this situation, a test data line is considered as an input data inserted in each branch in a test scenario. So for each test scenario, there is a list of input data (one test data line for each branch traversed by the steps). Then, for each scenario the list of input data is parsed to extract the ODC triggers T. The various scenarios are classified as follows: [0039] The scenario is classified as coverage if the T of the data inputs are all classified as C; [0040] The scenario is classified as variation if the T of the data inputs are classified as a mix of C and V (however, at least one V must be present); [0041] The scenario is classified as sequencing if the T of the data inputs are classified as a mix of C, V and S (where at least one S must be present); [0042] The scenario is classified as interaction if the T of the data inputs are classified as a mix of C, V, S and I (where at least one I must be present); [0043] The scenario is classified as backward compatibility if the T of the data inputs are classified as a mix of C, V, S, I and B (where at least one B must be present); and [0044] The scenario is classified as rare if the T of the data inputs are classified as a mix of C, V, S, I, B and R (where at least one R must be present). [0045] By adopting this method and system in the test phase, there are a number of benefits. For example, there is improved productivity in determining and writing test scenarios. There are improvements in the quality of the tests achieved and the maintainability of scenarios and tests. In addition, the estimation of execution costs for each scenario is associated with the complexity of the use case. The priority attributed to the scenarios depends on the critical values associated with the use case. Classification of scenarios which have ODC triggers are easily identified based on the different paths traversed. [0046] The system in accordance with the present invention is capable of parsing the activity diagram in order to determine the minimum number of independent paths. Subsequently, specific test data values belonging to that path can be retrieved and used as an input by testers. The system then applies the values to each independent path thereby generating test scenario matrices and the step-by-step procedures. [0047] The advantages provided by the present invention includes the ability to have a clearly defined and common approach for determining and estimation of execution costs of the scenario. This is achieved by assigning the costs of single actions and using these to form a more complex use case. Similarly prioritization of scenarios also depends on the critical value of the use case. This can also be been repeatable, by determining priorities for a smaller subsets rather than the whole. A number of advantages are achieved by classifying the ODC triggers dependent on paths and types of test values. The testers can more easily maintain the scenarios and less time is required to react to design changes, since this then only requires modification of test inputs and regeneration of test cases. The writing of the scenarios will also result in increased productivity since most of the tedious or time consuming elements are carried out by the present invention. The system and method also permits discovery of all paths of the activity diagram which will ensure an increased test coverage of the use case paths. [0048] In addition, the method and system provide the capability to generate a dynamic “ballpark” estimation of test effort directly from the use case without adding test data to the activity diagram. [0049] The “ballpark” estimates can be achieved as described below. In the first instance, the independent paths from the use case diagram are extracted. The system then assigns the mean cost (M) to each action in the list of steps carried out in a given scenario. This may be based on historic data (H) and the complexity (CX) of the scenario and may be assigned by a design team or otherwise specified. In other words: M=CX*H. [0050] The number of variation test cases (TC) into which each scenario can be split (with an acceptable test quality) can be determined from the critical value (CR) of the use case, either as assigned by a design team or otherwise. This can be expressed as TC=CR*3, the 3 is the “normal” test of one mean value and two boundary conditions. The test effort for the use case is estimated by considering the number of steps (N) of the independent path; the mean cost of each step (M); and the number of test cases (TC). Switched test effort can be expressed as follows: [0051] Test Effort=SUM(N*M*TC for each independent path) This ensures that a common definition of test effort estimation can be readily determined on a repeatable basis. The test effort estimation is available at a very early stage in the developmental cycle which can help with decision-making processes. If there are changes in the design in the test effort, the estimation can be quickly reevaluated. In addition, various different solutions can be evaluated to determine the optimum from the test effort point of view. [0052] It will be appreciated that examples other than those described above may exist, which fall within the scope of the present invention. For example, the steps may take place in different orders and by different modules.
A method of evaluating a cost associated with a test scenario, which test scenario comprises one or more branches making up a use case, the method comprising the steps of: determining a first parameter based on the complexity of the use case; determining a second parameter which indicates the criticality of the use case; determining a third parameter which indicates an execution cost of each action and decision point of the use case; determining a fourth parameter which indicates the priority of each branch of the use case; determining a fifth parameter which indicates the classification of each test parameter for each branch of the use case; determining a cost associated with the test scenario, based on a predetermined calculation using two or more of the first, second, third, fourth and fifth parameters.
6
FIELD OF THE INVENTION The present invention relates generally to a safety system for a firearm, and more particularly to a safety system for selectively disabling a firearm by use of a remote transmitter. BACKGROUND OF THE INVENTION A number of prior art devices have been disclosed which relate to safety systems for firearms. For example, in U.S. Pat. No. 4,003,152 (Barker et al) a safety system is described in which a firearm is normally disabled. The firearm is enabled only when a coded signal is transmitted by an authorized person. In U.S. Pat. No. 3,400,393 (Ash), a weapon safety system is disclosed in which an electromagnetic wave transceiver is mounted on a number of weapons. Each weapon is disabled if it is pointed at and detects identical electromagnetic waves transmitted by another weapon with the same transceiver. If no identical electromagnetic wave is received, the weapon is functional. A similar safety system is disclosed in U.S. Pat. No. 2,472,136 (Whitlock). A safety system in which a plurality of weapons can fire only when the weapon trigger is depressed and a specific command signal is received by the weapon is disclosed in U.S. Pat. No. 4,205,589 (Engler et al). SUMMARY OF THE INVENTION In accordance with the present invention, a safety system for selectively disabling a firearm which is fired by a mechanical movement is provided. The safety system includes a block which is moved between an engaged position whereby the mechanical firing movement is blocked and a disengaged position whereby the mechanical firing movement is not blocked. The block includes a bearing surface which engages a relatively immovable part of the firearm when the block is in the engaged position to positively prevent the mechanical firing movement from operating. A moving means is further provided for moving the block from the disengaged position to the engaged position. Normally, the moving means biases the block in the disengaged position. A remotely controlled actuating means is also provided for actuating the moving means. The actuating means includes a transmitter means which selectively transmits a signal and which is designed to be carried by the operator of the firearm. A receiving means is located adjacent the moving means in the firearm for receiving the signal from the transmitter means and for operating the moving means. In one preferred embodiment of the present invention, the mechanical movement includes a member which moves parallel to a metal surface. The block is then an elongate bar which is extendable through an aperture in the metal surface to prevent the member from moving along the metal surface. Conveniently, the member is the hammer of the firearm and the bar extends perpendicular to the metal surface. In another preferred embodiment of the present invention, the block is a lever which is pivoted intermediate two opposed ends. When the lever is in the engaged position, one end engages the mechanical firing movement while the other end is the bearing surface which engages a relatively immovable part of the firearm. Conveniently, the one end of the lever engages a hammer of the firearm or the rebound slide member. In still another embodiment of the present invention, the mechanical movement includes a reciprocating member and the block is a stop which is movable into the path of the reciprocating member. In the preferred embodiments of the present invention, the moving means for the block is a solenoid which is remotely actuated by a transmitter. Preferably, the transmitter is designed to be easily activated by a push button. If desired, the transmitter is additionally provided with a plurality of push buttons which must be pushed in a predetermined sequence to turn off the transmitter after the transmitter has been activated. It is an object of the present invention to provide a safety system for disabling a firearm when desired. The safety system is normally biased to the disengaged position so that only a positive actuation of the transmittor results in the firearm being disabled. It is another object of the present invention to provide a safety system in which any malfunction in the transmitter, receiver, or moving means for the block still allows the weapon to operate in the normal manner and not be disabled. It is a feature of the present invention that the safety system requires only a very low energy consumption, especially when the safety system is not activated. Other objects, features, and advantages of the present invention are stated in or apparent from a detailed description of presently preferred embodiments of the invention found hereinbelow. BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1a and 1b are side elevation views in partial cross section of a first embodiment of a safety system according to the present invention depicting the handle portion of a firearm with the safety system deactivated and activated, respectively. FIGS. 2a and 2b are side elevation views of a portion of a firearm including the rebound slide member of the mechanical firing movement and a block for the rebound slide depicted in the disengaged and engaged position, respectively. FIG. 3 is a side elevation view in partial cross section of a firearm containing two additional alternative embodiments of a safety system according to the present invention. FIG. 4 is a schematic diagram of the transmitter and receiver units used with the safety system of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS With reference now to the drawings in which like numerals represent like element throughout the several views, a first preferred embodiment of a safety system 10 is depicted in FIGS. 1a and 1b. Safety system 10 is incorporated in a revolver 12 of which only the handle portion 14 is depicted. As shown, revolver 12 includes a hammer 16 which is used to fire revolver 12. Handle portion 14 includes a hollow space 18 beneath the cover plate (not shown) normally provided on handle portion 14. It should be appreciated that the area of handle portion 14 which is shown in cross section is the metal frame 20 of the revolver. Located in hollow space 18 is a block 22, a moving means 24, and part of a remotely controlled actuating means 26. In this embodiment, block 22 is in the form of a lever 28 which has a blocking end 30 and a bearing end 32. As shown, lever 28 is pivoted intermediate the two ends 30 and 32 about a pivot pin 34. Lever 28 is conveniently attached to frame 20 by means of screws 36 in a base 38. Moving means 24 includes a solenoid 40 which is attached to frame 20. Solenoid 40 includes a movable arm 42 which is pivotably attached to lever 28. A spring 44 normally biases arm 42 outwardly of solenoid 40 so that lever 28 is normally located in the position depicted in FIG. 1 until solenoid 40 is energized. The portion of actuating means 26 located in hollow space 18 is receiver 46. Receiver 46 includes a receiving module 48, a decoder 50, and a battery 52. Battery 52 powers receiving module 48 and decoder 50 and also provides actuating power for solenoid 40. Receiver 46 is also depicted schematically in FIG. 4. Preferably, receiving module 48 also includes an antenna 54. Actuating means 26 also includes a transmitter 56 which is schematically depicted in FIG. 4. Transmitter 56 is designed to be carried by the operator of the revolver 12 and to include a simple push button 57 to actuate switch 59 of transmitter 56. As shown in FIG. 4, transmitter 56 includes an oscillator 58, a modulator 60 and an encoder 62. With these components, transmitter 56 transmits a suitable encoded signal upon activation which is suitably received by receiver 46 and decoded to actuate solenoid 40. If desired, switch 59 is also provided with a plurality of push buttons 61a, 61b and 61c which constitute a keyed lock means. Push buttons 61a, 61b and 61c are suitably connected to a switching circuit so that transmitter 56 cannot be deactivated after an initial actuation by push button 57 until push buttons 61a, 61b and 61c are sequentially pressed or keyed in a predetermined sequence. A push button unlocking a circuit of this type is well known in the art and a circuit of this type is disclosed in U.S. Pat. No. 3,831,065 (Martin et al). In operation, safety system 10 in revolver 12 functions in the following manner. Initially, safety system 10 is in a position depicted in FIG. 1a. In this position, hammer 16 is free to move in the normal manner and fire revolver 12. Receiver 46 is also energized by battery 52 so that receiving module 48 is capable of receiving a signal from transmitter 56 at all times. It should be appreciated that the energy required to maintain receiving module 48 in the "ready" condition is relatively small and that a rechargeable battery would be a suitable power source. Preferably, the weapon would be provided with a suitable circuit and plug-in charging device so that the battery could be easily and regularly recharged by simply plugging the weapon in the charging device. When it is desired to activate safety system 10, as for example when revolver 12 belongs to a police officer and an unauthorized user has gained control of revolver 12, the police officer merely presses the push button on transmitter 56. Preferably, transmitter 56 is carried by the police officer in such a position as to be easily actuated by the police officer. As soon as transmitter 56 is actuated, an encoded signal is sent by transmitter 56 to receiver 46 and decoded by decoder 50. A signal from decoder 50 is then sent to solenoid amplifier 64 which in turn energizes solenoid 40. As soon as solenoid 40 is energized, arm 42 is withdrawn into solenoid 40 against the force of spring 44. This causes lever 28 to pivot about pivot pin 34 until bearing surface 32 bears directly against base 38 and frame 20. At the same time, blocking end 30 pivots into a position to intercept the lower end of hammer 16 and thereby prevent hammer 16 from cocking and firing revolver 12. It should be appreciated that the force applied to blocking end 30 is transmitted through lever 28 to bearing end 32 so that the force is exerted directly against frame 20 which represents a relatively immovable portion of revolver 12. Therefore, it is very unlikely that lever 28 can be forceably broken to allow revolver 12 to fire. As long as transmitter 56 is activated, lever 28 remains in the blocking position depicted in FIG. 1b. Moreover, as soon as the police officer retrieves his revolver 12, transmitter 56 is immediately deactivated by the officer (if desired) by pushing buttons 61a, 61b and 61c in the necessary sequence to allow revolver 12 to again operate. When transmitter 56 is turned off, lever 28 immediately pivots back to the position depicted in FIG. 1a due to the force exerted by spring 44 against arm 42. At this time, safety system 10 is again capable of being actuated as soon as desired. If safety system 10 is actuated for a long period of time, battery 52 should be recharged or replaced as appropriate. It should be appreciated that safety system 10 is designed to be retrofitted to existing revolvers 12. In addition, it should also be appreciated that the elements of safety system 10 must be designed to fit in hollow space 18 of revolver 12 and to intercept hammer 16 appropriately. Depicted in FIGS. 2a and 2b is an alternative embodiment of a block 70 according to the present invention. Block 70 is designed to prevent the operation of rebound slide member 72 as rebound slide member 72 moves along surface 74 of frame 76 during the cocking action of the hammer. Block 70 includes a wedge-shaped member 78 which is pivotally attached about a pivot pin 80. Wedge-shaped member 78 is moved into and out of an engaged position with rebound slide member 72 by a moving means 82. Moving means 82 includes a solenoid 84 and an arm 86 which is attached to wedge-shaped member 78 as shown. As with solenoid 40, solenoid 84 is biased so that arm 86 is normally maintained in a position where wedge-shaped member 78 does not engage rebound slide member 72. This position is shown in FIG. 2a. In this embodiment, arm 86 is normally maintained in the withdrawn position relative to solenoid 84. In operation, block 70 functions in the following manner. Initially, wedge-shaped member 78 is maintained in the position depicted in FIG. 2a whereby rebound slide member 72 is free to move parallel to surface 74 as depicted in the dotted lines so that the hammer of the revolver is free to be cocked. When moving means 82 is actuated by an actuating means such as actuating means 26 described above, arm 86 is drawn into solenoid 84 when solenoid 84 is energized. When this occurs, wedge-shaped member 78 pivots about pivot pin 80 so that tip 88 of wedge-shaped member 78 blocks the path of rebound slide member 72. It should also be noted that bearing surface 90 of wedge-shaped member 78 rests against a portion of frame 76 so that any force exerted against tip 88 by rebound slide member 72 is resisted by frame 76 as depicted in FIG. 2b. Depicted in FIG. 3 is a third embodiment of a safety system in accordance with the present invention which includes a block 100. Block 100 is used to prevent the operation of a rebound slide member 102. In this embodiment, block 100 is a stop 104 which is movable into and out of an engaged position by solenoid 106. Stop 104 is directly attached to arm 108 extending from solenoid 106. Solenoid 106 is attached to frame 110 by a bracket 112 which includes a stop surface 114. Stop 104 includes a bearing end 116 and a blocking end 118. In operation, block 100 functions in the following manner. Initially, arm 108 is positioned in solenoid 106 so that stop 104 does not interfere with the sliding operation of rebound slide member 102. However, when solenoid 106 is energized in a suitable manner such as activating means 26 described above, arm 108 is withdrawn from solenoid 106 causing stop 104 to be positioned between rebound slide member 102 and stop surface 114 of bracket 112. This is the position depicted in FIG. 3. When this occurs, rebound slide member 102 contacts blocking end 118 of stop 104 when rebound slide member 102 attempts to move in the cocking of the hammer of the revolver. When rebound slide member 102 contacts blocking end 118, bearing end 116 bears against stop surface 114 of bracket 112 preventing any further movement of rebound slide member 102. As with the other embodiments, the force exerted by rebound slide member 102 is ultimately exerted against frame 110 which is sufficient to resist any such force. Also depicted in FIG. 3 is a fourth embodiment of the present invention including a block 120 and a solenoid 122. In this embodiment, block 120 forms a part of arm 124 which extends out of solenoid 122. In this embodiment, block 120 is designed to prevent hammer 126 from cocking. This embodiment of the present invention is designed to be incorporated in revolver during manufacture thereof. Thus, solenoid 122 is located in a cavity 128 provided in frame 110. In addition, arm 124 extends through an aperture 130 provided in frame 110. Thus, block 120 includes a blocking surface 132 which engages hammer 126 and a bearing surface 134 located in aperture 130 which engages frame 110. In operation, block 120 functions in the following manner which is similar to the operation of the previously described blocks. Thus, solenoid 122 is normally in the unenergized state whereby arm 124 and hence block 120 is positioned fully inside of solenoid 122. In this position, hammer 126 is free to cock and move past aperture 130. When a suitable transmitter is activated and a suitable receiver detects a signal and energizes solenoid 122, arm 124 is pushed out of solenoid 122 through aperture 130. This causes block 120, which is part of arm 124, to move beyond aperture 130 into the path normally traversed by hammer 126 in cocking. Thus, if hammer 126 is moved in a cocking motion, the end of hammer 126 adjacent block 120 contacts blocking surface 132. When this occurs, bearing surface 134 presses against frame 110 positively preventing hammer 126 from cocking. It should be appreciated that the force exerted by hammer 126 in attempting to cock hammer 126 is resisted by frame 110 as bearing surface 134 engages that portion of frame 110 around aperture 130. It should be appreciated that the safety systems described above are all designed to allow the weapon to operate should any component of the safety system fail. In addition, an easily concealed transmitter is provided whereby the user need be the only one to know that a safety system is installed in the associated weapon. Thus, if the user should inadvertently lose his weapon, the unauthorized person who retrieves the weapon would not immediately realize that the weapon was not capable of firing and would also not realize why the weapon was not capable of firing. It should further be appreciated that the safety system of the present invention allows the weapon to be reactivated at the discretion of the user and only an authorized user where a keyed code switch is used. In addition, by use of a coded signal, only a specific transmitter transmitting a specified control signal will operate to inactivate the weapon. The use of a solenoid also allows the operation of the safety system to be checked by merely activating the system and listening for the click of the solenoid action to indicate that the safety system is functioning properly. When the safety systems described above are used with the firearms of a police force, the transmitter can also be adapted to notify a controller that an officer has found it necessary to deactivate his weapon and that a potentially dangerous situation has occurred. In this manner, help can be immediately sent. If desired, an indicator on the weapon can also be provided to indicate when the safety system is engaged and use of the weapon is not possible. A small light or a discreet audio signal are suitable such indicators. Although the present invention has been described with the use of a radio transmitter and receiver, it should be appreciated that other types of transmitters and receivers are possible. For example, sonic, ultrasonic, and voice activated transmitters and receivers would also be possible. In order to further conserve the battery power which is used to power the receiver, a switch can be provided whereby the receiver is only powered to receive to a transmitted signal when the switch is on. Such a switch could be manually activated whenever the user had cause for concern that an unauthorized person might gain control of his weapon. Alternatively, a switch could be provided which would only power the receiver when the weapon is removed from a holster. A light switch, magnetic switch, spring loaded push out switch or other holster activated switch would be suitable for this purpose such as switch 140 shown in FIGS. 1a and 1b. Preferably, such a cut-off switch, once activated to supply power, would maintain the power for a set period of time so that no accidental or undesired return of the switch to the non-power delivering state would immediately cause the receiver to stop functioning. Other suitable switches could be actuated by the position of the weapon. Thus, when the barrel is not vertically oriented, that is pointed to the ground as normally occurs when a weapon is carried in a holster or the like, the receiver would not be powered. Suitable switches of this type include magnetic and mercury position switches. A timed switch could also be activated when the user carries the weapon. In such a case, the timed switch would be actuated for a period sufficient to cover the time period in which the user carries the weapon in a dangerous situation, such as the shift of a police officer. Although the present invention has been described with solenoids which immediately return to the inactivated position when no signal is received, it would also be possible to provide latching solenoids of the type that once activated the solenoids would maintain the block in the position to prevent use of the weapon even when the transmitted signal is no longer received. If this type of permanent block weapon is desired, the solenoid could also be replaced by a fused link or other electromechanical device to permanently deactivate a weapon. Thus, while the present invention has been described with respect to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that variations and modifications can be effected within the scope and spirit of the invention.
A safety system for selectively disabling a firearm which is fired by a mechanical movement is disclosed. The safety system includes a block which is moved between an engaged position whereby the mechanical firing movement is blocked and a disengaged position whereby the mechanical firing movement is not blocked. The block has a bearing surface which engages a relatively immovable part of the firearm when the block is in the engaged position. A moving device is also provided for moving the block from the disengaged position to the engaged position, with the moving device normally biasing the block to the disengaged position. A remotely controlled actuating device for actuating the moving device includes a transmitter which selectively transmits a signal and which is designed to be carried by the operator of the firearm. A receiver is located adjacent the moving device. The receiver receives the signal from the transmitter and operates the moving device. Where the mechanical movement includes a member which moves parallel to a metal surface, the block is an elongate bar which is extendable through an aperture in the metal surface. The block can also be a lever which is pivoted intermediate two opposed ends. Conveniently, the moving device is a solenoid.
5
FIELD OF INVENTION [0001] The present invention relates generally to nano-machining with lasers to improve surface finish and form. This invention relates more specifically to nano-machining of component surfaces in spindle motors. BACKGROUND [0002] Magnetic discs with magnetizable media are used for data storage in most all computer systems. Current magnetic hard disc drives operate with the read-write heads only a few nanometers above the disc surface and at rather high speeds, typically a few meters per second. [0003] Generally, the discs are mounted on a spindle that is turned by a spindle motor to pass the surfaces of the discs under the read/write heads. The spindle motor generally includes a shaft fixed to a base plate and a hub, to which the spindle is attached, having a sleeve into which the shaft is inserted. Permanent magnets attached to the hub interact with a stator winding on the base plate to rotate the hub relative to the shaft. In order to facilitate rotation, one or more bearings are usually disposed between the hub and the shaft. An alternate design uses a rotating shaft configuration. Here the sleeve is attached to the base plate. [0004] FIG. 1 shows a schematic of a magnetic disc drive for which a spindle motor having a fluid dynamic bearing manufactured by the method and apparatus of the present invention is particularly useful. Referring to FIG. 1 , a disc drive typically includes a housing having a base sealed to a cover by a seal. The disc drive has a spindle to which are attached a number of discs having surfaces covered with a magnetic media (not shown) for magnetically storing information. A spindle motor (not shown in this figure) rotates the discs past read/write heads, which are suspended above surfaces of the discs by a suspension arm assembly. In operation, spindle motor rotates the discs at high speed past the read/write heads while the suspension arm assembly moves and positions the read/write heads over one of a several radially spaced tracks (not shown). This allows the read/write heads to read and write magnetically encoded information to the magnetic media on the surfaces of the discs at selected locations. [0005] As illustrated in FIG. 2 , the spindle motor includes a shaft having an outer surface that abuts a sleeve. The shaft rotates relative to the sleeve or vice versa. Shafts can have a variety of shapes, including cylindrical (as shown) and conical. [0006] Over the years, storage density has tended to increase and the size of the storage system has tended to decrease. This trend has lead to greater precision and lower tolerance in the manufacturing and operating of magnetic storage discs. For example, to achieve increased storage densities the read/write heads must be placed increasingly close to the surface of the storage disc. This proximity requires that the disc rotate substantially in a single plane. A slight wobble or run-out in disc rotation can cause the surface of the disc to contact the read/write heads. This is known as a “crash” and can damage the read/write heads and surface of the storage disc resulting in loss of data. [0007] More precise machining can achieve desirably lower tolerances in disc drive manufacture. One area of disc drives particularly suited for laser honing (or finishing) is the spindle motor shaft and sleeve. Traditional material removal processes used in machining disc drives, such as turning or milling, leave machining marks (e.g., peaks and valleys). These machining marks can be due to: (1) cutting tool shape; (2) machining parameters such as feeds, depth of cut, speed, spindle runout, etc.; (3) vibrations induced by the motion of the part and the cutting tool, which can be amplified by structural resonances; and (5) deflection and distortion of the part due to cutting load and thermal changes. Further, electrochemical machining processes are known to leave sulfide inclusions protruding from the machined surface while eroding the surrounding metal, and processes such as grinding cause workpiece variation due to non-uniform yielding of the part and grinding wheel wear. [0008] Honing is used to remove machining marks, thereby improving a machined surface. It is known to use other types of honing such as abrasive grains and rotating tools carrying abrasives such as wires. It is also known to apply lasers directed perpendicular to the workpiece, which can remove machining marks, but are more commonly used to create recesses in the workpiece surface. SUMMARY OF THE INVENTION [0009] This invention relates to a method of finishing a surface, comprising providing a laser having a pulse shape and energy sufficient to remove asperities from the surface, and directing the laser at grazing incidence to the surface, so that it removes asperities from the surface. Grazing incidence means substantially tangential to and sometimes just above the surface to be finished if the surface is curved (e.g., a cylinder) or substantially parallel to and sometimes just above the surface to be finished if the surface is flat. [0010] This invention also relates to a method of machining a component of a disk drive, comprising providing a laser having a pulse shape and energy sufficient to remove material from the component, and directing the laser to machine and finish the surface of the component to a desired shape. [0011] This invention further relates to a method of finishing a surface of a workpiece, comprising providing a laser perpendicular to the surface, and focusing the laser onto or adjacent to the surface so that its energy density is sufficient for removing asperities that protrude from a surface without causing an undesirable amount of material to be removed from the surface. [0012] This invention is still further related to a workpiece comprising a finished surface having substantially no machining marks, wherein the machining marks were removed by an ultrafast pulse laser. [0013] Additional advantages of this invention will become readily apparent to those skilled in this art from the following detailed description, wherein only the preferred embodiments of this invention is shown and described, simply by way of illustration of the best mode contemplated for carrying out this invention. As will be realized, this invention is capable of other and different embodiments, and its details are capable of modifications in various obvious respects, all without departing from this invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not as restrictive. BRIEF DESCRIPTION OF THE DRAWINGS [0014] FIG. 1 illustrates schematically a magnetic disc drive. [0015] FIG. 2 illustrates a vertical cross section of a spindle motor for a spindle as shown in FIG. 1 . [0016] FIG. 3 schematically illustrates an embodiment of laser honing of a cylindrical workpiece in accordance with the present invention. [0017] FIG. 4 schematically illustrates an embodiment of laser honing of a flat surface in accordance with the present invention. [0018] FIG. 5 schematically illustrates another embodiment of laser honing of a cylindrical workpiece in accordance with the present invention. [0019] FIG. 6 schematically illustrates another embodiment of laser honing of a cylindrical workpiece in accordance with the present invention. [0020] FIG. 7 schematically illustrates an embodiment of laser honing of channels in accordance with the present invention. [0021] FIG. 8 schematically illustrates an embodiment of machining a workpiece in accordance with the present invention. [0022] FIGS. 9A-9C schematically illustrate exemplary shapes of pulses used in accordance with the present invention. [0023] FIG. 10 schematically illustrates yet another embodiment of laser honing of a cylindrical workpiece in accordance with the present invention. DETAILED DESCRIPTION [0024] The following description is presented to enable a person of ordinary skill in the art to make and use various aspects and embodiments of the invention. Descriptions of specific materials, techniques, and applications are provided only as examples. Various modifications to the examples described herein will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other examples and applications without departing from the spirit and scope of the inventions. [0025] The present invention contemplates using a laser to remove machining marks left on the surface of workpieces. The laser is preferably directed incident to the surface of the workpiece, and particularly at a grazing incidence (along the surface of the workpiece). In a preferred embodiment, the laser is an ultra-fast pulse laser, allowing ablation of the machining marks, rather than melting. In a particularly preferred embodiment of the invention, the laser is a femtosecond laser. [0026] Regarding laser types, “ultrafast” means that the laser emits ultra short pulses having a duration that is somewhat less than about 10 picoseconds—usually some fraction of a picosecond. By contrast, a long pulse laser has a pulse that is longer than about 10 picoseconds. The most fundamental feature of material interaction in the long pulse regime is that the heat deposited by the laser in the material diffuses away during the pulse duration. This may be desirable if you are doing laser welding, but for most micromachining jobs, heat diffusion into the surrounding material is undesirable for several reasons. One reason is that heat diffusion from long pulse lasers reduces the accuracy of a micro- or nano-machining operation, because heat diffuses away from the focal spot and melts an area that is much larger than the focal spot. It is therefore difficult to do very fine machining. Another reason is that heat diffusion affects a large zone around the machining spot, causing mechanical stress and creating microcracks (or in some cases macrocracks) in the surrounding material. [0027] Using ultrafast lasers, the heat deposited by the laser into the material does not have time to move away from a work spot within or on the material and accumulates at the level of the work spot, whose temperature rises instantly past the melting point of the material and goes, very quickly, well beyond even the evaporation point. In fact, the temperature continues climbing into what is called the plasma regime. [0028] Femtosecond lasers are ultrafast lasers that deliver a large amount of peak power. Peak power is the instantaneous laser beam power per unit area. These systems routinely deliver 5 to 10 Gigawatts of peak power, and the resulting laser intensity easily reaches the hundreds of Terawatts per square centimeter at the work spot. By ionizing the material being cut—removing it atom by atom—femtosecond lasers allow precise machining of many materials. Each pulse of these lasers is extremely short, lasting just 50 to 1,000 femtoseconds (or quadrillionths of a second). These ultrashort pulses are too brief to transfer heat or shock to the material being cut, which means that cutting, drilling, and machining occur with minimal damage to surrounding material. Ultrafast lasers machine without a melt phase, so that there is no splattering of material onto the surrounding surface. [0029] The present invention contemplates using other types of lasers having a pulse energy sufficient to remove asperities from the surface by ionizing the asperities, and contemplate machining and honing many parts of a spindle motor, for example the spindle shaft 175 , using such a laser. Other types of lasers may include, generally, titanium-sapphire lasers, diode-pumped lasers, and fiber lasers. [0030] FIG. 3 schematically illustrates honing with an ultrafast laser at grazing incidence to a workpiece, and the resulting removal or minimization of surface asperities on the workpiece. As can be seen, although the laser is incident to the workpiece surface, it is generally perpendicular to the asperity to be removed. To hone a flat surface of a workpiece with a linear laser beam as shown in FIG. 3 , the laser can be swept over the surface of the workpiece as illustrated by the arrow in FIG. 4 , or the laser can remain stationary and the workpiece can be moved relative to the laser. The present invention also contemplates both the laser and the surface moving. [0031] FIG. 5 schematically illustrates a planar ultrafast laser beam in cross-section, which is directed at grazing incidence to a workpiece. A planar laser beam can remove asperities from a larger surface area of a workpiece. When used with a workpiece having a flat surface, a properly sized laser beam could remove asperities from the workpiece surface without requiring any relative movement of the laser and workpiece. When used with a cylindrical workpiece (such as a spindle shaft) as shown in FIG. 5 , the ultrafast laser beam is directed tangential to the cylinder surface to remove asperities. The cylinder is then preferably rotated while the ultrafast laser beam remains incident (tangential) to its surface. The tangential beam can be planar, as shown, or a linear beam. [0032] The present invention also contemplates machining a circumference of a workpiece with a complimentary-shaped laser beam. For example, as shown in FIG. 6 , a collimated ultrafast laser ring can be directed to surround the perimeter of a cylindrical workpiece. [0033] As illustrated in FIG. 7 , an ultrafast pulse laser can additionally be used to clear channels or slots such as those found in electrodes. The beam can be directed at grazing incidence along one or more of the surfaces of each channel. [0034] The present invention also contemplates using an ultrafast pulse laser to shape workpieces. For example, as illustrated in FIG. 8 , an ultrafast pulse laser can be used to machine a controlled taper on both shafts and their associated sleeves (not shown). Such machining would produce a surface that is substantially free of machining asperities, because it would avoid machining marks caused by known machining processes. In addition, the present invention contemplates using an ultrafast pulse laser to machine matching bearing components in their final assembled state. [0035] Although the above disclosure is directed to honing the surface of a shaft or other male workpiece, the present invention contemplates using an ultrafast pulse laser to hone female workpieces such as sleeves, either as an alternative or in addition to honing of complimentary male workpieces. Thus a shaft and associated sleeve could both be laser honed to provide complimentary surfaces having a decreased number and size of asperities. [0036] It is known that laser energy is not consistent across its cross section. Thus, ultrafast pulse lasers, such as femtosecond lasers, come in a variety of pulse shapes. Certain pulse shapes can be beneficial to certain applications of laser honing, as discussed below with reference to FIGS. 9A through 9C . In a preferred embodiment of the invention, the portion of the ultrafast pulse laser beam with the appropriate energy to hone the surface to remove asperities is directed at the asperity and does not affect other portions of the workpiece surface. [0037] FIG. 9A illustrates an exemplary cross section of a bi-modal pulse laser beam, the horizontal line denoting the machining threshold of the material to be removed. As can be seen, the bi-modal pulse laser beam has two spaced peaks of energy sufficient to remove asperities from a workpiece surface. The bi-modal pulse laser beam is therefore desirable for machining the circumference of a cylinder. The cylinder's outer surface could be ablated more efficiently, requiring only a half rotation of the cylinder (or the laser). A bi-modal beam could also be used to simultaneously hone opposing sides of a rectangle, or to simultaneously hone two spaced surfaces. [0038] FIG. 9B illustrates an exemplary cross section of a flat-topped pulse laser beam. FIG. 9C illustrates an exemplary cross section of a Gaussian pulse laser beam. The horizontal lines denote the machining threshold of the material to be removed. As can be seen, the wide cross section of the flat-topped beam permits honing of larger asperities, while the finer cross section of the Gaussian beam allows more controlled honing. Due to its ability to permit more controlled honing, the Gaussian beam is particularly preferred for a wide variety of embodiments of the present invention. [0039] FIG. 10 illustrates an alternate embodiment of the invention utilizing a laser directed perpendicular to the workpiece surface, rather than at grazing incidence. As shown, a lens is used to focus the laser beam so that its energy density is sufficient for removing asperities only in a desired area. For example, by focusing the laser beam as shown, the energy density of the beam is sufficient for removing material only in the area that would be affected by a beam directed at grazing incidence. The beam can be focused to remove asperities without removing other material from the surface of the workpiece, or at least without causing an undesirable amount of material to be removed from the surface. [0040] Ultrafast pulse lasers can be used to hone a variety of materials, including a full range of metals and ceramics. The present invention contemplates using more than one laser consecutively or simultaneously.
A method of finishing a surface comprises providing a laser having a pulse shape and energy sufficient to remove asperities from the surface, and directing the laser at grazing incidence to the surface, so that it removes asperities from the surface.
1
TECHNICAL FIELD [0001] This invention relates to a technique for aligning an object, such as a robotic television camera, in several dimensions. BACKGROUND ART [0002] In many applications, a need exists to establish alignment of an object with a target. For example within a television studio, movement of a tripod or pedestal associated with a television camera to an alternate locations often occurs to better leverage the investment in such equipment. However, a change in the positioning of the tripod or pedestal with respect to the set often results a change in the camera position. As a consequence, the new position of the camera will likely differ by several centimeters, or even several meters from its previous position (referred to as a “preset”). In the case of a robotically operated camera, no mechanism typically exists for easily accomplishing re-alignment. Rather, the camera must undergo manual re-alignment and followed by time consuming re-programming of the location presets. [0003] Thus a need exists for a technique for simply and efficiently aligning a television camera. BRIEF SUMMARY OF THE INVENTION [0004] Briefly, in accordance with a preferred embodiment of the present principles, there is provided a method for aligning an object, such as but not limited to, a robotically controlled television camera, with a target. The method commences by directing a coherent beam of radiation, e.g., a laser beam, into an opening in an enclosure having a reflective interior such that the radiation strikes the target which lies in axial alignment with the enclosure opening. Upon striking the target, the beam undergoes reflection through the enclosure opening back to the object for detection. Alignment between the object and the target occurs when substantially all of the radiation undergoes reflection from the target to the object. BRIEF DESCRIPTION OF THE DRAWINGS [0005] FIG. 1 depicts a block schematic diagram of a system, in accordance with a preferred embodiment of the present principles, for aligning a robotically controlled camera with a target; [0006] FIGS. 2 and 3 depict front and side views, respectively, of the target of FIG. 1 ; and [0007] FIG. 4 depicts a flow chart illustrating the steps of a method for aligning the robotically controlled camera with the target, both of FIG. 1 . DETAILED DESCRIPTION [0008] FIG. 1 depicts a block schematic of a system 10 in accordance with a preferred embodiment of the present principles for aligning an object, illustratively depicted as a television camera 12 , with a fixed target 14 , illustratively attached to a solid surface 16 , such as a wall. The alignment system 10 of the present principles includes the combination of a radiation source 18 , and a receiver 20 . In practice, the radiation source 18 comprises a laser for generating a beam 21 of coherent radiation (e.g., light) having a relatively small cross section. Typically, the receiver 20 comprises a photo detector, a photo diode or the like, in combination with a beam splitter (not shown), for detecting the radiation reflected from the target 14 along a path coaxial with the incident beam 21 . The radiation source 18 and the receiver 20 are both mounted to the camera 12 such that when the camera becomes aligned with the target 14 in the manner described hereinafter, the receiver will detect the beam 21 with little if any scattering. [0009] An interface 22 links both the radiation source 18 and the receiver 20 to a controller 24 that typically includes a programmed computer or the like (not shown). The interface 22 also links the controller 24 to a robotic motor control unit 26 that includes one or more motors (not shown) that serve to pan and tilt the camera 12 , thereby displacing the camera along the X and Y axes, respectively, which lie in a plane normal to axis of the beam 21 as seen in FIG. 1 . In practice, the robotic motor controller 26 can also control a motorized pedestal (not shown) which serves to raise and lower the camera 12 . In addition, the controller 24 controls a camera lens control 28 coupled to the interface 22 . The camera lens control 28 includes one or more motors (not shown) that serve to adjust various functions of a camera lens (not shown), such as but not limited to, zoom, focus and iris. [0010] FIGS. 2 and 3 depict front and side views, respectively, of the target 14 associated with which is a hollow enclosure 30 , typically although not necessarily a tube, having a reflective surface. Referring to FIG. 3 , the wall 16 supports the enclosure 30 of FIG. 2 by way of a mounting mechanism (not shown) so that the enclosure has its central axis 34 normal to the wall. As best seen in FIG. 2 , the enclosure 30 has an opening 31 through which a beam of radiation, such as beam 21 of FIG. 1 , can enter. In practice, the target takes the form a reflector 32 , typically in the form of a circular mirror or the like, lies at the center of the enclosure opening 31 such that the central enclosure axis 34 lies coaxial with an axis normal to, and extending from the center of the reflector. Typically, the reflector 32 has a relatively small diameter (e.g., 0.1275 inches) as compared to the diameter of the enclosure opening 31 (e.g., 3 inches). [0011] The reflector 32 has its center at a fixed position in both along both the X and Y axes (typically 0, 0) known to the controller 24 of FIG. 1 . Alignment of the camera 12 of FIG. 1 with the target 14 will occur upon positioning of the camera such that the axis of the beam 21 of FIG. 1 lies substantially coaxial with the central enclosure axis 34 , as determined by nearly complete reflection of the beam by the reflector 32 back to the camera with nearly no scattering. To better understand the alignment of the camera 12 in this manner, refer to FIG. 3 . For purposes of discussion, assume that the camera 12 has a pedestal height such that the beam 21 can strike the reflector 32 when precisely aligned in X and Y. As seen in FIG. 3 , a misalignment of the beam 21 along the Y axis will result in reflection of the beam along one of axes 36 or 38 , respectively, depending on whether the camera is tilted high or low, respectively. Indeed, the camera misalignment of the camera 12 depicted in FIG. 3 is sufficiently great so that the beam 21 fails to enter the enclosure opening 31 . [0012] The alignment technique of the present principles can even detect a small misalignment between the camera 12 and the target 14 . Consider the circumstance when the camera 12 is roughly aligned with the target 14 to the degree that the beam 21 enters the enclosure opening 31 and even strikes the reflector 32 . However, presume that sufficient misalignment exists so that the beam 21 does not lie coaxial with the enclosure axis 34 . Under such circumstances, the reflector 32 will reflect the beam 21 off axis so that beam strikes the reflective interior surface of the enclosure 30 . Thus, the beam 21 will undergo scattering so that little if any portion of the beam will strike the receiver 20 . Thus, only when the camera 12 and target 14 are aligned such that the beam 21 enters the enclosure 30 and strikes the reflector 32 for reflection coaxial with the central enclosure axis 34 will the receiver 20 of FIG. 1 detect the beam with little if any scattering. Providing the beam 21 with the relatively narrow cross section and marking the reflector 32 relatively small in diameter increases the precision of the alignment technique of the present principles. [0013] As described with respect to FIG. 3 , the enclosure 30 is mounted to the support structure 16 to circumscribe the reflector 32 . However, the enclosure 30 could be mounted to the camera 12 to circumscribe the beam 21 . [0014] FIG. 4 depicts a flow chart showing the steps associated with camera set-up and camera alignment. Camera set-up commences by moving the camera 12 of FIG. 1 and its associated tripod or pedestal (not shown) to a given position (step 100 ). Thereafter, the laser 18 of FIG. 1 undergoes activation (step 102 ) to generate the beam 21 directed towards the target 14 . Assuming the camera 12 and the target 12 are aligned such that the laser beam 21 of FIG. 1 will enter the enclosure 30 and undergo reflection by the reflector 32 with substantially no scattering, the receiver 20 of FIG. 1 will detect the reflected beam during step 104 of FIG. 3 . Using the controller 24 of FIG. 1 , the user saves the camera 12 /laser 18 position as a “laser preset.” [0015] After initial alignment as described, the camera 12 and its tripod or pedestal can undergo repositioning during step 108 , thus prompting the need for alignment. Camera alignment commences by re-positioning the camera 12 during step 110 to a position close to its original X and Y position as in step 100 . Thereafter, the user activates the laser 18 of FIG. 1 through the controller 24 of FIG. 1 , during step 112 of FIG. 4 to generate the beam 21 of FIG. 1 . Assuming that the user did not perfectly align the camera 12 with the target 14 during step 110 , then the beam 21 will likely strike the support surface 16 (i.e., the wall) at a point outside of the enclosure opening 31 of FIG. 1 . Thereafter, the user will recall the desired camera (and hence, laser) position during step 116 that was previously saved as a preset during step 106 . Assuming that the user positioned the camera during step 110 to a position reasonably close to the original position, then the recalling the preset position during step 116 will cause the beam 21 to enter the enclosure opening 31 to strike close to the target 14 during step 118 . Thereafter, the user will displace the camera 12 , either though manual movement or through slight jogs using the controller 24 , or a combination thereof, to precisely align the camera with the target, as signified by the reception of the reflected beam by the receiver 20 . [0016] The foregoing describes a technique for aligning an object with a target.
An object, such as a robotically controlled television camera undergoes alignment with a reflective target by directing a coherent beam of radiation, e.g., a laser beam, into an opening in an enclosure having a reflective interior such that the radiation strikes a reflector in axial alignment with the enclosure opening. Upon striking the target, the beam undergoes reflection through the enclosure opening back to the object for detection. Alignment between the object and the target occurs when substantially all of the radiation undergoes reflection from the target to the object.
6
CROSS REFERENCE TO RELATED APPLICATION This is a continuation of Ser. No. 07/506,915 filed on Apr. 9, 1990, now abandoned, which is a continuation of Ser. No. 07/117,245 filed on Nov. 4, 19987 now abandoned. This application is related to the following commonly assigned application ______________________________________SERIALNO. FIL-(ATTY'S ING APPLI- STA-DOCKET) DATE TITLE CANTS TUS______________________________________(337,2064) now COPOLYMERS D. C. Clagett Pend-U.S. Ser. aband- AND D. W. Fox ingNo. oned, PROCESS FOR L. M. Maresca07/117,250 FOR THE S. J. Shafer PREPARATION THEREOF______________________________________ FIELD OF THE INVENTION The present invention relates to copolymer resins, thermoplastic compositions comprising them, and processes useful in their preparation. More particularly, it is concerned with copolymers comprising amide units and ester units, molding compositions comprising such copolymers and a melt phase process for their production by interchange of diaryl esters with diamines and dihydric alcohols. BACKGROUND OF THE INVENTION Blends of polyamides with polycarbonates, poly(ester carbonates) and polyarylates are known to exhibit desirable properties including excellent solvent resistance, ductility, hydrolytic stability and resistance to brittle failure when molded into articles. See, for example, the copending, commonly assigned U.S. patent application of L. M. Maresca, D. C. Clagett and U. S. Wascher, Ser. No. 812,433 filed Dec. 23, 1985 now abandoned, and U.S. Pat. No. 4,798,874, which is a continuation-in-part of Ser. No. 07/812,433. Novel polyamide-polyarylate copolymers have been prepared which have excellent and improved physical and mechanical properties, and good chemical resistance and barrier properties, and these are the subject matter of commonly assigned copending application Ser. No. 07/117,250, now abandoned. Such copolymers are prepared in a melt polymerization process. The microstructure of the polymer can be controlled by running the process in one or two steps. A wide variety of diamines, diphenols and diacid esters can be used in the process in both steps. If, for example, a polyamide polyarylate block copolymer is desired, a two step process is used. In the first step, for example, diphenyl iso/terephthalate is reacted with a diamine in the melt at, for example, 120° C.-280° C., to produce amide units. If a diphenol such as bisphenol-A and diphenyl iso/terephthalate is added in a second step and the temperature of 230° C.-320° C. is used arlyate units will then be smoothly produced at reduced pressures as byproduct phenol is removed. Although Fox and Shafer, U.S. Pat. No. 4,567,249, disclose the melt preparation of polyamides by amine-ester interchange, there is no hint of suggestion in that patent to employ the process employing both an amine on the one hand, and a dihydric phenol on the other. It has now been found that amide-ester copolymers, including random copolymers, block copolymers and alternating copolymers, can be synthesized by a melt polymerization process. If carried out stepwise, in one step a polyamide block can be formed by the reaction of a diamine with a diaryl ester, e.g., diphenyl iso/terephthalate at temperatures ranging from about 120° C. to about 280° C. In a second step, a diol such as ethylene glycol, or 1,4-butanediol can be used in the reaction along with diacid ester to form the polyester at similar temperatures i.e., more moderate than required to make the polyarylate blocks. The new materials, which can be made from a wide variety of diamines, diols and diacid esters, have excellent mechanical and physical properties good chemical resistance and barrier properties. SUMMARY OF THE INVENTION According to the present invention, there are provided block copolymers of the general formula ##STR1## wherein units A comprise from about 1 to about 99 percent by weight of said copolymer and units B comprise from about 99 to about 1 percent by weight of said copolymer, where E is selected from divalent alkyl, aryl, cycloalkyl, arylalkyl and alkylaryl groups of from 1 to 30 carbon atoms or a mixture of any of the foregoing, optionally substituted with at least one chlorine, bromine, fluorine, nitro, nitrile, alkyl of from 1 to 6 carbon atoms, alkoxy of from 1 to 6 carbon atoms or aryl of from 6 to 20 carbon atoms; G is a divalent alkyl, aryl, cycloalkyl, arylalkyl or alkylaryl group of from about 2 to about 30 carbon atoms or a mixture of any of the foregoing, optionally interrupted with alkylene, arylene, carbonyl, ether, amino or sulfur-containing groups, optionally substituted with at least one of chlorine, bromine, fluorine, nitro, nitrile, alkyl of from 1 to 6 carbon atoms, alkoxy of from 1 to 6 carbon atoms or aryl of from 6 to 20 carbon atoms; R is a divalent alkyl, cycloalkyl, aliphatic ether group of from about 2 to about 20 carbon atoms or a mixture of any of such groups; and Ar is a divalent aromatic carbocyclic group, optionally substitued with at least one of chlorine, bromine, fluorine, nitro, nitrile, alkyl of from 1 to 6 carbon atoms, alkoxy of from 1 to 6 carbon atoms aryl of from 6 to 20 carbon atoms or a mixture of any of such groups, and x, y and z are each integers of from 1 to 100,000. Preferred features of this aspect of the invention comprise a block copolymer as defined above wherein x and y are at least about 20. Preferred are copolymers wherein units of A comprise from about 20 to about 80 percent by weight and units of B comprise from about 80 to about 20 percent by weight of A and B combined, and especially preferred are copolymers wherein units of A comprise from about 40 to about 60 percent by weight and units of B comprise from about 60 to about 40 percent by weight of A and B combined. Special mention is made of block copolymers as above defined wherein E and Ar are ##STR2## G is divalent alkyl cycloalkyl, aryl or alkylaryl of from about 2 to about 20 carbon atoms and R is ##STR3## wherein n is an integer of from 2 to 6. Especially preferred are block copolymers wherein G is the residuum of ethylenediamine, trimethylenediamine, tetramethylenediamine, pentamethylenediamine, 2-methylpentamethylenediamine, hexamethylenediamine, isomeric trimethylhexamethylenediamine, meta-xylylenediamine, para-xylylenediamine, 1,3-bis(aminomethyl)cyclohexane, 1,4-bis(aminomethyl)cyclohexane, 1,3-diaminocyclohexane, 1,4-diaminocyclohexane, bis(4-aminocyclohexyl)methane, 2,2-bis(4-aminocyclohexyl)propane, 1,4-piperazine, meta-phenylenediamine, para-phenylenediamine, bis(4-aminophenyl)methane and the like or mixtures thereof. Also provided by the present invention is a process to make the copolymers above defined, said process comprising heating a mixture of at least one diaryl ester of a dicarboxylic acid of the formula ##STR4## wherein the groups Ar 3 represent the same or different aryl groups, optionally substituted with at least one of chlorine, bromine, fluorine or alkyl of from 1 to 6 carbon atoms and E is as above defined an amine of the formula R.sup.2 NH--G--NHR.sup.2 wherein G is as above defined and R 2 is hydrogen or alkyl of from 1 to 10 carbon atoms, a dihydric alcohol of the formula HO--R--OH wherein R is as above defined and at least one diester of a dicarboxylic acid of the formula ##STR5## wherein R 3 is alkyl of from 1 to 12 carbon atoms or a group as defined for Ar 3 above and Ar is as above defined optionally in the presence of an effective amount of a transesterification catalyst and removing byproduct phenol, alcohol and/or water until formation of said copolymer is substantially complete. This process can be carried out in one or two stages depending on the structure of the final copolymer desired. For example carrying out the process in one stage with all components mixed produces a random copolymer in which x, y and z have no consistently recurring values. If, however, essentially stoicimetric amounts of the diaryl ester of a dicarboxylic acid and a diamine are reacted in the first stage followed by further polymerization in a second stage with essentially stoichiometric amounts of a diol and a diaryl or dialkyl ester of an aromatic dicarboxylic acid then a block copolymer is formed where in x and y are consistantly greater than 15. In a third variation, if 2 equivalents of a diaryl ester of a dicarboxylic acid is reacted with a diamine in step one then very small nylon oligomers are formed; addition of a diol in a second step results in the formation of an essentially alternating amide-ester copolymer. Values of x and y are essentially less then about 5. In all cases the combined concentrations of diamines and diol must be essentially equal to the combined concentrations of the diaryl and/or dialky esters. Preferably, the diaryl ester comprises a diaryl terephthalate, a diaryl isophthalate, a diaryl adipate or a mixture thereof. Especially preferably, the diaryl ester will comprise diphenyl isophthalate, diphenyl terephthalate or diphenyl adipate. Preferably also, the diamine comprises ethylenediamine, trimethylenediamine, tetramethylenediamine, pentamethylenediamine, 2-methylpentamethylenediamine, hexamethylenediamine, isomeric trimethylhexamethylenediamine, meta-xylylenediamine, para-xylylenediamine, 1,3-bis(aminomethyl) cyclohexane, 1,4-bis (aminomethyl)cyclohexane, 1,3 diaminocyclohexane, 1,4-diaminocyclohexane, bis(4-aminocyclohexyl)methane, 2,2-bis(4-aminocyclohexyl)propane, 1,4-piperazine, meta-phenylenediamine, para-phenylenediamine, bis(4-aminophenyl)methane and the like or mixtures thereof. Preferably the diester of the aromatic dicarboxylic acid will comprise a dialkyl or diaryl terephthalate, a dialkyl or diaryl isophthalate or a mixture thereof. Special mention is made of a process wherein the dihydric alcohol comprises ethylene glycol, 1,4-butanediol, polybutylene glycol, 1,4-cyclohexanedimethanol, or a mixture of any of the foregoing. Also among the preferred features of the invention are copolymers prepared in a melt phase process by the interchange of an excess of a diamine or diaryl ester to produce a polyamide having amine or ester terminal groups and further reacting the the polyamide with a dihydric alcohol and a diester of a dicarboxylic acid to form a polyamide-polyester block copolymer containing from about 1 to about 99 percent by weight of polyamide segments and from about 99 to about 1 percent by weight of polyester segments. In these, preferably, the diamine comprises a diprimary or disecondary amine. The copolymers are thermoformable into shaped articles which are tough, thermally stable and resistant to chemicals and hydrolysis. They are also useful as blending resins. DETAILED DESCRIPTION OF THE INVENTION As examples of diamines particularly suitable for use in preparing the A units can be mentioned diprimary and disecondary as well as mixed primary and secondary diamines of the general formula above. Illustrative examples are ethylenediamine, trimethylenediamine, tetramethylenediamine, pentamethylenediamine, 2-methylpentamethylene diamine, hexamethylenediamine, isomeric trimethylhexamethylenediamine, meta-xylylenediamine, para-xylylene diamine, 1,3-bis(aminomethyl) cyclohexane, 1,4-bis (aminomethyl)cyclohexane, 1,3-diaminocyclohexane, 1,4-diaminocyclohexane, bis(4-aminocyclohexyl)methane, 2,2-bis(4-aminocyclohexyl)propane, 1,4-piperazine, meta-phenylenediamine, para-phenylenediamine, bis(4-aminophenyl)methane and the like or mixtures thereof. Illustratively useful diesters suitable as sources for structural units E are esters of dicarboxylic acids such as diphenylic esters derived from phenolic compounds, e.g., a monohydric phenol, including phenol itself, and alkyl- or halo-substituted phenols, such as o-, m- and p-cresols, and o- and p-chlorophenol and the like, and a dicarboxylic acid, such as adipic, sebacic, glutaric, phthalic, terephthalic, isophthalic, naphthalene dicarboxylic, biphenyl dicarboxylic acid, and the like. A preferred family of diesters comprises the diphenyl esters of terephthalic acid, isophthalic acid, and mixtures thereof. With respect to the ester unit B, these are derived from an aliphatic, aliphatic ether or cycloaliphatic diols, or mixtures thereof, containing from 2 to about 10 carbon atoms and at least one aromatic dicarboxylic acid. Preferred polyester blocks are derived from an aliphatic diol and an aromatic dicarboxylic acid and have repeating units of the following general formula: ##STR6## wherein n is an integer of from 2 to 6. The most preferred polyester blocks comprise poly(ethylene terephthalate) or poly(1,4-butylene terephthalate). Also contemplated herein are units of the above esters with minor amounts, e.g., from 0.5 to about 2 percent by weight, of units derived from aliphatic acids and/or aliphatic polyols, to form copolyesters. The aliphatic polyols include glycols, such as poly (ethylene glycol). All such polyesters can be made following the teachings of, for example, U.S. Pat. Nos. 2,465,319 and 3,047,539. The ester units that are derived from a cycloaliphatic diol and an aromatic and/or cycloaliphatic dicarboxylic acid are prepared, for example, from reaction of either the cis-or trans-isomer (or mixtures thereof), of 1,4-cyclohexanedimethanol, with an aromatic dicarboxylic acid so as to produce an ester having units of the following formula: ##STR7## wherein the cyclohexane ring is selected from the cis- and trans-isomers thereof and Ar represents an aryl or substituted aryl radical containing 6 to 20 carbon atoms and which is the decarboxylated residue derived from an aromatic dicarboxylic acid. Examples of aromatic dicarboxylic acids represented by the decarboxylated residue Ar are isophthalic or terephthalic acid, 1,2-di(p-carboxyphenyl) ethane, 4,4'-dicarboxydiphenyl ether, etc., and mixtures of these. All of these acids contain at least one aromatic nucleus. Acids containing fused rings can also be present, such as in 1,4- or 1,5-naphthalenedicarboxylic acids. The preferred dicarboxylic acids are terehthalic acid or a mixture of terephthalic and isophthalic acids. Another preferred ester unit may be derived from the reaction of either the cis- or trans-isomer (or a mixture thereof) of 1,4-cyclohexanedimethanol with a mixture of isophthalic and terephthalic acids. Such an ester would have units of the formula: ##STR8## Also included within this invention are polyesters derived from aliphatic ether diols, for example, tetraethyleneoxy diol, and the same diesters of diacids. In general, any diester of an aromatic dicarboxylic acid conventionally used in the preparation of polyesters, may be used for the preparation of the polyester blocks described above. The esters of aromatic dicarboxylic acids which may be used include those of aliphatic-aromatic dicarboxylic acids, in addition to those of wholly aromatic dicarboxylic acids. The diesters of dicarboxylic acids are represented by the general formula: ##STR9## wherein R 3 and Ar are as defined above, Ar being, for example, phenylene, naphthylene, biphenylene, substituted phenylene, etc.; two or more aromatic groups connected through non-aromatic linkages or a divalent aliphatic-aromatic hydrocarbon radical such as an arylalkyl or alkylaryl radical. For purposes of the present invention, R 3 is an aliphatic or cycloaliphatic radical, such as methyl, ethyl, n-propyl, dodecyl, octadecyl or an aromatic radical such as phenylene, biphenylene, naphthylene, substituted phenylene, etc. Some nonlimiting examples of suitable diesters of aromatic dicarboxylic acids which may be used in preparing the ester units of the instant invention include dialkyl and diaryl esters of phthalic acid, isophthalic acid, terephthalic acid, homophthalic acid, o-, m-, and p-phenylenediacetic acid, and the polynuclear aromatic acids such as diphenyl dicarboxylic acid, and isomeric naphthalene dicarboxylic acids. The aromatics may be substituted with inert groups such as bromine, chlorine, fluorine alkyl of from 1 to 6 carbon atoms, alkoxy of from 1 to 6 carbon atoms, aryl of from 6 to 20 carbon atoms, and the like. Of course, these esters may be used individually or as mixtures of two or more different acids. If desired, a conventional esterification catalyst can be used. Preferred as catalysts suitable for this purpose are, for example, acetates, carboxylates, hydroxides, oxides, alcoholates or organic complex compounds of zinc, manganese, antimony, cobalt, lead, calcium and the alkali metals. Preferably, inorganic or organic titanium-containing catalysts will be used such as tetrabutyl titanate or tetraoctyl titanate. In general, from about 0.005 to about 2.0 percent by weight of catalyst will be used, based on ester forming reactants. The alcoholic or phenolic byproducts can be removed, e.g., by vacuum devolatilization in the reactor or an extruder or a combination of the two. Alternatively, the byproduct can be solvent-extracted, e.g., with toluene. The resulting copolymer can be recovered in any convenient manner, remaining, for example, as a residue after vacuum devolatilization, or by precipitation from a solvent by means of an antisolvent, such as methanol. The products of the process may be molded in any desired shape and are useful as structural and engineering materials to replace metal parts, in automotive applications, electrical appliances, and in food wrappings, as stand alone resins, in blends with other resins such as polyesters, polyarylates and nylons and as tie resins to bond two different resin layers. DESCRIPTION OF THE PREFERRED EMBODIMENTS The following examples illustrate the invention. They are not to be construed to limit the claims in any manner whatsoever. EXAMPLE 1 A 4CV Helicone mixer was charge with 487.1 g (1.53 moles) of diphenyl isophthalate and 174.3 g (1.50 moles) of hexamethylenediamine and blanketed with nitrogen. Agitation was started and the temperature was raised to 180° C.-185° C. After 45 minutes at 180° C. to 185° C. the temperature was lowered to 165° C. and 324.0 g (1.67 moles) of dimethyl terephthalate, 251.0 g (2.79 moles) of 1,4-butanediol and 1.0 ml of tetraoctyl titanate were added. After 15 minutes methanol began to distill. The reaction temperature was increased to 200° C.-205° C. after 75% of the theoretical amount of methanol distilled and 235° C. at 95% theoretical. A partial vacuum of 125 mm of Hg was applied to the system and slowly decreased to full vacuum, less than 2 mm of Hg, over 1 hour. At full vacuum, the temperature was increased to 250° C.-255° C. and held there for 2 to 2.5 hours. After breaking vacuum the block copolymer was discharged from the reactor and allowed to cool to room temperature. The polymer extrudate was tough and opaque. Its instrinsic viscosity (IV), glass transition temperature (Tg) and melting point (Tm) are shown in Table 1. EXAMPLES 2 AND 3 Example 1 was repeated and the resulting block copolymers were tough and had the IVs, Tgs and Tms shown in Table 1. TABLE 1______________________________________Example IV.sup.1 Tg(°C.).sup.2 Tm(°C.).sup.2______________________________________1 0.77 118 2192 0.76 115 2183 0.69 115 218______________________________________ .sup.1 Intrinsic Viscosity, measured in phenol/tetrachloroethane (60/40) at 23° C. .sup.2 Glass transition and melting temperatures, measured by differentia scanning calorimetry. EXAMPLE 4 AND 7 If the procedure of Example 1 is repeated, substituting for the hexamethylenediamine, 1,3-bis(aminomethyl)cyclohexane, 1,4-bis(aminomethyl)cyclohexane, meta-xylylenediamine or para-xylylene diamine, block copolymers according to this invention will be obtained. EXAMPLE 8 If the procedure of Example 1 is repeated, substituting piperazine for hexamethylenediamine, a block copolymer product according to this invention will be obtained. EXAMPLE 9 If the procedure of Example 1 is repeated, substituting diphenyl adipate for diphenyl isophthalate in the first stage, a block copolymer according to the invention will be obtained. EXAMPLE 10 If the procedure of Example 1 is repeated, substituting for the diphenyl isophthalate in the first stage a 50--50 weight/weight mixture of diphenyl isophthalate and diphenyl terephthalate and dimethyl isophthalate in the second stage, a block copolymer according to this invention will be obtained. EXAMPLES 11-12 If the procedure of Example 1 is repeated, substituting, respectively, ethylene glycol or 1,4-cyclohexanedimethanol for the 1,4-butanediol employed in the second stage, block copolymers in accordance with this invention will be obtained. EXAMPLE 13 If the procedure of Example 1 is carried out in one stage, by adding all of the ingredients, including the catalyst, at once to the reactor, a random amide-ester copolymer in accordance with this invention will be obtained. EXAMPLE 14 The procedure of Example 1 is repeated except that 2 equivalents of diphenyl isophthalate is reacted with hexamethylenediamine in step 1. One equivalent of 1,4-butanediol is added in step 2. An essentially alternating amide ester copolymer in accordance with this invention is produced. The above-mentioned patents, patent applications and publications are incorporated herein by reference. Many variations of this invention will suggest themselves to those skilled in this art in light of the above, detailed description. For example, instead of diphenyl isophthalate and diphenyl terephthalate, the following diaryl esters can be used, diphenyl adipate, diphenyl sebacate, diphenyl glutarate, diphenyl naphthalene dicarboxylate, diphenyl biphenyl dicarboxylate, mixtures of any of the foregoing, and the like. Instead of hexamethylenediamine and the other diamines used, the following may be substituted: ethylenediamine, trimethylenediamine, tetramethylenediamine, pentamethylenediamine, 2-methylpentamethylenediamine, hexamethylenediamine, isomeric trimethylhexamethylenediamine, meta-xylylenediamine, para-xylylenediamine, 1,3-bis(aminomethyl) cyclohexane, 1,4-bis(aminomethyl)cyclohexane, 1,3-bis(aminomethyl)cyclohexane, 1,4-bis(aminomethyl) cyclohexane, 1,3-diaminocyclohexane, 1,4-diaminocylohexane, bis(4-aminocyclohexyl)methane, 2,2-bis(4-aminocyclohexyl)propane, 1,4-piperazine, meta-phenylenediamine, para-phenylenediamine, bis(4-aminophenyl) methane and the like or mixtures thereof. Instead of 1,4-butanediol, there can be substituted ethylene glycol, 1,3-propanediol, 1,4-cyclohexanedimethanol, polytetramethylene ether diol, mixtures of any of the foregoing and the like. All such obvious variations are within the full intended scope of the appended claims.
Copolymers comprising amide units and ester units are prepared by melt phase interchange of diaryl esters of dicarboxylic acids and diamines with dihydric alcohols and diesters of aromatic dicarboxylic acids. The products are tough resins, useful per se as molding compounds, and to compatibilize and toughen other thermoplastic polymers.
2
BRIEF SUMMARY OF THE INVENTION The invention relates to testing a clothes dryer installation to ascertain whether it has a blocked exhaust vent, and particularly for such as have a dryer with a port on the top surface for insertion and removal of a lint filter. In many service calls to fix inoperative clothes dryers, service personnel need to ascertain whether the exhaust vent of the dryer is blocked. The vent is often ,not easily accessible and test equipment is difficult to connect. The present invention provides apparatus and method for easily testing for vent blockage. According to the invention, a service person replaces a lint filter accessible through a top surface port with a test instrument. The instrument senses a pressure difference between its front and back faces and displays an indication of whether the dryer's vent is blocked. BRIEF DESCRIPTION OF THE DRAWING FIG. 1 shows a clothes dryer employing a test instrument according to the invention. FIG. 2 shots partly schematically the air passages of the dryer of FIG. 1. FIG. 3 :shows the test instrument of FIG. 1 in greater detail. FIG. 4 shows schematically circuitry which is part of the test instrument. DETAILED DESCRIPTION The invention may be described more particularly with reference to the Figures. Clothes dryer 10 has an exhaust discharged through vent 11 which is typically a permanently installed tube connected to the back of the dryer with a length of flexible tubing. Dryer 10 has door 12 giving access to clothes chamber 13 enclosed by rotating drum 14 and back plate 15. Duct 16 connects intake opening 17 to back plate 15 where perforations 18 admit air into chamber 13. Perforations 19 in back plate 15 let air flow from chamber 15 into duct 20 which connects to blower 21 connected in turn to duct 22, exhaust port 23 and vent 11. Lint filter removal passage 24 connects duct 20 to filter access port 25 on the top of dryer 10. In normal operation, that is to say when the installation is not being tested for vent blockage, a lint filter assembly is inserted into passage 24 through port 25 so as to close port 25 and interpose a filter in the air path between duct 20 and blower 21. When testing for vent blockage according to the invention, the filter assembly is removed from passage 24 and port 25 and test instrument 26 is emplaced in port 25. Test instrument 26, as shown particularly in FIG. 3 installed in port 25, includes body 27 with peripheral seal 28 which engages port 25 and cooperating with body 27 seals and prevents ambient air from entering passage 24. Passage face 29 of body 27 thus faces into passage 24 and feels the air pressure therein. Ambrose face 30 of body 27 faces outward and feels the ambient pressure. Test passage 31 traverses body 27 from passage face 29 to ambient face 30. Thermistor 32 is placed in test passage 31 where it will be in the stream air passing through test passage 31. Thermistor 32 is connected to circuitry 33, as shown particularly in FIG. 4, which includes signal light 34 and signal light 35 all mounted on board 36. Operation of the test procedure is as follows. A service person wishing to ascertain whether the exhaust vent of a dryer is blocked pulls the filter assembly out from port 25 and inserts test instrument body into port 25 so that passage face 23 faces into passage 29, ambient face 30 faces outward, and seal 28 engages port 25. The circuitry 26 is then powered, which heats thermistor 32, and the dryer is turned on, which runs blower 21 and moves air through the dryer. If there is no blockage in vent 11, the pressure difference between passage 24 and ambient will have some value which can be designated a normal value. The air flow through test passage 31 will have a normal value corresponding to this normal pressure difference, and will in turn cool thermistor by a normal amount. The circuitry 33 will respond to the normally cooled thermistor by lighting green light 35, thereby giving an indication that vent 11 is not blocked. If, on the other hand, vent 11 is blocked, the pressure difference between passage 24 and ambient will have some value which is less than the normal amount. The resulting air flow through test passage and thermistor cooling will be correspondingly less. The circuitry 33 will respond to the condition of the less cooled thermistor to light red sight 34, thereby giving an indication that vent 11 is blocked. Test passage 31, together with thermistor 32 and circuitry thus function as a sensor of pressure difference between passage 24 and the ambient and operate a display of lights 34 and 35 to give and indication of whether there is a blockage in vent 11.
A test instrument inserted into a filter access port of a clothes dryer blocks air flow through the port and has a sensor which senses a pressure difference between its front and back faces. A display responsive to the sensor gives indication of whether the dryer's vent is
3
BACKGROUND OF THE INVENTION This invention relates to positive displacement pumps for delivering a fluid in an accurate and reproducible manner. More particularly, the invention relates to a positive displacement pump that delivers fuel and/or water to a fuel cell which utilizes direct oxidation of a hydrogen-containing fuel for the production of electricity. Over 150 years ago a British physicist conceived of the first fuel cell consisting of an electrochemical reaction of hydrogen and oxygen to produce electricity and water. The electrochemical reaction in the reverse direction is the subject of many secondary education science experiments. In these experiments, the student passes an electrical current through a beaker of water to split water molecules thereby producing hydrogen gas and oxygen gas in a two to one molar ratio. A fuel cell reverses this secondary education learning experience. Simply put, combining hydrogen (a fuel) with oxygen (an oxidant) under the proper conditions, yields water and an electrical charge. The basic chemical equation reveals the most attractive feature of electrical power production using fuel cell technology. The only byproducts of fuel cells that use hydrogen as the fuel and oxygen as the oxidant are water and electricity. The environmental advantages of using such a fuel cell to generate electrical power are readily apparent. Furthermore, relative to internal combustion engines, fuel cells produce very little waste heat and do not need to “idle” thereby operating more efficiently than internal combustion engines. Of course, implementation of fuel cell technology in an economical and practical manner has proved difficult. The air around us contains an abundant supply of oxygen for use as the oxidant. Providing suitable hydrogen fuel, however, is recognized as a primary hurdle facing commercial realization of fuel cell technology, especially in vehicles. Storing pure hydrogen gas or liquid on board a vehicle or at vehicle filling stations is unfeasible at this time. A promising solution to the hydrogen storage problem is the use of an organic compound such as methanol (CH 4 O; CH 3 OH) as the fuel. The methanol fuel is then chemically treated or “reformed” to increase the percentage of hydrogen within the fuel before introducing it into the fuel cell. Many organic compounds are suitable as fuels, including many hydrocarbons and other compounds. Although using such fuels increases the environmentally harmful emissions from the fuel cell, these emissions remain an order of magnitude or two below that of internal combustion engines and still at least half that of battery-powered vehicles (when emissions from generation of power to charge the battery are included). One difficulty with using organic compound fuels is delivering or pumping the fuel through the reforming process and then to the fuel cell. When starting with a liquid fuel such as methanol, the reforming process includes vaporizing the fuel and then introducing the fuel to a catalyst to strip out carbon and oxygen molecules. The reforming process requires that the fuel be pumped into a vaporizer at a high pressure that is directly related to the flow rate of fuel through the reformer. Additionally, the reforming process produces random pressure fluctuations on top of the flow rate-related pressure. Furthermore, in order to optimize efficiency of the fuel cell, it is very important to deliver precise quantities and flow rates of the fuel to the fuel cell. Otherwise, the fuel will be wasted because there will be either too much or too little oxidant in the fuel cell with which to react. Finally, a fluid delivery system should have a short response time for changes in fuel flow rate in order to adequately respond to the power demands of a typical vehicle. Water circulation is another difficulty with fuel cells that use organic-compound fuels. In addition to being a byproduct of the electrochemical reaction at the fuel cell, water may be used as an additive to or humidifier of the fuel (see, e.g., U.S. Pat. No. 5,573,866 to Van Dine et al.), as a coolant in the fuel cell (see, e.g., U.S. Pat. No. 5,503,944 to Meyer et al.) and as an humidifier of the oxidant-air supply (see, e.g., U.S. Pat. No. 5,366,818 to Wilkinson et al.). Thus, it is important to provide a fluid delivery system that is compatible with both organic solvents and water. Traditional systems of delivering fuel, such as a fuel injector used with an internal combustion engine, have proved inadequate for use in a fuel cell with a reformer process In general, these types of systems do not respond well or quickly to a varying and random back pressure such as that produced by a reformer in a fuel cell system. In particular, and among other difficulties, there are three basic shortcomings present in fuel injectors and related systems. First, a fuel injection system depends upon maintaining precise pressures and pressure differentials within the system. Thus, a relatively complicated and expensive pressure regulating mechanism (often including a booster pump and return fuel line) is required within the fuel injection system. Second, the fuel injector system cannot provide reproducible and accurate fuel delivery rates against a variable and/or random back pressure. The fuel injector system delivers fuel by opening a fuel injector valve. A typical fuel injector valve operates electro-mechanically and opens upon a signal from a fuel injector controller. Other fuel injector valves respond to changes in fuel line pressure and upon a sharp increase line pressure, the valve opens and delivers fuel to the engine. In either case, however, the pressure regulator is too slow to respond satisfactorily, and in the face of variable and random back pressure (such as that from a vaporizer or reformer), a constant pressure differential across the valve is difficult to maintain. Without a constant pressure differential, the flow rate from the valve will be uneven. Thus, fuel injection systems cannot provide reproducible and accurate fuel delivery rates against a variable and random back pressure. The third difficulty is that fuel injection systems are incompatible with water and will corrode when exposed to water based solutions. In view of the foregoing, an object of the invention is to provide an improved apparatus for delivering fluid to a fuel cell and a reforming process. Another object of the invention is to provide such apparatus to deliver fluid to the fuel cell against a back pressure that is flow-rate dependent. Yet another object of the invention is to provide such apparatus to deliver fluid to the fuel cell against a back pressure that is randomly variable. Yet still another object of the invention is to provide such apparatus to deliver fluid to the fuel cell at an accurate and reproducible flow rate against a variable and fluctuating back pressure. An additional object of the invention is to provide such apparatus to deliver fluid to the fuel cell with a short response time for flow rate changes. It is another object of the invention to provide such apparatus for delivering both an organic based fluid and a water based fluid to the fuel cell. Yet still a further object of the invention is to provide such apparatus as can be implemented inexpensively. SUMMARY OF THE INVENTION The foregoing objects are among those attained by the invention, which provides in one aspect a system to deliver fluid to a fuel cell. The system includes a source of fluid, a fuel cell and a fluid delivery device in fluid communication therewith. The delivery device includes a pump having a reciprocating piston for drawing fluid from the source, pressurizing the fluid and delivering the fluid to the fuel cell. In a further aspect of the invention, the system includes a reformer system in fluid communication with an outlet of the pump. The reformer system includes a vaporizer which converts the fluid into a gas thereby generating a back pressure with respect to the pump. The back pressure varies with fluid flow rate and the back pressure also has a random component. The pump accurately and reproducibly delivers the fluid to the vaporizer against such back pressure. In another aspect of the invention the fluid delivery system includes a controllable piston driver coupled to the piston for discharging fluid from the pump chamber. The fluid delivery system also includes a controller coupled to the piston driver. The controller causes the driver to discharge the fluid from the chamber at a controllable flow rate. The flow rate may depend on a signal which is based upon the amount of electricity desired from the fuel cell. In yet another aspect of the invention, the pump delivers a water based solvent and another pump delivers a fuel such as methanol. The same type of pump may be used to deliver either fluid to the fuel cell. Additional pumps may be added to the system in parallel to prevent pulsation in the fluid flow. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram of a fluid delivery system for a fuel cell and reformer system in accordance with the present invention. FIG. 2 . is a block diagram of another embodiment of the fluid delivery system of the present invention. FIGS. 3A and 3B are detailed cross-sectional views of the side and top of a pump for use in the fluid delivery system. FIG. 3C is an end view of the pump of FIGS. 3A and 3B. FIG. 4 is an exploded view of the pump of FIGS. 3 A and 3 B. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a block diagram of a fuel cell electrical power system indicated generally by reference numeral 10 . The fuel cell system 10 includes a fluid source 12 , a reformer system 20 , a fuel cell 30 and a fluid delivery system 40 . The fuel cell system 10 is particularly well-suited for use in a vehicle (not shown) because rather than providing a cumbersome and expensive pure hydrogen fuel storage system, the reformer system 20 converts another fuel, such as methanol or natural gas, into a hydrogen-rich fuel on board the vehicle itself Fuels such as methanol are readily stored in tanks similar to currently mass-produced gasoline tanks. Similarly, filling stations could easily be converted to methanol dispensing stations. Thus, the fuel cell system 10 can produce the hydrogen necessary for the electrochemical reaction while the vehicle is being operated. It will be readily recognized, however, that the invention disclosed herein is not limited to use with a vehicle, but may also be used with any electricity-generating fuel cell system. The fluid source 12 provides a fuel 14 to the fluid delivery system 40 . The fluid delivery system 40 includes a positive displacement pump 42 . The pump 42 draws fuel from the source 12 , pressurizes the fuel and discharges it into the reformer system 20 . The reformer system 20 includes a vaporizer 22 and a reformer 24 . The reformer system 20 serves to produce a hydrogen rich gas from the fuel 14 . The hydrogen rich gas 17 is introduced into the fuel cell 30 which combines the hydrogen with an oxidant (preferably oxygen from the air) 18 to generate electricity 19 , water and a relatively small amount of heat. A portion of the electricity 19 produced by the fuel cell may be used to power the fluid delivery system 40 , the reformer system 20 and other components within the fuel cell system. The remainder of the electricity 19 can be used to drive a high-efficiency motor, such as an inductance motor utilizing electromagnets, to power, for example, a vehicle. The fluid source 12 contains fuel 14 which is a fuel suitable for use in a fuel cell electrochemical reaction, such as methanol, natural gas (or methane) or other hydrocarbon*based liquid. The fluid source 12 may instead contain a water based solution in order to cool the fuel cell system or to humidify the fuel 14 or the oxidant 18 . The fluid source 12 includes a tank: or any other storage device capable of holding a water or an organic-compound solution. The fluid source is vented to the atmosphere such that the fuel 14 in the tank is substantially atmospheric. A filter 16 prevents contaminating particles from harming the remainder of the system 10 . The fuel cell 30 may be any fuel cell that oxidizes a hydrogen rich solution and produces electrical energy. Countless fuel cells are known in the art, e.g. U.S. Pat. No. 5,262,249 to Beal et al., and many are suitable for use with this system 10 . Similarly, the reformer system 20 for producing hydrogen rich gas is well known in the art. The byproducts of the reforming process generally include carbon monoxide and carbon dioxide 15 . In order to provide sufficient electrical energy to power a vehicle, the fuel 14 must be provided to the reformer system 20 and then to the fuel cell 30 at a certain flow rate and pressure. To produce sufficient quantities of electricity, the fluid delivery system 40 should provide fuel at flow rates varying from about 0.50 to 850 milliliters (ml) per minute, and more preferably providing a maximum flow rate of about 750 ml/min. Furthermore, for practical application in a vehicle, the fluid delivery system 40 should have a dynamic reaction time of about 100 milliseconds (ms) when transitioning from 10% to 90% of the maximum flow rate. The vaporizer 22 and reformer 24 are such that they produce a back pressure relative to the fluid delivery device 40 . It has been found that a reformer system 20 suitable for generating sufficient hydrogen-rich gas to adequately supply the fuel cell 30 produces as much as 300 psi of back pressure and more generally up to 150 psi of back pressure. The back pressure generated by the reformer system is generally related to the flow rate of the fuel through the vaporizer 22 . In addition to back pressure caused by the flow rate of fuel passing through the reformer system 20 , operational variables within the reformer system cause random back pressure fluctuations as well. These random fluctuations have been found to be between 1 and 10 psi and more generally between 3 and 6 psi. The fluid delivery device 40 includes the pump 42 , a motor 44 and a controller 46 . The pump 42 is a positive displacement pump, preferably including a piston 48 . The piston 48 engages a chamber 46 formed by housing 49 . A spring 50 biases the piston 48 away from a bottom 52 of the chamber. When the piston 48 moves away from the chamber bottom 52 , fuel from the source is drawn into the chamber through inlet 54 . When the piston 48 is driven towards the chamber bottom 52 , the piston forces the fuel through outlet 56 . Check valves 58 , 60 prevent back flow and are located at the inlet 54 and the outlet 56 of the chamber 46 . To provide the required flow rates and pressure, without unduly wearing pump seals, it has been found that a desirable piston diameter for use with a passenger vehicle is between about 1.0 to 1.5 inches. Other sizes for other applications are readily used. Similarly, a piston stroke length is about 0.25 to 0.50 inches. A typical stroke volume for the pump, which is determined by multiplying the piston area by the stroke length, is approximately 0.20 to 0.90 cubic inches. The maximum speed at which the pump operates is generally about 100 to 130 strokes/min. The motor 44 imparts rotational forces on a cam 60 and cam shaft which drives the piston into the chamber 46 . The motor is a standard DC motor or stepper motor and operates on 12 volt power, and, of course, other power supplies having 24 or 48 volts DC may also be used. The cam 60 may be designed so that at a constant rotational speed, fluid is drawn into the chamber quickly and subsequently pressurized and discharged at a desired rate. Of course, those skilled in the art will recognize that means other than a cam may be used to drive the piston 48 . For example, a linear drive or hydraulic drive could be coupled to the piston. Furthermore, depending on the driver means, the spring 50 may be eliminated from the pump 42 . The controller 46 controls the motor 44 to provide accurate and reproducible pump action. The controller 46 operates based upon predetermined commands or may receive an input signal or signals 51 other devices. In a vehicle, for example, the controller 46 is coupled to a gas pedal to control the desired power level of the vehicle. As in a typical automobile, pressing on the gas pedal provides a signal 51 to the controller to pump more fuel to the fuel cell 30 , which in turn generates more electricity to power the vehicle. As will be recognized by those skilled in the art, the flow rate and pressure of the fluid delivered by pump 42 will have at least some pulsation due to the fluid intake portion of the delivery cycle. Although cam 60 , motor 44 and controller 46 design and operation can minimize the pulsation, some pulsation will remain. Two pumps (or more) operating in parallel and out of phase would eliminate such pulsation. See U.S. Pat. No. 3,917,531 to Magnussen, incorporated herein by reference, for an example of such out of phase pump operation. Turning now to FIG. 2, two fluid delivery devices 40 a , 40 b are shown. One delivery device 40 a delivers fuel 14 a to the fuel cell 30 and the other delivery device 40 b provides a water-based solution 14 b to the system. The reference numerals used in FIG. 1 correspond to those used in FIG. 2 and the remainder of the figures, with an “a” suffix on the numeral indicating that it is part of a fuel channel and a “b” suffix on the numeral indicating that it is pan of a water channel. The fluid delivery device 40 b operates in substantially the same manner as the fluid delivery device 40 described with respect to FIG. 1 . The water based solution 14 b pumped by device 40 b may serve a variety of functions in the fuel cell system. As shown in FIG. 2, the water solution 14 b is vaporized by vaporizer 22 b and then directed to the reformer 24 . The vaporized water-based fluid serves to humidify the fuel in the reformer 24 . Other application for the water-based channel include using it to cool the fuel cell (not shown). A return line (not shown) from the fuel cell may be used to recycle the water back to the water source 12 b. The controllers 46 a , 46 b are coupled together to coordinate the water flow rate and the fuel flow rate in the fuel cell system 10 . In many instances it is essential to deliver and maintain a predetermined ratio of water and fuel in the fuel cell system because otherwise the relatively sensitive fuel cell 30 may be damaged. Controllers 46 a , 46 b are preferably powered by the same power source as the motors 44 a , 44 b . Of course, the controllers 46 a , 46 b need not be two separate components. Similarly, the motors 44 a , 44 b and the cams 60 a , 60 b may also be arranged as one component. FIGS. 3A and 3B depict a detailed cross-sectional side view and top view of the pump 42 , and FIG. 4 shows an exploded view of the pump 42 . The housing 49 includes liquid head 49 a , piston back-up 49 b , back-up disk 49 c , and spring housing 49 d secured together with fasteners 51 , 53 . Liquid head 49 a contains the chamber 46 with the chamber bottom 52 . The inlet 54 and the outlet 56 from the chamber are located opposite each other across the chamber. The piston 48 engages the chamber 46 , and back-up ring 70 a and seal 70 b (see also FIG. 4) prevent fluid leakage from chamber 46 . Seal 70 b is made of a standard sealant material, preferably an ultra-high molecular weight polyethylene. The seal 70 b should also be hydrophobic and organic-solvent resistant in order to withstand both a water and fuel environment. The back-up ring 70 a prevents seal 70 b from cold flowing as a result of piston movement and friction. A sleeve 68 provides support to the piston 48 . A piston shaft 72 having a shoulder 73 extends from the piston 48 through the housing 49 and through an bearing housing 74 . The bearing housing 74 mounts to spring housing 49 d with fasteners 76 . The shoulder 73 of the piston shaft 72 engages the spring 50 at one end thereof The other end of spring 50 engages back-up disk 49 c thereby biasing the piston away from the chamber bottom 52 . The spring 50 must be sufficiently strong to draw fluid into the chamber 46 . A piston cup 78 mounts to the end of the piston shaft 72 with a shaft-stop 80 therebetween. The shaft-stop serves to distribute force from the piston cup 78 to the shaft 72 . The piston cup 78 extends outside the bearing housing 74 . Force applied to the piston cup (by, for example, the cam 60 shown in FIG. 1) causes the piston 48 to pressurize fluid in the chamber 46 and discharge the fluid through outlet 56 . A cap 82 contains a linear bearing 84 within bearing housing 74 . The linear bearing 84 maintains a seal for piston cup 78 and provides a surface against which the piston cup 78 moves. The various parts the pump 42 that encounter the fluid being pumped should be both water and organic-solvent compatible. The pump is primarily made of stainless steel or other corrosion resistant materials. FIG. 3C shows an end view of the pump 42 . Check valves 58 , 60 mount to the outlet 54 a seal 92 is provided in check valve 58 and inlet 56 , respectively. A standard high-pressure valve mechanism is provided in the outlet check valve 58 . A standard ball and seat assembly 94 provides the checking mechanism in the inlet check valve 60 . It should be understood that the preceding is merely a detailed description of certain preferred embodiments. It therefore should be apparent to those skilled in the art that various modifications and equivalents can be made without departing from the spirit or scope of the invention.
Described is a system to deliver fluid to a fuel cell. The system includes a source of fluid, a fuel cell and a fluid delivery device in fluid communication therewith. The delivery device includes a pump having a reciprocating piston for drawing fluid from the source, pressurizing the fluid and delivering the fluid to the fuel cell accurately and reproducibly. In a further aspect of the disclosure, there is included a reformer system in fluid communication with an outlet of the pump. The reformer system includes a vaporizer which converts the fluid into a gas thereby generating a back pressure with respect to the pump. The back pressure varies with fluid flow rate and the back pressure also has a random component. The pump accurately and reproducibly delivers the fluid to the vaporizer against such back pressure.
1
FIELD OF THE INVENTION [0001] The present invention relates to the art of heat exchangers, and particularly to heat exchangers that are used for heating physiological infusate or solutions. BACKGROUND OF THE INVENTION [0002] Heat exchangers for warming physiological solutions are known. One such heat exchanger is disclosed in U.S. Pat. Nos. 4,759,749 and 4,878,537, both assigned to the assignee of the instant invention. The heat exchanger disclosed in the '749 and '537 patents has an outer conduit covering an inner conduit that is made of aluminum. End caps seal the outer conduit. A through channel is provided by the inner conduit and another flow channel is provided between the outer wall of the inner conduit and the inner wall of the outer conduit. The outer wall of the inner conduit has a spiral configuration so that the infusate that is to be heated would follow the spiral path established between the outer wall of the inner conduit and the inner wall of the outer conduit. The infusate is therefore heated by convection from the wall of the inner conduit. This heat exchanger works well. However, due to the fact that the inner conduit is made of aluminum, the cost of manufacturing the heat exchanger is relatively high. Moreover, a multi-step manufacturing process is required to effect a spiraled path at the outer wall of the inner conduit and the fitting of the inner conduit to the outer conduit, and to ensure that there is a flow channel established between the outer spiraled wall of the inner conduit and the inner wall of the outer conduit. Furthermore, given that only the inner conduit is heated by the heated water from the heater, the infusate is only convectively heated by the heat at the outer wall of the inner conduit, while at the same time heat loss occurs due to the infusate contacting the inner wall of the outer conduit which is exposed to atmosphere. SUMMARY OF THE PRESENT INVENTION [0003] The present invention heat exchanger has a one piece tubing that is configured to have a central lumen, a middle lumen that surrounds the central lumen, and an outer lumen that surrounds the middle lumen. The tubing is made of medical grade plastics material, such as for example PVC, urethane and Pebax, and can be manufactured by a conventional extrusion method whereby the tubing is extruded from a mold to include the central and concentric middle and outer lumens. A supply fitting is connected to one end of the tubing. This supply fitting has a proximal port, an inlet and an outlet, and is configured to connect the proximal port to the middle lumen, the inlet to the central lumen and the outlet to the outer lumen. A return fitting is connected to the other end of the tubing. The return fitting has a distal port and an internal orifice that establishes a through passageway between the central lumen and the outer lumen of the tubing. The return fitting is further configured to connect the middle lumen to the distal port, so that a through passage extends from the proximal port at the supply fitting to the distal port at the return tubing. [0004] The proximal port is connected to an infusate line so that infusate or physiological solution may be input to the heat exchanger. The inlet and the outlet of the supply fitting are mated to an output port and input port, respectively, of a heater device that is adaptable to heat a fluid to a predetermined temperature and output the temperature regulated fluid through its output port to the inlet of the heat exchanger, and to receive from the outlet of the heat exchanger, via its inlet port, the fluid that has circulated through the heat exchanger for reheating. The distal port at the return fitting outputs the infusate to a patient or a patient line. [0005] With the construction of the heat exchanger of the instant invention, a heated or heating fluid, such as for example heated water, is provided from the heater device to the supply fitting of the heat exchanger. This heated fluid is then fed by the supply fitting to the central lumen of the tubing where, by means of the internal orifice at its distal end, which is at the return fitting, the heated fluid is routed to the outer lumen of the tubing. As the heated fluid from the heater traverses through the central lumen, the central lumen is heated; and as the heated fluid is rerouted to the outer lumen, the outer lumen is heated, albeit the temperature of the heated fluid returned by the outer lumen to the supply fitting is at a lower temperature, due to heat loss, than that fed by the heater device to the supply fitting. The cooler heating fluid is returned to the heater device where it is once more heated to the predetermined temperature and re-circulated back to the heater exchanger. In the meantime, the infusate input to the heat exchanger at the proximal port, which is traversing through the heat exchanger by way of the latter's middle lumen, is heated convectively by the heat being conducted from both the central lumen and the outer lumen. In other words, the infusate that flows through the middle lumen of the heat exchanger tubing is enveloped by heat from the heating fluid with no heat loss to the ambient environment. The infusate thus warmed by the heated fluid is output from the distal port of the returned fitting. [0006] The present invention therefore is directed to a heat exchanger that comprises a tubing having a central lumen, a middle lumen surrounding the central lumen and an outer lumen surrounding the middle lumen. The heat exchanger further includes a supply fitting connected to one end of the tubing. The supply fitting has a proximal port, an inlet and an outlet, and is configured to connect the proximal port to the middle lumen, the inlet to the central lumen and the outlet to the outer lumen. Also included in the heat exchanger is a return fitting connected to the other end of the tubing. The return fitting has a distal port and an internal orifice, and is configured to connect the middle lumen of the tubing to the distal port so that a through path is established between the proximal port of the supply fitting and the distal port of the return fitting. The return fitting further is configured to establish a through passage between the central lumen and the outer lumen via the internal orifice, such that a fluid input to the inlet at the supply fitting would flow from the supply fitting to the central lumen and then be rerouted to the outer lumen and thereafter the outlet at the supply fitting. [0007] The present invention is further directed to a heat exchanger that comprises a tubing having one end fixedly connected to its supply fitting and an other end fixedly connected to a return fitting. The tubing has a central lumen, a middle lumen surrounding the central lumen and an outer lumen surrounding the middle lumen. The supply fitting has an inlet in fluid communication with the central lumen and an outlet in fluid communication with the outer lumen. The return fitting is configured to have an internal orifice for establishing a fluid communication passage between the central lumen and the outer lumen. A proximal port is provided at the supply fitting and a distal port is provided at the return fitting. The proximal and distal ports are connected by the middle lumen, with the proximal port connectable to an infusate line and the distal port connectable to a patient line. The inlet and the outlet at the supply fitting are mateable to an output port and an input port, respectively, of a heater device so that a heated fluid may be output from the heater device to circulate from the central lumen to the outer lumen and then back to the heater device via the input port, so that an infusate that flows through the proximal port, the middle lumen and the distal port is heated by the heated fluid that circulates through the central and outer lumens. [0008] The instant invention is further related to a heat exchanger tube that comprises an elongate tube extruded from a plastics material to have a central lumen, a middle lumen surrounding the central lumen and an outer lumen surrounding the middle lumen. Each of the lumens has a plurality of sections separated by the plastics material, with each of the sections of each of the lumens extending along the length of each of the lumens. One end of the tube is fixedly connected to a supply fitting and the other end of the tube is fixedly connected to a return fitting. A passageway is provided between the central and outer lumen at the return fitting to enable a first fluid to circulate between the central and outer lumens. BRIEF DESCRIPTION OF THE FIGURES [0009] The present invention will become more apparent and the invention itself will be best understood by reference to the following description of the invention taken in conjunction with the following drawings, wherein: [0010] FIG. 1 is a disassembled view of the various components of the instant invention heat exchanger, shown relative to a mount to which the supply fitting of the heat exchanger is coupled; [0011] FIGS. 2A and 2B are side views of the assembled FIG. 1 heat exchanger coupled to the mount of a heater device; [0012] FIG. 3A is a sectional view along section A-A of FIG. 2A ; [0013] FIG. 3B is a cross-sectional view along section B-B of FIG. 2A ; [0014] FIG. 3C is an enlarged view of detail C shown in FIG. 3A ; [0015] FIG. 3D is an enlarged view of detail D shown in FIG. 3A ; [0016] FIG. 3E is a cross-sectional along section E-E shown in FIG. 2B ; [0017] FIG. 3F is an enlarged view of detail F of FIG. 3E ; [0018] FIG. 3G is an enlarged view of detail G shown in FIG. 3E ; [0019] FIG. 4 is a cross-sectional view of the tubing of the instant invention heat exchanger; [0020] FIG. 5A is a perspective view of the core of the supply fitting of the heat exchanger of the instant invention; [0021] FIG. 5B is a cross-sectional view of the core of the supply fitting; [0022] FIG. 6A is a perspective view of the core of the return fitting of the inventive heat exchanger; [0023] FIG. 6B is a cross-sectional view of the core of the return fitting; [0024] FIG. 7A shows in perspective view the fluid paths at the distal end of the heat exchanger sans the physical components; [0025] FIG. 7B is a cross-sectional view of the fluid paths of FIG. 7A ; [0026] FIG. 8 is a view showing the fluid paths of the various fluids at the proximal end of the heat exchanger sans the physical components; and [0027] FIG. 9 is a simplified schematic illustrating the heat exchanger of the instant invention coupled to a heater device. DETAILED DESCRIPTION OF THE INVENTION [0028] With reference to FIG. 1 , the heat exchanger 2 of the instant invention is shown to include a tubing 4 , a supply fitting 6 and a return fitting 8 . Supply fitting 6 is shown to include a core 10 , a housing 12 to which the core is fitted, and a cap 14 that fixedly attaches to the top end of core 10 for providing a sealed environment for the supply fitting. As shown, housing 12 has two hollow arms 12 a and 12 b each fitted with a corresponding gasket 16 , so that arms 12 a and 12 b may be mated to ports 18 a and 18 b , respectively, of a mount 20 that is a part of a heater device 22 , per shown in FIG. 9 . The main part of core 10 is fitted to the inside of housing 12 , and the base 14 b of cap 14 is fixedly secured, for example by bonding, to the proximal end 10 a of core 10 , per shown in FIG. 3A for example. The distal end 12 d of housing 12 is connected to the distal end 4 a of tubing 4 . [0029] Return fitting 8 has a housing 22 , a core 24 fitted in the housing and a cap 26 . Housing 22 has a proximal end 22 a that fixedly attaches to distal end 4 b of tubing 4 . Core 24 is fitted inside housing 22 , and the base 26 b of cap 26 is securely bonded to a base 24 a of core 24 so as to form a sealed environment for return fitting 8 . Given that tubing 4 is sealingly attached to supply fitting 6 per its proximal end 4 a and to return fitting 24 per its distal end 4 b , by capping its proximal port 14 c at cap of 14 and the distal port 26 c at cap 16 , the heat exchanger 2 is sealed against the environment and remains sterile before use. [0030] FIGS. 2A and 2B show the coupling of heat exchanger 2 to mount 20 of a heater device. As shown, cap 14 of supply fitting 6 has a bore for its distal port 14 c . It is at this port that an infusate line 28 , shown in FIG. 9 , is connected to enable an infusate, such as for example an intravenous (IV) fluid or other physiological fluids, to be introduced to the heat exchanger 2 . The infusate is conveyed along the heat exchanger 2 and exits at a bore that forms the distal port 26 c at cap 26 of the return fitting 8 . A patient line, such as 30 shown in FIG. 9 , may be connected to distal port 26 c for conveying the infusate to a patient. [0031] With reference to the cross-sectional view of section A-A in FIG. 3A and the cross-sectional view of FIG. 4 , tubing 4 is shown to have a central lumen 4 a , a middle lumen 4 b that surrounds the central lumen 4 a , and an outer lumen 4 c that surrounds the middle lumen 4 b . The diameter of the central lumen 4 a is much larger than the respective widths of the middle and outer lumens. Note that the concentric middle lumen 4 b and outer lumen 4 c each comprise a plurality of sections, for example 4 b 1 , 4 b 2 and 4 b 3 for the middle lumen 4 b , and 4 c 1 , 4 c 2 and 4 c 3 for the outer lumen 4 c . The various sections of lumens 4 b and 4 c extend along the length of each of the lumens. The multiple sections of lumens 4 b and 4 c are separated by the plastics material in a spoke wheel fashion, which is effected when tubing 4 is extruded from a medical plastics material such as PVC, urethane and Pebax by a conventional extrusion method. To enable tubing 4 to be fixedly connected to housing 12 of supply fitting 6 and housing 22 of return fitting 8 in a manner that allows the warming of the infusate, the central portion of tubing 4 is extended at its proximal end 4 a and its distal end 4 b , per shown in FIG. 1 and the cross-sectional views of FIGS. 3A and 3E . [0032] With reference to FIGS. 3C and 3F illustrating the enlarged details C and F, respectively, the proximal end of the heat exchanger is shown to include cap 14 , housing 12 and core 10 of supply fitting 6 . Base 10 a of core 10 is shown to form an upside down well 10 i that is fixedly attached to base 14 b of cap 14 . Well 10 i of core 10 extends to a passageway 10 c that is connected to the middle lumen 4 b of tubing 4 . The central lumen 4 a of tubing 4 is shown to be connected to core 10 and exits to a space 28 , which leads to the inlet of supply fitting 6 represented by the hollow arm 12 a shown in FIG. 1 . Outer lumen 4 c is shown to extend into a passageway 30 defined by the external wall of a tubular extension 10 b of core 10 and the inside wall of housing 12 . Supply fitting 6 is also shown to be grasped by arms 20 a and 20 b of mount 20 in FIG. 3C . [0033] The cross-sectional view of enlarged detail F of FIG. 3F shows the mating of outlet 12 b of supply fitting 6 to mount 20 . As shown, the infusate is fed through bore 14 c of cap 14 into the cavity formed by well 10 i , per directional arrow 32 . The infusate is then directed to the passageway 10 c at tubular extension 10 b of core 10 , and from there to the middle lumen 4 b. [0034] With reference to FIGS. 3D and 3G , which are the enlarged details D and G, respectively, of FIGS. 3A and 3E , the distal end of the heat exchanger where the return fitting 8 is connected to tubing 4 is illustrated. As shown, base 24 a of core 24 is fixedly bonded to base 26 b of cap 26 . The well area formed by base 24 a of core 24 is designated 24 c . It is there that the infusate input from proximal port 14 c of cap 14 at supply fitting 6 is fed, by means of middle lumen 4 b . The infusate collected at cap 24 b is output from distal port 26 c to the patient line 30 ( FIG. 9 ), per directional arrow 34 . [0035] As further shown in FIG. 3D , and also FIGS. 8 a and 8 b , between the inner wall of housing 22 and the outer wall of tubular extension 24 b there is a circular space 36 that connects to outer lumen 4 c of tubing 4 . This circular space is where the heated fluid that flows through central lumen 4 a is being rerouted to outer lumen 4 c for return to the supply fitting, and from there returned to the heater device for reheating. The space at supply fitting 6 to which the cooler heating fluid is returned had previously been designated as space 30 . Thus, the hot recirculating fluid, i.e., the heated water for example, is fed by heater device 22 from its output port 18 a to supply fitting 6 , which routes it to central lumen 4 a of tubing 4 . The heated fluid is then returned to heater device 22 by means of outer lumen 4 c. [0036] A cross-sectional view illustrating the flow of the heated fluid from the heater device to the heat exchanger, and the return of the heated fluid back to the heater device at supply fitting 6 is shown in FIG. 3B . The feeding of the heated fluid from the heater device to the supply fitting, and the routing of the heated fluid and the infusate to tubing 4 are best discussed with reference to core 10 for the supply fitting shown in FIGS. 5A and 5B . [0037] As shown, core 10 for supply fitting 6 has a base portion 10 a and a tubular extension 10 b . Base 10 a has a well area 10 i that, together with cap 14 shown in FIG. 3C , provide a cavity whereto the infusate from an infusate line is fed. Well 10 i extends to a passageway 10 c at tubular extension 10 b . Passageway 10 c in turn is connected to middle lumen 4 b , so that the infusate can be conveyed from proximal port 14 c , shown in FIG. 3 c , to middle lumen 4 b. [0038] Core 10 also has a space 10 d that forms a part of the inlet that connects to output port 18 a of mount 20 of the heater device. Space 10 d is aligned with hollow arm 12 a of housing 12 , when core 10 is fitted within housing 12 . Thus, the heated fluid output from output port 18 a of the heater device is fed through inlet 12 a into space 10 d , and from there flows to a passageway 10 e that is connected to central lumen 4 a of tubing 4 . The flow of the heated fluid from the heater device is shown per directional arrow 38 . Space 10 d is defined by the back wall 10 f of base 10 a and a flange 10 g , and of course also the inside wall of housing 12 when core 10 is fitted therein. [0039] Core 10 for supply fitting 6 further has a space 10 h , when core 10 is fitted within housing 12 , that is defined by the back wall 10 f of base 10 d , the underside 10 g ′ of flange 10 g , the outer wall of tubular extension 10 b , designated 10 b ′, and the inside wall, designated by the dotted lines 12 e in FIG. 5 a , of housing 12 . This space 10 h is communicatively connected to outer lumen 4 c of tubing 4 so that it in effect, along with hollow arm 12 b , provide the outlet for supply fitting 6 to mate to inlet port 18 b of mount 20 . It is therefore through this outlet that the heated fluid, now having been cooled due to heat dissipation as it flows through the heat exchanger, is returned to heater device 22 for reheating, and subsequent re-circulation through the heat exchanger. [0040] With reference to FIGS. 6A and 6B , core 24 for the return fitting has a base 24 a and a tubular extension 24 b . As was the case with supply fitting core 10 , base 24 a of return fitting core 24 provides a well area 24 c that is fixedly coupled to base 26 b of cap 26 , which is connected to patient line 30 for outputting the infusate to the patient. As shown, cavity 24 c extends into a circumferential passageway 24 d , that in turn is connected to the middle lumen 4 b of tubing 4 . A fluid communication path is thereby established between cavity 24 c and passageway 24 d of return fitting 8 , middle lumen 4 b , and passageway 10 c and cavity 10 i of supply fitting core 10 . [0041] There is formed at return fitting core 24 a central passage 24 e that ends at the back wall 24 f of base 24 a . An internal orifice 24 g is formed at the lowermost portion of passageway 24 e that connects passageway 24 e to a space 24 h that is defined by the back wall 24 f of base 24 a , the outside wall 24 b ′ of tubular extension 24 b and the inside wall of housing 22 , designated by the dotted line 22 c in FIG. 6A . Space 24 h in turn is connected to outside lumen 4 c , so that a through passage extends from space 24 h to lumen 4 c , and from there to defined space 10 h at supply fitting 6 , per shown in FIG. 5A , so that the heated fluid from central lumen 4 a that flows through passage 24 e , per shown by directional arrow 40 , would pass through orifice 24 g , and be rerouted into defined space 24 h , per shown by directional arrow 42 . The rerouted heated fluid is then directed to outer lumen 4 c of tubing 4 , and from there to defined space 10 h of supply fitting 6 for return to the input port 18 b of the heater device. [0042] The respective flows of the infusate and the heated recirculating fluid are shown in FIGS. 7A , 7 B and 8 . For the sake of clarity, only the fluids are shown. [0043] With reference to the distal end of the heat exchanger shown in FIGS. 7A and 7B , note that the infusate (IV) 44 flows from the middle lumen, designated 44 a , to the tubular extension of the return fitting, identified as 44 b , and from there to the base of the return fitting, designated 44 c . The infusate next is output to the cavity formed by the return fitting cap and the base of the return fitting core, designated 44 d , and then out to the patient line. [0044] In the meanwhile, the heated fluid, for example heated water, flows through the central lumen, designated 46 in FIGS. 7A and 7B . As best shown in FIG. 7A , the hot fluid traverses down the central lumen. Due to internal orifice 24 g provided at return fitting core 24 ( FIGS. 6A and 6B ) that creates a passageway between the central lumen and the outer lumen, the hot fluid is rerouted, per indicated by directional arrow 48 , from the central lumen to the outer lumen. By the time that the heated fluid gets to the distal end of the heat exchanger, it has lost a measurable amount of heat due to heat dissipation. Therefore, the return fluid, designated 50 , has a cooler temperature than heated fluid 46 flowing along the central lumen of the heat exchanger. Nonetheless, there continues to be heat in the cooler heating fluid as it traverses to the proximal end of the heat exchanger where the supply fitting is. [0045] With reference to FIG. 8 , it can be seen that hot fluid 46 from the heater is fed to the heat exchanger at the latter's inlet. Being guided by space 10 d of the supply fitting ( FIGS. 5A and 5B ), hot fluid 46 is fed to the tubular extension of the supply fitting core, and then the central lumen of the tubing, per shown by the directional arrow 52 . The being returned cooler heating fluid 50 is shown to flow along the outer lumen of the tubing and also space 10 h defined by the supply fitting core and the supply fitting housing, so that the cooler heating fluid is returned to the outlet of the heat exchanger and the input port of the heater device, per shown by the direction arrow 54 . In the meanwhile, infusate 44 is fed from an infusate line to the proximal port of the supply fitting, designated 44 e , flows into the cavity defined by the supply fitting cap and the supply fitting core base, designated 44 f , and from there through the tubular extension of the supply fitting core, designated 44 g , and finally to the central lumen, previously designated 44 a in FIGS. 7A and 7B . [0046] As the middle lumen of the heat exchanger tube concentrically bounds the central lumen and is in turn concentrically bounded by the outer lumen, when the infusate flows through the central lumen, heat exchange is provided thereto from both directions at both its inside and outside perimeters due to the recirculating heating fluid flowing along the central lumen and the outer lumen. The effective heat exchange to the infusate by the instant invention tubing is maximized due to the narrow annular shape of the central lumen, which provides a large effective perimeter for heat exchange from the recirculating fluid to take place. Further, the temperature gradient of the hot recirculated fluid in the central lumen radiates outwards toward the infusate for maximally warming the infusate. The heating of the heat exchanger of the instant invention is therefore quite efficient in that there is no direct heat loss by the hot fluid flowing through the central lumen, as it is surrounded by the infusate flowing through the central lumen. [0047] FIG. 9 shows the coupling of the heat exchanger to a heater device 22 . As shown, outlet 12 b and inlet 12 a of supply fitting 6 are mated to inlet port 18 b and output port 18 a , respectively, of mount 20 of heater device 22 . The heater device 22 may be a Level 1 H-1200 Fast Flow Fluid Warmer. The returned fluid from the heat exchanger is first routed to a reservoir 56 , and from there to a heater 58 . A pump 60 pumps the heated fluid to output port 18 a , and from there to inlet 12 a of the heat exchanger for circulation as discussed above. Pump 60 , instead of being placed at the output line of the heater device, may also be placed at the input line to enhance the inflow of the cooler heating fluid being returned to heater device 22 . [0048] An infusate line 28 is connected to proximal port 14 c of supply fitting 6 , while a patient line 30 is connected to distal port 26 c at return fitting 8 of the heat exchanger. As discussed above, the infusate, as it flows from the proximal end to the distal end of the heat exchanger via the central lumen, is heated both by the central lumen through which the hot fluid flows and the outer lumen through which the now cooler heating fluid is being returned to the heater device. As the heating fluid is continuously circulated through the heat exchanger, the temperature of the fluid is kept to a predetermined temperature so that the amount of heat for warming the infusate or other physiological fluids fed to the heat exchanger can be readily regulated. [0049] Inasmuch as the present invention is subject to many variations, modifications and changes in detail, it is intended that all matters described throughout this specification and shown in the accompanying drawings be interpreted as illustrative only and not in a limiting sense. Accordingly, it is intended that the invention be limited only the spirit and scope of the hereto appended claims.
A heat exchanger has a multi-lumen tubing having one end connected to a supply fitting and another end connected to a return fitting. The tubing has a central lumen, a middle lumen that surrounds the central lumen and an outer lumen that surrounds the middle lumen. The supply fitting has an inlet, an outlet and a proximal port wherethrough an infusate is input to the heat exchanger. The supply fitting is configured such that its inlet is connected to the central lumen, its outlet connected to the outer lumen, and its proximal port connected to the middle lumen of the tubing. The return fitting is configured to establish a through passage between the central lumen and the outer lumen of the tubing so that a heating fluid fed through the supply fitting to the central lumen is returned to the supply fitting by way of the outer lumen. The return fitting further has a distal port configured to connect to the central lumen of the tubing, so that the infusate fed to the proximal port of the supply fitting may be output from the distal port of the return fitting, after passing through the central lumen of the tubing. As the infusate traverses along the heat exchanger, it is heated by the heating fluid that flows along the central lumen, and also by the rerouted heating fluid that flows along the outer lumen of the tubing. The heat exchanger is fluidly coupled to a heater by its inlet and outlet so that the temperature of the heating fluid for warming the infusate is maintained at a predetermined temperature.
0
[0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 09/517,808, filed Mar. 2, 2000, attorney docket 2229/106, which application is herein incorporated by reference in its entirety. TECHNICAL FIELD [0002] The present invention pertains to hybrid electric vehicles utilizing an external combustion engine and in particular, a Stirling cycle engine. BACKGROUND OF THE INVENTION [0003] In response to energy and environmental issues and concerns, hybrid electric vehicles, such as buses and cars, have been developed in an attempt to provide efficient, low emission vehicles. In general, a hybrid electric vehicle combines a combustion engine with a battery and an electric motor. Typically, the combustion engine is an internal combustion engine. Some hybrid electric vehicles have been developed using external combustion engines, such as a Stirling engine. [0004] As mentioned, one type of external combustion engine which may be used in a hybrid electric vehicle is a Stirling cycle engine. A Stirling cycle engine produces both mechanical energy and heat energy appropriate for space heating. The history of Stirling cycle engines is described in detail in Walker, Stirling Engines, Oxford University Press (1980), herein incorporated by reference. The principle of operation of a Stirling engine is well known in the art. Stirling cycle engines have not generally been used in practical applications, such as hybrid electric vehicles, due to several daunting engineering challenges in their development. These involve such practical considerations as efficiency, vibration, lifetime and cost. [0005] For example, Stirling cycle engines generally make poor traction motors due to poor throttle response and limited power in comparison to an internal combustion. The response time of a Stirling cycle engine is limited by the heat transfer rates between the external combustion gases and the internal working fluid of the engine and may be on the order of 30 seconds. The response time of an internal combustion engine, on the other hand, is very short because the combustion gas is the working fluid and can be directly controlled by the fuel flow rate. Prior attempts to increase the responsiveness of a Stirling cycle engine provided a variable dead space for the working fluid as described in U.S. Pat. No. 3,940,933 to Nystrom and U.S. Pat. No. 4,996,841 to Meijer or controlled the pressure of the working fluid as described in U.S. Pat. No. 5,755,100 to Lamos. The foregoing references are hereby incorporated by reference in their entirety. However, both these approaches tend to increase the complexity, size, and weight of the engine design. SUMMARY OF THE INVENTION [0006] In accordance with an embodiment of the invention, a personal vehicle for transporting a user over a surface includes a support for supporting the user, a ground contacting module having at least one ground contacting member and a drive arrangement for causing locomotion of the support, ground contacting module and user over a surface. The drive arrangement includes an external combustion engine for generating mechanical energy and thermal energy, a generator for converting the mechanical energy produced by the external combustion engine to electrical energy and an energy storage device for storing power provided by the generator and for providing power to the external combustion engine and the assembly. The external combustion engine and the generator may be housed in a hermetically sealed pressure vessel. In addition, the personal vehicle includes a controller for controlling a total power load placed on the external combustion engine so as to provide short term regulation of external combustion engine parameters. [0007] In one embodiment, the external combustion engine is a Stirling cycle engine. The thermal energy produced by the external combustion engine may be used to provide heat to an area surrounding the personal vehicle. In another embodiment, the personal vehicle includes a power output coupled to the energy storage device for providing power to an external load. In yet another embodiment, the personal vehicle has modes in which it is not statically stable. The personal vehicle may have balancing capability on lateral and foe-aft places defined by the support. [0008] In another embodiment of the invention a personal vehicle for transporting a user over a surface includes a support for supporting the user, a ground contacting module having at least one ground contacting member and a drive arrangement for causing locomotion of the support, ground contacting module and user over a surface. The drive arrangement includes an external combustion engine for generating mechanical energy and thermal energy, a generator for converting the mechanical energy produced by the external combustion engine to electrical energy and an energy storage device for storing power provided by the generator and for providing power to the external combustion engine and the assembly. The vehicle further includes a power output coupled to the energy storage device for providing power to an external load, while the vehicle is stationary. The vehicle may include an inverter coupled to the energy storage device so that alternating current power may be derive for an external load. BRIEF DESCRIPTION OF THE DRAWINGS [0009] The invention will be more readily understood by reference to the following description taken with the accompanying drawings, in which: [0010] [0010]FIG. 1 is a schematic diagram of a personal hybrid electric vehicle using a Stirling engine in accordance with an embodiment of the invention; [0011] [0011]FIG. 2 is a schematic diagram of a personal hybrid electric vehicle in accordance with an alternative embodiment of the invention; [0012] [0012]FIG. 3 is a schematic diagram of a personal hybrid electric vehicle in accordance with an alternative embodiment of the invention; [0013] [0013]FIG. 4 is a schematic block diagram of the power, drive and control components for the personal hybrid electric vehicle of FIG. 1 in accordance with an embodiment of the invention; [0014] [0014]FIG. 5 is a cross section view of a Stirling cycle engine in accordance with a preferred embodiment of the invention; [0015] [0015]FIG. 6A is a schematic block diagram of the power control system for the engine of the personal vehicle of FIG. 1 in accordance with an embodiment of the invention [0016] [0016]FIG. 6B is a schematic block diagram of a method of control for the power control system of FIG. 6A in accordance with an embodiment of the invention; [0017] [0017]FIG. 7 illustrates the circuitry for the power control system in FIG. 6A in accordance with an embodiment of the invention; [0018] [0018]FIG. 8 is a schematic block diagram of the power control system of the personal vehicle of FIG. 1 including a burner controller in accordance with an embodiment of the invention; [0019] [0019]FIG. 9 is a schematic block diagram of the power control system of the personal vehicle of FIG. 1 including a burner controller in accordance with an alternative embodiment of the invention; [0020] [0020]FIG. 10 a is a side view in cross section of the burner and exhaust heat recovery assembly, in accordance with an embodiment of the invention; [0021] [0021]FIG. 10 b shows a perspective top view of a heater head including heat transfer pin arrays in accordance with an embodiment of the invention; [0022] [0022]FIG. 10 c shows a perspective view of an alternative heater head including heater transfer tubes in accordance with an embodiment of the invention; [0023] [0023]FIG. 11 a shows a cross-sectional view from the side of a fuel intake manifold for a Stirling cycle engine in accordance with a preferred embodiment of the invention; [0024] [0024]FIG. 11 b shows a cross-sectional view from the top of the fuel intake manifold of FIG. 11 a taken through cut BB; and [0025] [0025]FIG. 11 c is a cross-sectional view from the top of the fuel intake manifold of FIG. 1 a taken through cut AA, showing the fuel jet nozzles. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0026] In accordance with an embodiment of the invention, a personal vehicle is provided that includes a hybrid Stirling engine/generator to provide power to the vehicle. The hybrid Stirling engine/generator as described herein has the benefits of a Stirling engine such as low emissions, long life and quiet operation. In addition, the hybrid Stirling engine/generator has good throttle response and instant power as required by a vehicle for operation. The hybrid Stirling engine/generator is advantageously of a small size (5 kW or less) with ultra low emissions and may be implemented in a variety of personal vehicles. [0027] The invention may be implemented in a wide range of embodiments. FIG. 1 is a schematic diagram of a personal hybrid electric vehicle using a Stirling engine in accordance with an embodiment of the invention. A personal hybrid electric vehicle as used in the description and the following claims means a vehicle with a weight less than 1400 lbs, with an engine power output less than 5 kW and at least one ground contacting member, such as a wheel. FIG. 1 shows a scooter type personal vehicle 100 with two ground contacting members 110 . The scooter 100 is powered by an external combustion engine 105 , preferably a Stirling cycle engine. A support 104 covers the components of the scooter and serves to support a user of the scooter 100 . The support 104 includes a seat 114 on which a user may sit while using the vehicle. [0028] Scooter 100 includes a drive arrangement to provide the power to cause the locomotion of the scooter. The drive arrangement includes a Stirling cycle engine and generator combination 105 and an energy storage device 107 . The outputs of the Stirling cycle engine 105 during operation typically include both mechanical energy and residual heat energy. The Stirling cycle engine 105 is coupled to the generator and the generator/engine combination may be housed in a sealed pressure vessel. Alternatively, the generator may be external to the pressure vessel containing the engine. The pressure vessel contains a high pressure working fluid, preferably helium, nitrogen or a mixture of these gases at 20 to 30 atmospheres pressure. The generator converts the mechanical energy produced by the Stirling cycle engine to electrical energy. The working gas of the Stirling engine is heated by heat from an external thermal source, such as burner 102 . Burner 102 burns a fuel provided by a fuel supply 103 . [0029] The Stirling cycle engine and generator combination 105 produces electrical energy that may be used to power the scooter. Accordingly, the generator is used to power a motor 106 coupled to the ground contacting members 110 . The electrical energy produced is also stored in the energy storage device 107 . In a preferred embodiment, the energy storage device is a rechargeable battery. The energy storage device may also be used to power the scooter 100 . Accordingly, energy storage device 107 is coupled to the motor 106 . [0030] Scooter 100 may also include a radiator 108 coupled to the Stirling cycle engine 105 to provide cooling during operation of the engine. A controller 109 is coupled to the Stirling cycle engine and generator 105 , a fuel regulator (not shown, a blower (not shown) and the energy storage device 107 . Controller 109 is used to control the power output produced by the Stirling engine and generator. An electrical output 114 is optionally connected to the energy storage device 107 to provide electricity to an external load when the scooter is not being used for transportation. [0031] [0031]FIG. 2 and FIG. 3 show alternative forms of a personal hybrid electric vehicle. FIG. 2 shows an exemplary electric wheelchair. A support arrangement 212 includes a chair, on which a user 213 may be seated. A pair of laterally disposed ground contacting members 211 is used to suspend the user 213 over a surface with respect to which the user is being transported. In a further embodiment, the hybrid Stirling engine/generator may be used to replace the battery pack used in may standard electric wheelchairs. FIG. 3 shows a scooter on which a user stands. A support arrangement includes a platform 311 on which the user stands and holds grip 312 on handle 313 attached to the platform. The scooter also includes ground contacting members 314 . In a further embodiment, the hybrid Stirling engine/generator may be used in a personal vehicle that includes a set of pedals on the support arrangement that may be used by the user during operation. [0032] In alternative embodiments, the personal vehicle is configured such that the vehicle lacks inherent stability at least a portion of the time with respect to a vertical in a fore-aft plane but is relatively stable with respect to a vertical in the lateral plane. These dynamically stabilized personal vehicles include a control system that actively maintains the stability of the personal vehicle while the vehicle is operating. The control system maintains the stability of the personal vehicle by continuously sensing the orientation of the vehicle, determining the corrective action to maintain stability, and commanding the wheel motors to make the corrective action. Dynamically stabilized vehicles are discussed in more detail in U.S. Pat. Nos. 5,701,965 and 5,971,091, both of which are herein incorporated by reference. [0033] [0033]FIG. 4 is a schematic block diagram of the power, drive and control components of the personal vehicle of FIG. 1, in accordance with an embodiment of the invention. As discussed above with respect to FIG. 1, the personal vehicle includes a Stirling engine 401 coupled to a generator 402 . The outputs of the Stirling cycle engine 401 during operation include both mechanical energy and residual heat energy. Heat produced in the combustion of a fuel in a burner 404 is applied as an input to the Stirling cycle engine 401 , and partially converted to mechanical energy. The unconverted heat or thermal energy accounts for 65 to 85% of the energy released in the burner 404 . This heat is available to provide heating to the local environment around the scooter. The exhaust gases are relatively hot, typically 100 to 300° C., and represent 10 to 20% of the thermal energy produced by the Stirling engine 401 . The cooler rejects 80 to 90% of the thermal energy at 10 to 40° C. above the ambient temperature. The heat is rejected to either a flow of water, or, more typically, to the air via a radiator 407 . [0034] As mentioned above, burner 404 combusts a fuel to produce hot exhaust gases which are used to drive the Stirling engine 401 . A controller 408 is coupled to the burner 404 and a fuel supply 410 . Controller 408 delivers a fuel from the fuel supply 410 to the burner 404 . The controller 408 also delivers a measured amount of air to the burner 404 to advantageously ensure substantially complete combustion. The fuel combusted by burner 404 is preferably a clean burning and commercially available fuel such as propane. A clean burning fuel is a fuel that does not contain large amounts of contaminants, the most important being sulfur. Natural gas, ethane, propane, butane, ethanol, methanol and liquefied petroleum gas (“LPG”) are all clean burning fuels when the contaminants are limited to a few percent. One example of a commercially available propane fuel is HD-5, an industry grade defined by the Society of Automotive Engineers and available from Bernzomatic. Alternatively, the fuel may be any commercially available liquid fuel including diesel, gasoline, kerosene, methanol and ethanol. In accordance with an embodiment of the invention, and as discussed in more detail below, the Stirling engine 401 and burner 404 provide substantially complete combustion in order to provide high thermal efficiency as well as low emissions. The characteristics of high efficiency and low emissions are highly desired characteristics of a hybrid electric vehicle. [0035] Controller 408 also controls the power output produced by the Stirling cycle engine 401 and generator 402 . Generator 402 is coupled to a crankshaft (not shown) of Stirling engine 401 . In an alternative embodiment, the external combustion engine 401 is a free piston Stirling engine and the generator is coupled mechanically to the pistons of the Stirling engine. The term “generator”, as used in the specification and in any appended claims, unless context requires otherwise, will encompass the class of electric machines such as generators wherein mechanical energy is converted to electrical energy or motors wherein electrical energy is converted to mechanical energy. The generator 402 is preferably a permanent magnet brushless motor. An energy storage device 413 is coupled to the controller 408 and is used to provide power at various points during operation. For example, energy storage device 413 may be used to provide starting power for the personal transport vehicle 100 as well as direct current (“DC”) or alternating current (“AC”) power to a wheel motor. In a preferred embodiment, the energy storage device 113 is a rechargeable battery. In an alternative embodiment, the personal transport vehicle may include an AC outlet to provide power to an external load. An inverter 416 is coupled to the battery 413 in order to convert the DC power produced by battery 413 to AC power. [0036] In the course of operation, Stirling engine 401 also produces heat from, for example, the exhaust gases of the burner 404 as well as the supply and extraction of heat from a working fluid. Accordingly, the excess heat produced by the Stirling engine 401 may be used to advantageously heat the atmosphere surrounding the personal vehicle or the user of the personal vehicle. In this manner, the Stirling engine may be used to provide both electrical power and heat for the vehicle. [0037] The operation of Stirling cycle engine 401 will now be described in more detail with respect to FIG. 5 which is a cross-sectional view of a Stirling engine in accordance with an embodiment of the invention. The configuration of Stirling engine 401 shown in FIG. 5 is referred to as an alpha configuration, characterized in that a compression piston 500 and an expansion piston 502 undergo linear motion within respective and distinct cylinders: compression piston 500 in a compression cylinder 504 and expansion piston 502 in an expansion cylinder 506 . The principle of operation of a Stirling engine configured in an “alpha” configuration and employing a first “compression” piston and a second “expansion” piston is described at length in U.S. Pat. No. 6,062,023 which is herein incorporated by reference. The alpha configuration is discussed by way of example only, and without limitation of the scope of any appended claims. [0038] In addition to compression piston 500 and expansion piston 502 , the main components of Stirling engine 401 include a burner (not shown), a heater heat exchanger 522 , a regenerator 524 , and a cooler heat exchanger 528 . Compression piston 500 and expansion piston 502 , referred to collectively as pistons, are constrained to move in reciprocating linear motion within respective volumes 508 and 510 defined laterally by compression cylinder 504 and expansion cylinder liner 512 . The volumes of the cylinder interior proximate to the burner heat exchanger 522 and cooler heat exchanger 528 will be referred to, herein, as hot and cold sections, respectively of engine 501 . The relative phase (the “phase angle”) of the reciprocating linear motion of compression piston 500 and expansion piston 502 is governed by their respective coupling to drive mechanism 514 housed in crankcase 516 . Drive mechanism 514 may be one of various mechanisms known in the art of engine design which may be employed to govern the relative timing of pistons and to interconvert linear and rotary motion. For additional information relating to a preferred drive mechanism 514 , see U.S. Pat. No. 6,253,550, “Folded Guide Link Stirling Engine,” which is incorporated herein by reference. [0039] Compression piston 500 and expansion piston 502 are coupled, respectively, to drive mechanism 514 via a first connecting rod 518 and a second connecting rod 520 . The volume of compression cylinder 508 is coupled to cooler heat exchanger 528 via duct 515 to allow cooling of compressed working fluid during the compression phase. Duct 515 , more particularly, couples compression volume 508 to the annular heat exchangers comprising cooler heat exchanger 528 , regenerator 524 , and heater heat exchanger 522 . The burner (not shown) combusts a fuel in order to provide heat to the heater heat exchanger 522 of a heater head 530 of the Stirling engine. The expansion cylinder and piston are disposed within a heater head 530 such that the working fluid in the expansion cylinder may be heated via the heater heat exchanger 522 . For additional information relating to a preferred configuration of a burner, regenerator 524 and heater head 530 , see U.S. Pat. No. 6,381,958, entitled “Stirling Engine Thermal System Improvements,” which is incorporated herein by reference in its entirety. [0040] Returning to FIG. 4, as mentioned, the Stirling cycle engine 401 and generator 402 may be disposed within a pressure vessel 418 . The pressure vessel 418 contains a high pressure working fluid, preferably helium or nitrogen at 20 to 30 atmospheres pressure. The expansion cylinder and piston (shown in FIG. 5) of the Stirling engine 401 extend through the pressure vessel 418 and a cold collar (or cooler) 403 . In an alternative embodiment, the cold collar may be disposed within the pressure vessel 418 . The end of the expansion cylinder (including heater head 530 ) is contained within the burner 404 . The cold collar 403 circulates a cooling fluid through cooling lines 406 and through radiator 407 . The cooling fluid is pumped through the cold collar 403 by a cooling pump 405 . A fan 411 may be used to force air past the radiator 407 thereby heating the air and cooling the cooling fluid. The heated air may then be forced through openings in the body of the personal vehicle to heat the surrounding area including the person on the personal vehicle. In alternative embodiments, the excess heat created by the combustion within burner 404 may be directly provided to the surrounding ambient air. [0041] The pressure vessel 418 has a pass-through port for an electrical connection 419 between the generator 402 contained within the pressure vessel 418 and the controller 408 . The controller 408 supplies power to cooling pump 405 and fan 411 through power supply lines 415 . The controller 408 also controls the power output of the Stirling engine 401 and generator 402 as well as the charge level of the battery 413 by varying the speed and temperature of the Stirling engine. Controller 408 provides command signals to the burner 404 in order to control the temperature of the Stirling engine 401 . Controller 408 also provides command signals to generator 402 in order to control the speed of the Stirling engine 401 . In one embodiment, the controller 408 varies the temperature of the heater head of the Stirling engine to meet the power demands, while the engine is allowed to operate at speeds permitted by a simple rectifier. The temperature of the heater head may be controlled by varying the fuel flow. The temperature of the heater head, however, is subject to maximum temperature limits. Alternatively, the controller 408 varies the speed of the Stirling engine to meet the power demands, while the heater head temperature is held constant at the maximum allowed temperature. In other embodiments of the invention, the generator is disposed outside the pressure vessel and a sealed coupling between engine and generator is effected. [0042] Preferably, the power output of generator 402 and Stirling engine 401 are controlled using controller 408 so as to maintain the optimal charge and voltage levels in the battery 413 . Electrical loads (e.g., the motor used to propel the ground contacting members of the vehicle) will reduce the charge and voltage of the battery 413 causing the controller 408 to command additional power from the engine. FIG. 6A is a schematic block diagram of the power control system included in the controller 408 (shown in FIG. 4) in accordance with an embodiment of the invention. The power control system controls the speed and temperature of the Stirling engine in order to provide the necessary power to meet the demand (or load) placed on the Stirling engine and generator by the wheel motor of the scooter and maintaining the charge level of the battery. The power control system as shown in FIG. 6A includes a motor/generator 602 , a motor-amplifier 605 , and a battery 613 . [0043] As discussed above with respect to FIG. 4, the generator 602 is coupled to the crankshaft of a Stirling engine (not shown). The Stirling engine provides mechanical power (P mech ) to the generator 602 which in turn converts the mechanical power to three-phase electrical power. Generator 602 also, as discussed in more detail below, acts as an adjustable load on the engine in order to control the speed of the engine. Generator 602 delivers the three-phase electrical power to motor-amplifier 605 . Motor-amplifier 605 transfers electrical power produced by the motor generator 602 to a high voltage DC bus (P amp ). The power provided to the high voltage DC bus (P amp ) is delivered to a DC to DC converter 606 (P dcdch ) which steps down the power to a low voltage DC bus for delivery to the battery 613 (P bat ). The DC to DC converter 606 may also be used to step up the power to the high voltage DC bus used for power control and AC power conversion. Alternate embodiments may omit the DC to DC converter and connect the high voltage DC bus directly to the battery 613 . Battery 613 is used to start the Stirling engine and to provide power to auxiliary circuitry 608 of the APU such as fans, pumps, etc., as well as to provide output power when the load on the APU exceeds the power produced by the motor/generator 602 . In addition, the battery 613 provides power to the vehicle, while the engine is warming up, thereby allowing immediate operation of the vehicle. As described further below, battery 613 acts as an energy reservoir during the operation of the personal vehicle. [0044] An emergency shunt 607 may be used to remove excess power from the high voltage DC bus in the case of an overvoltage condition in either DC bus. In one embodiment, the emergency shunt resistors are located in the water of the radiator 107 (shown in FIG. 1). In this manner, the excess heat produced by the shunt resistors when they are utilized to remove excess power, is advantageously absorbed by the same system used to dissipate the excess heat of the personal vehicle (i.e., radiator 107 ). Alternatively, the emergency shunt may be located on the frame of the vehicle or in the open air. An inverter 616 is used to deliver AC power (P out ) to a load 610 . The inverter 616 draws power (P inv ) from the DC bus. [0045] The charge level of the battery 613 reflects changes in the load 610 over time (e.g., the requirements of the motor used to propel the vehicle). In order to provide the required power output, the power control system of FIG. 6A attempts to keep the battery 613 at its optimum charge, without overcharging, in response to changes in the output load 610 . The optimum charge is not necessarily a full charge and may be 80-100% of the full charge. The optimum charge is a tradeoff between keeping the battery ready for extended periods of discharge and increasing the battery cycle life. Charging the battery to nearly 100% of full charge maximizes the availability of the battery for extended periods of discharge but also stresses the battery, resulting in a shorter battery cycle life. Charging the battery to less than full charge reduces the stresses placed on the battery and thereby extends the battery cycle life but also reduces the energy available in the battery for sudden load changes. The selection of the optimum charge will depend on the expected load variations of the personal vehicle and the battery capacity and is well within the scope of one of ordinary skill in the power management art. In a preferred embodiment, the optimum charge is set at 90% of full charge. In another embodiment, the battery may be brought to above 100% of its theoretical charge capacity to extend the life of certain types of batteries, such as lead-acid batteries. Another goal of the power control system is to reduce the fuel consumption of the engine by maximizing the efficiency from fuel input to power output. The power control system of FIG. 6A adjusts the engine temperature and the engine speed in order to produce the desired battery charge and thus, the required power output. [0046] The charge of the battery 613 may be roughly estimated by the battery voltage which is roughly related to the battery charge. Monitoring only the battery voltage provides a simpler and cheaper method to determine the battery charge. As described above, differences between the load power (P out ) and the power generated by the Stirling engine (P mech or P amp ) will result in power flow to or from the battery 613 . For example, if the engine does not produce enough power to meet the demand of the load 610 , the battery 613 will provide the remaining power necessary to support the load 610 . If the engine produces more power than required to meet the demand of the load 610 , the excess power may be used to charge the battery 613 . The power control system determines whether it is necessary to command the engine to produce more or less power in response to changes in the load. The engine speed and engine temperature are then adjusted accordingly to produce the required power. When the battery 613 is being discharged (i.e. the demand from the load 610 is greater than the power produced by the engine for extended periods of time), the engine temperature and speed are adjusted so that the engine produces more power. Typically, the engine temperature and speed are increased in order to produce more power. Preferably, when more power is needed, raising engine temperature is given preference over raising engine speed. Conversely, when the battery 613 is being charged for extended periods of time (i.e., the engine is producing more power than the load 610 demands), the engine temperature and speed are decreased to decrease the amount of power produced by the engine. Typically, the engine temperature and speed are adjusted to decrease the amount of power produced by the engine. Preferably, when less power is needed, reducing engine speed is given preference over reducing engine temperature. [0047] Once the power control system determines the desired engine temperature and speed based on the desired battery power, the power control system sends a temperature command to the controller 109 (shown in FIG. 1) indicating the desired engine temperature and a speed command to the generator 602 indicating the desired engine speed. As mentioned above, the speed of the engine may be controlled by modulating the torque applied to the crankshaft of the engine by the motor/generator 602 using the motor amplifier 605 . As such, the generator 602 acts as an adjustable load on the engine. When the generator 602 increases demand on the engine, the load on the crankshaft increases and thereby slows down the speed of the engine. The motor amplifier 605 adjusts the motor current in order to obtain the necessary torque in the motor and accordingly the necessary engine speed. [0048] A Stirling cycle engine (or other external combustion engine) typically has a long response time to sudden changes in the load (i.e., there is a time lag between the engine's receipt of an increase or decrease temperature command and the engine reaching the desired temperature). The power control system, therefore, is designed to account for the lengthy response time of a Stirling cycle engine. For a sudden increase in the load 610 , the torque load applied by the generator 602 on the crankshaft of the engine is reduced, thereby allowing the crankshaft to speed up and temporarily maintain an increased power output of the generator 602 until an increased temperature command sent to the controller 109 (shown in FIG. 1) takes effect. For a sudden load decrease, the torque applied by the generator 602 on the crankshaft of the engine may be increased in order to slow down the crankshaft and decrease the power output until a decreased temperature command sent to the burner control unit takes effect. The excess charge or power produced by the generator 602 may be used to charge the battery 613 . As discussed above, any further excess electrical energy may also be directed to the emergency shunt 607 . The process of controlling the temperature of the engine using the controller 109 is described in more detail below with respect to FIGS. 8 - 11 c. [0049] [0049]FIG. 6B is a schematic block diagram of a method for determining the desired engine temperature and speed in order to provide the required electrical power to maintain the optimal charge for the battery and meet the applied load. First, at block 620 , the power control system estimates the state of charge of the battery. The estimated battery state of charge (Q est ) is determined using the measured battery current (I B ) as well as, when necessary, an adjustment current (I adj ) as shown in the following equation: Q est ( t )= Q est ( t−dt )+ I B ( t ) dt+I adj ( t ) dt,   (Eqn. 1) [0050] in block 620 . When the engine is first started, the initial estimated state of charge (Q est ) is set to a preselected value. In a preferred embodiment, the initial state of charge value is 10% of full charge. The adjustment current is then used to correct the battery current such that Q est approaches a value near the actual state of charge. By selecting a low initial value for Q est at startup, faster correction is achieved because a lower value for Q est allows for a higher charging current. [0051] The adjustment current may be selected based on the known V-I characteristics of the battery. In a preferred embodiment, the battery is a lead-acid battery. The determination of the V-I plane for a particular battery is well within the scope of one of ordinary skill in the art. The V-I plane for the battery 613 (shown in FIG. 6A) may be divided into operating regions where the state of the charge of the battery is reasonably known. The measured battery voltage, V B , and battery current, I B , are used to identify the to current state of the battery in the V-I plane. The estimated charge Q est is then compared to the identified state of charge corresponding to the region of the V-I plane in which the measured battery voltage and current fall. The adjustment current, I adj , is estimated by taking the product of a constant, which is a function of the measured voltage and current of the battery, and the difference between the estimated state of charge Q est and the state of charge estimated using the V-I plane and the measured battery voltage and current. [0052] At block 622 , a power error P err is determined by comparing the desired battery power P batdes and the actual battery power P B . The power error P err is indicative of whether the APU must produce more or less power output. The actual battery power P B is the measured battery power flowing into the battery (I B V B ). The desired battery power may be estimated using two methods. The first method is based on the charging voltage of the battery V chg and the second method is based on the estimated state of charge Q est of the battery. In the following discussion, the desired battery power estimated using the first method will be referred to as P V and the desired battery power estimated using the second method will be referred to as P Q . [0053] The first method estimates a desired battery power, P V , using the charging voltage of the battery (V chg ). In a preferred embodiment, P V is estimated using the following equation: P V =V chg *MAX [ I min , I B ]−I OC ,  (Eqn. 2 ). [0054] The charging voltage V chg is the optimum battery voltage to keep the battery charged and is typically specified by the manufacturer of a particular battery. For example, in a preferred embodiment, the lead-acid battery has a charging voltage of 2.45V/cell. V chg is multiplied by the larger of either the measured battery current (I B ) or a predetermined minimum current value (I min ). I min may be selected based on the known characteristics of the V-I plane of the battery. For example, in one embodiment, when the measured battery voltage V B is much less than V chg , I min may be set to a high value in order to quickly increase the voltage of the battery, V B, up to V chg . If V B is near V chg , I min may be set to a low value as it will not require as much additional energy to bring the battery voltage V B up to V chg . If V B is greater than V chg , however, an overcharge current I OC may be subtracted from the greater of I B and I min in order to avoid an overvoltage condition. [0055] The second method estimates a desired battery power P Q based on the estimated state of charge (Q est ) of the battery (as determined in block 620 ). In a preferred embodiment, P Q is estimated using the following equation: P Q =K Q ( Q G −Q est )−(η I bus V bus −I B V B ),  (Eqn. 3) [0056] where: [0057] K Q is a gain constant that may be configured, either in design of the system or in real-time, on the basis of current operating mode and operating conditions as well as the preference of the user; [0058] Q G is the desired state of charge of the battery; [0059] I bus is the measured bus current exiting the motor amplifier; [0060] V bus is the measured bus voltage; and [0061] η is an estimated efficiency factor for the DC/DC converter (shown in FIG. 4A) between the motor amplifier and the battery. [0062] The desired power P Q is based on the difference between the desired charged state Q G of the battery and the estimated charge state Q est of the battery. Q G is a predetermined value between 0 (fully discharged) and 1 (fully charged) and represents the state of charge the controller is trying to maintain in the battery. In a preferred embodiment, the desired state of charge of the battery is 90% of full charge. The farther away the estimated battery charge Q est is from the desired charge state Q G , the more power which can safely be requested to charge the battery. The closer Q est is to Q G , the less power that is needed to bring the battery voltage, V B , up to V chg . [0063] The estimation of the desired battery power P Q is also adjusted to account for possible load changes. If the load on the Stirling engine and generator were suddenly decreased, the excess power produced by the engine must be directed elsewhere until the amount of power generated by the engine may be reduced (i.e., the system has time to react to the sudden change in load). The excess power represents the worst case additional power that could flow into the battery if the load were suddenly removed from the system. Accordingly, it is desirable to select a desired battery power which leaves room in the battery to absorb the excess power produced by a change in the load. The excess power is subtracted from P Q in order to leave additional room in the battery to absorb the excess power. The excess power may be determined by comparing the power generated by the engine to the power entering the battery and is represented by the term ηI bus V bus −I B V B in Eqn. 3 above. The power generated by the engine is estimated using the bus voltage V bus measured at the motor amplifier and the bus current I bus measured exiting the motor amplifier. The power entering the battery is the product of the measured battery voltage and current (I B V B ). [0064] At block 622 , the minimum of the two estimated desired battery powers P V and P Q is used to determine the power error P err . The power error P err is the difference between the selected desired battery power and the measured power flowing into the battery as shown by the following equation: P err =MIN [ P V , P Q ]−I B V B ,  (Eqn. 4) [0065] The measured power P B flowing into the battery is the product of the measured battery current I B and the measured battery voltage V B . As mentioned above, the power error P err is indicative of whether the APU must produce more or less power output. In other words, if the actual battery power is less than the desired battery power, the APU will need to produce more power (i.e., increase speed and temperature). If the actual battery voltage is greater than the desired battery voltage, the APU will need to produce less power (i.e., decrease speed and temperature). [0066] In response to the power error signal P err , the power control system produces an engine temperature command signal output (T) and an engine speed command signal output (ω) at block 624 which indicate the engine temperature and speed required to produce the desired power. In a preferred embodiment, the engine temperature T is proportional to the engine speed and the integral of a function of P err . In this embodiment, T is governed by the control law T=∫fdt,  (Eqn 5) [0067] where: [0068] f=K it P err when ω mot <ω motidle ; [0069] f=K it P err +K drift when P err ≧0 and ω mot ≧ω motidle ; and [0070] f=K drift when P err <0 and ω mot >ω motidle . [0071] In the above control law, ω mot is the measured engine speed, ω motidle is a predetermined nominal engine speed, and K it is a gain constant. When the speed of the engine is greater than a nominal motor speed, an additional drift term (K drift ) is added which has the effect of slowly increasing the engine temperature as well as indirectly decreasing the engine speed to the nominal speed of the engine. Operation of the engine at the nominal engine speed maximizes the efficiency of the engine. [0072] In a preferred embodiment, the speed of the engine (ω) is proportional to the power error P err and the integral of P err and is governed by the following control law: ω=ω min +K pw P err +K iw ∫P err dt   (Eqn. 6) [0073] where: [0074] ω min represents the minimum allowable engine speed; and [0075] K pw and K iw are gain constants. [0076] The motor speed, ω, is limited to be at least some minimum speed ω min . The engine speed is also limited to a maximum speed ω max to reduce the engine cooling effect when the speed increases. [0077] [0077]FIG. 7 shows the structural details of the power electronics circuitry of FIG. 6A. The generator 702 is coupled to a battery 713 , an inverter 716 , an amplifier 705 and an emergency shunt 707 . The behavior of these elements is similar to that described above with respect to FIGS. 6A and 6B. [0078] As discussed above with respect to FIGS. 6A and 6B, once the power control system determines the desired engine temperature and speed required to maintain the optimal charge level of the battery, a speed command (ω) is sent to the generator 602 (shown in FIG. 6A) indicating the desired engine speed and a temperature command (T) is sent to the controller 109 (shown in FIG. 1) indicating the desired engine temperature. Returning to FIG. 4, the controller 408 controls the burner 404 to achieve the desired engine temperature. The controller 408 delivers a clean burning fuel, preferably propane, supplied from a fuel supply 410 to the burner 404 . The controller 408 also delivers a measured amount of air to the burner 404 to ensure substantially complete combustion of the fuel. The controller 408 sets the fuel and air flow rates to provide the required engine temperature and to minimize emissions. [0079] Preferred methods of improving thermal efficiency and providing low emissions of Stirling engine 401 will now be discussed in more detail in reference to FIGS. 8 - 11 . Components of such thermal efficiency include efficient pumping of an oxidant (typically air, and, referred to herein as “air”) through the burner 404 to provide combustion, and the recovery of hot exhaust leaving the heater head 530 (shown in FIG. 5) of the Stirling engine. In many applications, air (or other oxidant) is pre-heated, prior to combustion, nearly to the temperature of the heater head 530 , so as to achieve thermal efficiency. There is still a considerable amount of energy left in the combustion gases after the heater head of the Stirling engine has been heated, and, as known to persons skilled in the art, a heat exchanger may be used to transfer heat from the exhaust gases to the combustion air prior to introduction into burner 404 . A preheater assembly is discussed in more detail below with respect to FIG. 10. [0080] In addition, minimizing emissions of carbon monoxide (CO), hydrocarbons (HC) and oxides of nitrogen (NOx) requires a lean fuel-air mixture which still achieves complete combustion. A lean fuel air mixture has more air than a stoichiometric mixture (i.e., 15.67 grams of air per gram of propane, for example). As more air is added to the fuel, the emissions of CO, HC and NOx decrease until the amount of air is large enough that the flame becomes unstable. At this point, pockets of the fuel-air mixture will pass through the burner without complete combustion. Incomplete combustion of the fuel-air mixture produces large amounts of CO and HC. The CO and HC emissions will continue to increase as more air is added to the fuel-air mixture until the flame extinguishes at a Lean Blow-Out limit (“LBO”). The LBO will increase as the temperature of the incoming air (i.e., the preheated air) increases. As a result, the optimal fuel-air ratio decreases as the temperature of the preheated air increases during the warmup phase of the engine. Once the engine is warmed up, the fuel-air ratio is adjusted to minimize the emissions produced and to maintain a stable flame. As used in this description and the following claims, a fuel-air ratio is the ratio of the mass of the fuel to the mass of the air flowing into the combustion chamber of the burner. [0081] Accordingly, the fuel-air ratio is first controlled by the controller (shown in FIGS. 1 and 4) to provide the optimal fuel-air ratio for ignition. Once the flame is proved, the fuel-air ratio is controlled to minimize emissions based upon the temperature of the preheated air and the fuel type. The controller then controls the fuel flow rate to bring the heater head 530 temperature up to the commanded temperature. The air flow rate is adjusted in order to maintain a desired level of oxygen in the exhaust of the engine as the fuel flow rate changes and as the air preheat temperature changes. [0082] [0082]FIG. 8 is a schematic block diagram of the power control system including the burner controller 809 and an engine controller 811 . Engine controller 811 calculates the required engine temperature and engine speed at block 806 as discussed above with respect to FIGS. 6A and 6B. The desired engine temperature (i.e. the desired temperature of the heater head) is provided as a temperature command input 807 to the burner controller 809 . A slew rate limiter 801 is advantageously used to limit the increase in engine temperature so that the temperature increase is gradual in order to minimize temperature over- and under-shoot. Upon receiving a temperature command 807 from the engine controller 811 for an engine temperature above a minimum operating temperature, the burner controller 809 initiates a lighting sequence for the burner 804 . A water pump (not shown) and a radiator fan (not shown) are controlled to maintain the temperature of the coolant. [0083] A given fuel will only ignite over a limited range of fuel-air ratios. At ignition, an ignition fuel-air ratio chosen which is equal to or less than the stoichiometric fuel-air ratio corresponding to the fuel being used. In a preferred embodiment, where the fuel is propane, the ignition fuel-air ratio is set to 0.1 IB grams propane per grams air. The ignition fuel air ratio is maintained until the flame stabilizes and the temperature of the interior of the combustion chamber of the burner 804 increases to a warmup temperature. In a preferred embodiment, the ignition fuel-air ratio is maintained until the heater head 530 temperature reaches 300° C. [0084] Once the flame is stabilized, and the temperature of the combustion chamber of the burner reaches the desired warmup temperature, the fuel-air ratio is then controlled based on the air preheat temperature and the fuel type. As described above, the optimal fuel-air ratio of the fuel-air mixture decreases as the temperature of the preheated air increases. The optimal fuel-air ratio first decreases linearly from a “start” fuel-air ratio for room temperature air to a “run” fuel-air ratio, for warmed up preheated air temperature. The air is considered fully warmed up when it exceeds its known ignition temperature. For example, the ignition temperature for propane is 490° C. In a preferred embodiment, where the fuel is propane, the “start” fuel-air ratio is 0.052 grams fuel to gram air, which results in approximately 4% oxygen in the exhaust of the engine. The “run” fuel-air ratio in the preferred embodiment is 0.026 grams fuel to gram air, which results in approximately 13% oxygen in the exhaust of the engine. Once the air reaches its warmed up preheated temperature, the air flow rate is adjusted to maintain the optimal fuel-air ratio for the warmed up preheated temperature. The air flow rate may be adjusted, for example, in response to a change in the fuel flow rate or a change in the air preheat temperature. [0085] In the embodiment of FIG. 8, the fuel-air ratio may be determined by measuring the air and fuel mass flow rates. The air flow rate may be measured with a pressure sensor and a venturi tube at the blower 805 . The fuel flow rate may be determined from the pressure upstream and downstream of a set of fuel control valves and monitoring which valves are currently commanded open. In an alternative embodiment, the fuel-air ratio may be based on the measurement of the oxygen content in the exhaust of the APU as shown in FIG. 9. An oxygen sensor may be placed in the engine to sample the exhaust gas and measure the percentage of oxygen in the exhaust. [0086] Returning to FIG. 8, the engine temperature (T head ) is measured and compared to the desired engine temperature 807 using a feed back loop. The engine temperature will continue to be increased (by increasing the fuel and air flow rates) until the engine temperature reaches the desired engine temperature. As discussed previously, the slew rate limiter 801 provides a gradual increase in the temperature to minimize temperature over- and under-shoot. When the engine controller 811 commands a heater head temperature below a minimum heater head temperature, the burner controller 809 turns off the fuel and air and controls the water pump and radiator fan to avoid coolant boil-over. [0087] In addition to providing the optimal fuel-air ratio, the fuel and air combusted in burner 804 must be well-mixed with sufficient amounts of oxygen to limit the emission of carbon monoxide (CO) and hydrocarbon (HC) and, additionally, must be burned at low enough flame temperatures to limit the formation of oxides of nitrogen (NO x ). The high temperature of pre-heated air, which as described above is desirable for achieving high thermal efficiency, complicates achieving low emission goals by making it difficult to premix the fuel and air and requiring large amounts of excess air in order to limit the flame temperature. As used herein, the term “auto-ignition temperature” is defined as the temperature at which a fuel will ignite without a temperature-decreasing catalyst under existing conditions of air and fuel pressure. The typical preheated air temperature exceeds the auto-ignition temperature of most fuels, potentially causing the fuel air mixture to ignite before entering the combustion chamber of the burner. One solution to this problem is to use a non-pre-mixed diffusion flame. However, since such diffusion flames are not well mixed, higher than desirable emissions of CO and NOx result. A detailed discussion of flame dynamics is provided by Turns, An Introduction to Combustion: Concepts and Applications, (McGraw-Hill, 1996), which is incorporated herein by reference. An increased air flow provided to limit flame temperature typically increases the power consumed by an air pump or blower, thereby degrading overall engine efficiency. [0088] In accordance with an embodiment of the present invention, low emissions and high efficiency may be provided by producing a pre-mixed flame even in the presence of air heated above the auto-ignition temperature of the fuel, and additionally, by minimizing the pressure drop between the air inlet and the flame region thereby minimizing blower power consumption. [0089] The term “flame speed” is defined as the speed at which a flame front will propagate through a particular fuel-air mixture. Within the specification and the following claims, the term “combustion axis” shall refer to the direction of predominant fluid flow upon combustion of the fluid. [0090] Typical components of the burner and preheater assemblies, in accordance with embodiments of the present invention, are described with reference to FIG. 10 a . The target range for combustion gases is 1700-2300K, with a preferred range of 1900-1950K. Operating temperatures are limited by the strength of heater head 530 which must contain working fluid at an operating pressure of typically several atmospheres and by the oxidation resistance of the burner structure. Since the strength and oxidation resistance of metals typically decreases at high temperatures, it is important to shield metal components from the high combustion temperatures. To that end, burner 122 is surrounded by a ceramic combustion chamber 1004 , itself encased in a metal combustion chamber liner 1006 , thermally sunk to heater head 530 and cooled by incoming air from the preheater path or by exhaust gases 1010 . Additionally, heater head 530 is shielded from direct flame heating by head flame cap 1002 . The exhaust products of the combustion process follow path 1008 past heater head 530 through a channel providing for efficient transfer of heat to the heater head and to the working gas contained within the heater head. [0091] The overall efficiency of a thermal engine is dependent in part on the efficiency of heat transfer between the combustion gases and the working fluid of the engine. In order to increase the efficiency of heat transfer from exhaust products of the combustion process generated by burner 122 , to the working fluid contained within heater head 530 of the engine, a large wetted surface area, on either side of heater head 530 is required. Referring to FIG. 5, heater head 530 is substantially a cylinder having one closed end 532 (otherwise referred to as the cylinder head) and an open end 534 . Closed end 532 is disposed in burner 122 as shown in FIG. 10 a. [0092] Referring to FIG. 10 b , in accordance with a preferred embodiment of the invention, fins or pins may be used to increase the interfacial area between the hot fluid combustion products and the solid heater head 530 so as to transfer heat, in turn, to the working fluid of the engine. Heater head 530 may have heat transfer pins 152 , disposed on the exterior surface as shown in FIG. 8 b , so as to provide a large surface area for the transfer of heat by conduction to heater head 530 , and thence to the working fluid, from combustion gases flowing from burner 122 (shown in FIG. 10 a ) past the heat transfer pins. Heat transfer pins may also be disposed on the interior surface (not shown) of heater head 530 . Interior-facing heat transfer pins serve to provide a large surface area for the transfer of heat by conduction from heater head 530 to the working fluid. [0093] The use and method of manufacture of heat transfer pins is described in copending U.S. Pat. No. 6,381,958, titled “Stirling Engine Thermal System Improvements”, incorporated by reference above. [0094] {/102} Depending on the size of heater head 530 , hundreds or thousands of inner transfer pins and outer heat transfer pins may be desirable. In accordance with certain embodiments of the invention, individual arrays of pins 150 , comprise arcuate fractions of the circumferential distance around the heater head 530 . This is apparent in the top view of the heater head assembly shown in perspective in FIG. 10 b . Between successive heat transfer pin array segments 150 are trapezoidal dividers 506 which are baffled to block the flow of exhaust gases in a downward direction through any path other than past the heat transfer pins. Since exhaust gases do not flow through dividers 506 , a temperature sensor, such as thermocouple 138 is advantageously disposed in divider 506 in order to monitor the temperature of heater head 530 with which the temperature sensor is in thermal contact. [0095] Temperature sensing device 138 is preferably disposed within divider 506 as depicted in FIG. 10 b . More particularly, temperature sensing tip 139 of temperature sensor 138 is preferably located in the slot corresponding to divider 506 as nearly as possible to cylinder head 332 in that this area is typically the hottest part of the heater head. Alternatively, temperature sensor 138 might be mounted directly to cylinder head 332 ; however location of the sensor in the slot, as described, is preferred. Engine performance, in terms of both power and efficiency, is highest at the highest possible temperature, yet the maximum temperature is typically limited by metallurgical properties. Therefore, sensor 138 should be placed to measure the temperature of the hottest, and therefore the limiting, part of the heater head. Additionally, temperature sensor 138 should be insulated from combustion gases and walls of divider 506 by ceramic insulation (not shown). The ceramic can also form an adhesive bond with the walls of the divider to retain the temperature sensor in place. Electrical leads 144 of temperature sensor 138 should also be electrically insulated. [0096] Returning to FIG. 10 a , exhaust gases follow path 1008 past heater head 530 and are then channeled up along path 1010 , between chamber liner 1006 and inner insulation 1012 , thereby absorbing additional heat from chamber liner 1006 , with the additional advantage of preventing overheating of the chamber liner. The exhaust gases are then returned downward through preheater 1014 and exhausted around the circumference of heater head 530 as shown by arrows designated 1016 . Preheater 1014 allows for exchange of heat from the exhaust gases to air taken in from the ambient environment, typically by an air pump or blower. Preheater 1014 may be fabricated from corrugated folder fins, typically, Inconel, however, any means for exchange of heat from the exhaust to the input air is within the scope of the present invention. [0097] In an alternative embodiment, heater tubes may be used to transfer heat from the hot fluid combustion products to the working fluid of the engine. FIG. 10 c shows an exemplary heater head including heater tubes. Additional information on a preferred heater tube design is discussed in U.S. patent application Ser. No. 09/883,077, filed Jun. 15, 2001, entitled, Thermal Improvements for an External Combustion Engine, which is herein incorporated by reference. [0098] Referring now to FIGS. 11 a - 11 c , an intake manifold 1199 is shown for application to a Stirling cycle engine or other combustion application in accordance with an embodiment of the invention. In accordance with a preferred embodiment of the invention, fuel is pre-mixed with air that may be heated above the fuels auto-ignition temperature and a flame is prevented from forming until the fuel and air are well mixed. FIG. 11 a shows a preferred embodiment of the apparatus including an intake manifold 1199 and a combustion chamber 1110 . The intake manifold 1199 has an axisymmetrical conduit 1101 with an inlet 1103 for receiving air 1100 . Air 1100 is pre-heated to a temperature, typically above 900K, which may be above the auto-ignition temperature of the fuel. Conduit 1101 conveys air 1100 flowing inward radially with respect to combustion axis 1120 to a swirler 1102 disposed within the conduit 1101 . [0099] [0099]FIG. 11 b shows a cross sectional view of the conduit 1101 including swirler 1102 in accordance with an embodiment of the invention. In the embodiment of FIG. 11 b , swirler 1102 has several spiral-shaped vanes 1126 for directing the flow of air 1100 radially inward and imparting a rotational component on the air. The diameter of the swirler section of the conduit decreases from the inlet 1124 to the outlet 1122 of swirler 1102 as defined by the length of the swirler section conduit 1101 . The decrease in diameter of swirler vanes 1126 increases the flow rate of air 1100 in substantially inverse proportion to the diameter. The flow rate is increased so that it is above the flame speed of the fuel. At outlet 1122 of swirler 1102 , fuel 1106 , which in a preferred embodiment is propane, is injected into the inwardly flowing air. [0100] In a preferred embodiment, fuel 1106 is injected by fuel injector 1104 through a series of nozzles 1128 as shown in FIG. 11 c . More particularly, FIG. 11 c shows a cross sectional view of conduit 1101 and includes the fuel jet nozzles 1128 . Each of the nozzles 1128 is positioned at the exit of the swirler vanes 1126 and is centralized between two adjacent vanes. Nozzles 1128 are positioned in this way for increasing the efficiency of mixing the air and fuel. Nozzles 1128 simultaneously inject the fuel 1106 across the air flow 1100 . Since the air flow is faster than the flame speed, a flame will not form at that point even though the temperature of the air and fuel mixture is above the fuel's auto-ignition temperature. In a preferred embodiment, where propane is used, the preheat temperature, as governed by the temperature of the heater head, is approximately 900 K. [0101] Referring again to FIG. 11 a , the air and fuel, now mixed, referred to hereafter as “air-fuel mixture” 1109 , is transitioned in direction through a throat 1108 which has a contoured fairing 1130 and is attached to the outlet 1107 of the conduit 1101 . Fuel 1106 is supplied via fuel regulator 1132 . Throat 1108 has an inner radius 1114 and an outer dimension 1116 . The transition of the air-fuel mixture is from a direction which is substantially transverse and radially inward with respect to combustion axis 1120 to a direction which is substantially parallel to the combustion axis. The contour of the fairing 1130 of throat 1108 has the shape of an inverted bell such that the cross sectional area of throat 1108 with respect to the combustion axis remains constant from the inlet 1111 of the throat to outlet 1112 of the throat. The contour is smooth without steps and maintains the flow speed from the outlet of the swirler to the outlet of the throat 1108 to avoid separation and the resulting recirculation along any of the surfaces. The constant cross sectional area allows the air and fuel to continue to mix without decreasing the flow speed and causing a pressure drop. A smooth and constant cross section produces an efficient swirler, where swirler efficiency refers to the fraction of static pressure drop across the swirler that is converted to swirling flow dynamic pressure. Swirl efficiencies of better than 80% may typically be achieved by practice of the invention. Thus, the parasitic power drain of the combustion air fan may be minimized. [0102] Outlet 1112 of the throat flares outward allowing the air-fuel mixture 1109 to disperse into the chamber 1110 slowing the air-fuel mixture 1109 thereby localizing and containing the flame and causing a toroidal flame to form. The rotational momentum generated by the swirler 1102 produces a flame stabilizing ring vortex as well known in the art. The operation of the fuel intake valve as shown in FIGS. 11 a - 11 c is further described in U.S. Pat. No. 6,062,023, which is herein incorporated by reference. [0103] The described embodiments of the invention are intended to be merely exemplary and numerous variations and modifications will be apparent to those skilled in the art. All such variations and modifications are intended to be within the scope of the present invention as defined in the appended claims.
A personal vehicle for transporting a user over a surface including an external combustion engine. The vehicle includes a generator for converting the mechanical energy produced by the external combustion engine to electrical energy and an energy storage device for storing power provided by the generator and for providing power to the external combustion engine and the assembly. The personal vehicle includes a controller for controlling a total power load placed on the external combustion engine providing short term regulation of external combustion engine parameters.
1
BACKGROUND AND SUMMARY OF THE INVENTION The present invention is directed to an improved isolation mounting system useful for vibratory compactor drums. More particularly, this invention is directed to a dual-stage isolation mounting system which provides significantly improved isolation between the compactor drum and its primary support structure. Pavement or earth compactors include vehicles in which one or both sets of wheels are replaced with a rotary compactor drum mounted upon a frame or support. The vehicular frame includes a seat and controls for an operator. An eccentric weight rotates within the drum to generate the vibratory forces desired which are used to compact the surface in question. Conventionally, elastomeric mounts, or single-stage isolators, are used to mount the compactor roller to the primary support structure in an attempt to isolate the support and the operator from the vibratory forces. Single-stage isolation mountings used to mount compactor drums to a support are capable of preventing up to 97% of the vibrational energy generated in the vibratory drum from making its way into the support. Still, the rotating eccentric employed to generate the vibrational energy is capable of generating such large amplitude vibrations that the residual vibration which does find its way into the support is capable of creating structural fatigue and causing fatiguing discomfort to the operator. Improved isolation capability is required for both extending the life of the equipment and enhancing the working conditions for the operator. The present isolation mounting system provides the desired improvement using a dual-stage mounting. A first set of elastomeric isolator mounts connects the rotary compactor dram to an intermediate support structure and a second set of elastomeric isolator mounts connects the intermediate structure to the primary support structure (the frame). The intermediate support structure has significant mass, weighing as much as is practical, typically, between 20 and 40% of the weight of the compactor drum. The spring rate of the first set of isolator mounts is as low as practical, preferably no more than 1/2 the spring rate of the second set. The mass of the intermediate support and respective values of spring rates must be selected to prevent inordinate static deflection of the drum relative to the primary support structure while still enabling significantly improved isolation. Various features, advantages and characteristics of the present invention will become apparent after a reading of the following detailed description thereof. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings depict the preferred embodiment(s) of the present invention, with like elements in various Figures bearing like reference numerals, in which FIG. 1 is a perspective view of a typical asphalt compactor drum vehicle employing both a front and rear compactor drum; FIG. 2 is a schematic top view of a compactor drum employing the dual stage isolator of the present invention; FIG. 3 is a diagrammatic side view of the compactor drum of FIG. 2; FIG. 4A is a schematic isometric detailing the position of a fast end of said compactor drum; FIG. 4B is an exploded view of the isolator mounting on the first end of said compactor drum; FIG. 5A is a schematic isometric detailing the position of a second end of said compactor drum; FIG. 5B is an exploded view of the isolator mounting on the second end of said compactor drum; FIG. 6a is a fore and aft force analysis diagram for a single-stage suspension system; FIG. 6b is a vertical force analysis diagram for a single-stage suspension system; FIG. 7a is a fore and aft force analysis diagram for a dual-stage suspension system; and FIG. 7b is a vertical force analysis diagram for a dual-stage suspension system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A compactor vehicle of the type upon which one or more drums employing the dual-stage mounting system of the present invention is depicted in FIG. 1 generally at 11. The compactor vehicle 11 depicted here is an asphalt compactor having a front drum assembly 13 and a rear drum assembly 15. Similar vehicles for use in compacting earth have only a front compactor drum and pneumatic tires on the rear. Nonetheless, because of the additional force necessary to compact the earth surface and the more uneven nature thereof, the vibratory forces experienced by the primary support and the operator of such a vehicle can be even greater than those experienced on the featured vehicle. Accordingly, a dual-stage isolation mount of the type taught herein would be of significant benefit to the earth compactor vehicle, as well. A dual-stage isolation mounting system of the present invention is depicted in detail in FIGS. 2-5 at 20. Compactor drum 22 is mounted within frame or primary support structure 24 by mounting system 20. Mounting system 20 includes an intermediate support structure 26 having a first portion 26R and a second portion 26L, with first portion 26R including the drive motor 27 for rotating the drum 22. Preferably, the relative masses or weights of 26R and 26L are substantially equal. Drum 22 has attached thereto a motor 29 which rotates an eccentric weight (not shown) which is inside the compactor drum 22 to cause vibratory motion thereof. A first set of elastomeric mounts 28 connect said drum 22 to the intermediate support structure 26 while a second set of elastomeric mounts 30 connect the intermediate support structure 26 to the primary support 24. The first set of mounts 28 includes a first group 28R of mounts which, by way of example, could comprise three pairs of closely spaced mounts (FIG. 4) attached between two similarly shaped propeller-shaped plates 31 (only one shown). Obviously, other configurations of mounts could be used without affecting the invention. A second group 28L of mounts in the set 28 are positioned on the other side of drum 22 and attach drum 22 to intermediate structure 26L. A second set of mounts 30 include a third group 30R of mounts which interconnect intermediate support 26R to primary support structure 24 on the right side and a fourth group 30L of mounts which interconnect intermediate support 26L to primary support 24 on the left side of dram 22. While the mounts of first and second sets 28 and 30 may be of whatever type desired and may be of the same general construction, as depicted here, the mounts of set 28 are depicted as model SMA070 and the mounts of set 30 are depicted as J-6332, both of which are available from Lord Corporation, one of the assignees of the present invention. Both mounts are of a sandwich construction having top and bottom plates which are readily boltable to adjacent supporting and supported structure. While the weight of the intermediate support 26 is preferably as large as practical, the upper limits can be expressed in terms related to the weight of the compactor drum 22. The intermediate support is preferably within the range of from about 20% to about 40% of the weight of drum 22, with the weight most preferably being about 24% of the drum's weight. The stiffness of the second set of mounts is determined by practical considerations: the second set 30 of mounts must directly support the intermediate support 26 and indirectly support the drum 22. Accordingly, by way of example, the spring rate k of second set 30 of mounts can be about 40,000 lb/in. The spring rate of the first set 28 of mounts is preferably as soft as practical (i.e., limited by the desired maximum static deflection) and, preferably, in no event greater than one half of the value of the second set 30, in this example 20,000 lb/in., to provide optimum isolation. FIGS. 6a and 6b are diagrammatic models of the longitudinal and vertical forces acting in the single stage mount system of the prior art and FIGS. 7a and 7b diagram the dual-stage mounting system of the present invention. These figures indicate the weights W of the respective components, the spring rates k of the elastomeric elements and of the ground (arbitrarily chosen to have a spring rate of 300,000 lb/in.), the viscous loss element C of the ground, and the loss factor. Mathematical modeling was performed on these two systems and on a rigid mounting system (not shown) for purposes of comparison. The models provided the 97% reduction figure cited earlier of the single stage mount over the rigid mounting. The modeling also demonstrated that the single mounting system was 38% more efficient at directing vibrational energy into the surface being compacted than a rigid mounting. This is due to the fact that the vibration-inducing apparatus does not have to attempt to move as much of the structural support weight as the rigidly mounted system. The dual stage mount was yet again another improvement over the single stage, as will be discussed more fully hereinafter. Actual figures from the modeling showed that the vertical g forces experienced by the frame were as follows: rigid mount--2.203 single-stage isolation system--0.111 (95% reduction) dual-stage isolation system--0.030 (an additional 73% reduction) The fore-and-aft g forces were shown by the model to be as follows: rigid mount--0.964 single-stage isolation system--0.072 (97% reduction) dual-stage isolation system--0.020 (an additional 72% reduction) The results of these mathematical models suggest that nearly 3/4 of the vibration which would be transmitted by a single-stage system can be eliminated by the dual-stage system of the present invention. The vibrational energy is dissipated by shearing of the elastomeric portions of the associated mounts. This additional reduction will have significant benefits in both the life of the support structure (and, hence, the compactor vehicle) and in the operator comfort. These results were achieved at minimal cost: the static deflection, or sag, of the compacting roller relative to the frame is increased from about 0.68 in. to about 1.01 in. This minimal increase in static deflection will not have any significant impact the operation of the compactor vehicle. Various changes, alternatives and modifications will become apparent to a person of ordinary skill in the art following a reading of the foregoing specification. It is intended that all such changes, alternatives and modifications as fall within the scope of the appended claims be considered pan of the present invention.
A dual-stage mounting system having an auxiliary support. A first set of elastomeric mounts connects the vibratory compactor drum to the auxiliary support and a second set of elastomeric mounts interconnect the auxiliary support to the vehicular frame. The dual-stage mounting system reduces by more than 70% the vibration transmitted from the drum to the primary support by a single-stage isolation mounting system thereby extending the life of the vehicle and improving operator comfort.
4
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation of the U.S. national stage designation of copending International Patent Application PCT/EP01/05671, filed May 17, 2001, which claims the benefit of European Patent Application EP 00119642.7, filed Sep. 8, 2000, the entire contents of which are expressly incorporated herein by reference thereto. FIELD OF THE INVENTION [0002] The invention relates to a sliding clutch such as for a hand-held device for transferring a film from a backing tape onto a substrate. BACKGROUND OF THE INVENTION [0003] A sliding clutch of this type is described in U.S. Pat. No. 4,891,090 to Lorinez et al. (corresponding to EP 0 362 697 A1). This known sliding clutch is disposed between a rotary drive member for a supply reel with the sliding clutch comprising two bearing members arranged concentrically within one another, one of these bearing members having the form of a round ring and the other bearing member being formed by a hollow cylindrical reel body. The round ring is made up of a plurality of annular segments formed by radial and axial slots which extend axially in one piece from a toothed disc while engaging concentrically in the hollow cylindrical reel body. It is guaranteed that slidable torsional slaving can be achieved by the ring segments pressing radially against the inner shell surface of the hollow cylindrical reel body with a certain amount of tensional force at its free end portions as a result of a prefabricated oversized portion. [0004] In this known sliding clutch, it is difficult to predetermine the size of the torque at which the transmission force is to be limited. This is caused by the level having to be predetermined during manufacture of the annular segments as they have to be produced with a radially oversized section so that they abut such that they are elastically pushed together with a radial bias at the inner shell surface of the reel body in the mounted position. In doing so, it has to be taken into consideration that even slight angular deviations of the annular segments can lead to a considerable radial change in position of their effective friction surfaces and a predetermined torque restriction can therefore only be implemented within a large tolerance range. In addition, in the known design, one has to expect alterations in tension caused by relatively high stress existing at the connection point between the annular segments and the toothed disc because of the desired small design which, for one thing, is inclined to decrease stress because of the material becoming fatigued and, for another thing, leans towards an unintentional increase or decrease in frictional tension as a result of changes in shape caused by differences in temperature. For reasons connected with handling and the defect-free transportation of the backing tape and the film, it is however desired to achieve as uniform a tension of the frictional surfaces on one another and as uniform a torque slaving as possible. [0005] U.S. Pat. No. 6,145,770 to Manusch et al. (corresponding to EP 0 883 564 B1) describes a sliding clutch for torque-limiting force transmission between a reel core and a reel for winding up or unwinding a tape which has two rotating parts arranged concentrically within one another, one of which has the shape of an oval ring with an annular wall which is radially elastically deformable towards the rotational axis and where the torsional force is transmitted by frictional slaving between the oval annular wall and the other bearing member provided in the form of a polygon. In this known structure, the ring is severely deformed and a concentric bearing of the rotating parts is not guaranteed either. [0006] A need exists for improving the frictional slaving of a sliding clutch of the type described above while guaranteeing a simple concentric mounting. A need also exists for the improved torque-limiting transmission of force and to make it easier to predetermine the force more precisely. Furthermore, the sliding clutch should have a long lifetime with the maximum transferable torque of the force transmission not substantially changing over a longer period of time or remaining constant. SUMMARY OF THE INVENTION [0007] The present invention is directed to a tensioning element provided between a circular bearing sleeve and a bearing member. The tensioning element is arranged on the side of the bearing sleeve opposite the bearing member such that it presses elastically against the bearing sleeve and is thereby resiliently deformed or bends, thus elastically biasing the bearing sleeve against the bearing member. This creates frictional slaving where the circular bearing sleeve is only very slightly resiliently deformed, namely by the amount of play of the joint, wherein this measurement is just a few tenths of a millimeter and can theoretically be zero so that the radial elastic deforming or bending of the bearing sleeve is also very small and can theoretically be zero. Consequently, the elastic deforming of the tensioning element in the sense described above found in the embodiment according to the invention is also low or non-existent. Changes in tension at the bearing sleeve and at the tensioning element caused by material fatigue are therefore slight and not damaging, thus the desired long product life is achieved. In addition, the frictional surfaces form a simple concentric pivot bearing for the bearing members during sliding of the sliding clutch. [0008] The effectiveness of the tensional force of the tensioning element can be increased or the necessary tensional force of the tensioning element can be reduced when the tensioning element is formed by a free section of the bearing sleeve which preferably extends in the longitudinal direction of the rotational axis and can be separated from the other part of the bearing sleeve by a joint or gap, especially in the form of a tongue. The partial separation from the bearing sleeve causes the free section to be connected at one end to the bearing sleeve which means that it not only cannot be lost but it is also connected in a radially resiliently flexible manner. The bearing sleeve can comprise one or several free sections which are preferably formed by one or more segments. [0009] The tensioning element is preferably formed to be ring-shaped. The annular form can serve to hold the tensioning element itself. In addition, the annular form also means that the tensioning element can essentially spread apart or press together one or more free sections or segments distributed around the periphery more or less equally. The tensioning element is preferably formed by a quartered annular spring or a helical spring in the form of a tension or compression spring. Within the boundaries of the invention, the bearing sleeve can be disposed outside or inside the other bearing member. If the bearing sleeve is disposed inside, the other bearing member is also formed by a hollow cylindrical bearing sleeve. If the circular annular wall is disposed outside, the other bearing member can also be formed as a hollow cylindrical bearing sleeve. [0010] Owing to the low deformation of the bearing sleeve and the tensioning element that follows it, especially when the tensioning element is formed in an annular fashion, frictional tension with a relatively small tolerance can be achieved by prefabricating the associated parts. In addition, the frictional tension remains constant, even after a long lifetime. [0011] The sliding clutch used in the invention is particularly suitable for torque-limiting transmission of force between a reel and a rotating member of a hand-held device for applying a film from a backing tape onto a substrate. This sliding clutch can be associated to a supply reel or a take-up reel of the handpiece. The sliding clutch used in the invention is ideally suited to such a hand-held device because it has a construction which is small and inexpensive to produce and can be integrated excellently into a hand-held device. BRIEF DESCRIPTION OF THE DRAWINGS [0012] [Preferred features of the present invention are disclosed in the accompanying drawings, wherein similar reference characters denote similar elements throughout the several views, and wherein: [0013] FIG. 1 shows a hand-held device for applying a film from a backing tape onto a substrate having a sliding clutch as described in the invention, the hand-held device being situated in its use position and a separable or opened housing of the hand-held device being illustrated open to one side; [0014] FIG. 2 shows a cross-sectional view along line II-II of FIG. 1 ; [0015] FIG. 3 shows a take-up reel in a perspective side view; [0016] FIG. 4 shows a view similar to that of FIG. 2 , but in a modified configuration; [0017] FIG. 5 shows a side view of a tensioning element of the sliding clutch in enlarged form; [0018] FIG. 6 shows a tensioning element of FIG. 4 in a modified configuration; and [0019] FIG. 7 shows a diagram illustrating the stress course versus time. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0020] The hand-held device referred to as a whole as 1 serves to transfer a film F disposed on a backing tape 2 onto a substrate S, the backing tape 2 being disposed on a supply reel 4 and a take-up reel 5 in a housing 6 of the hand-held device 1 . The housing 6 has an elongated design with an essentially rectangular cross-section and is disposed in an upright position in its functioning position as per FIG. 1 , which shall be described later. An application member 7 is provided protruding from the housing 6 , this member being arranged in the lower section of the front end of the housing and the backing tape 2 running about it. By pressing the preferably spatula-shaped application member 7 manually on the substrate S while at the same time pushing the hand-held device in the rearwards direction 3 , the lower backing tape section 2 a can be pulled off the supply reel 4 and is automatically wound back up onto the take-up reel 5 as an upper backing tape section 2 b . In the present exemplified embodiment, the supply reel 4 and the take-up reel 5 are mounted so as to be rotatable about two rotational axes 8 , 9 extending transversely to the deflection plane E of the backing tape 2 ; these axes are spaced apart from each other in the lengthwise direction of the housing 6 with the take-up reel 5 being disposed behind the supply reel 4 . [0021] The housing 6 is made up of two housing parts 6 a , 6 b , the dividing joint 6 c of which runs in or parallel to the deflection plane E of the backing tape. It is possible for the housing part 6 b , shown for example on the right hand side in FIG. 2 , to be formed with a shell-shaped peripheral wall 6 d and the other housing part 6 a to be essentially flat and fulfilling the function of a lid. The reels 4 , 5 are rotatably mounted on pivot bearing parts 10 a , 10 b which project from the side walls of one of the housing parts 6 a , 6 b and are preferably formed by hollow cylindrical bearing sleeves molded onto side walls on both sides. [0022] Between the reels 4 , 5 , there is disposed a drive connection 11 with an integrated sliding clutch 12 . The drive connection 11 is formed such that—bearing in mind the respective effective winding diameters of the full and empty reels 4 , 5 —it drives the take-up reel 5 at such a speed that the backing tape section 2 b being wound up is always slightly taut. In doing so, the sliding clutch 12 prevents the backing tape 2 from being overstretched and ripping. Once a certain effective drive torque in the drive connection 11 has been exceeded, the sliding clutch 12 activates so that, although the drive connection 11 attempts to drive the take-up reel at a higher speed, it is only driven at a speed corresponding to the speed of the backing tape 2 on the take-up surface. In the present exemplified embodiment, the drive connection 11 is formed by a toothed gearing having two meshing toothed discs 11 a , 11 b , each of which is rotatably mounted on the pivot bearing parts 10 a , 10 b with a small amount of play with a hollow cylindrical bearing sleeve 11 c , 11 d . The bearing sleeve 11 c of the toothed disc 11 a forms the supply reel 4 . The latter is thus rigidly connected to the driving part of the drive connection 11 with the supply reel 4 and the toothed disc 11 a having a common pivot bearing 13 which is formed by the pivot bearing parts or bearing sleeves disposed concentrically within one another. [0023] The take-up reel 5 is mounted in a rotatable manner on the driven part of the drive connection 11 by a concentric pivot bearing 14 , in this case on the driven toothed disc 11 b. The pivot bearing 14 which is provided additionally to the pivot bearing 15 between the toothed disc 11 b and the housing 6 is formed by two pivot bearing parts engaging concentrically within one another and in particular by hollow cylindrical bearing sleeves. The inner pivot bearing part of pivot bearing 14 is formed by the hollow cylindrical bearing sleeve 11 d and the outer pivot bearing member is formed by a hollow cylindrical bearing sleeve 5 a in the form of an annular wall 5 b on the body of the take-up reel 5 , which wall is circular on at least its inside. The bearing sleeves 11 d, 5 a extend in opposite axial directions to each other, one extending concentrically beyond the other socket-like with a small amount of bearing play and, in the embodiment exemplified in FIG. 2 , the bearing sleeve 5 a of the take-up reel 5 forming the outer bearing member. The bearing sleeve 5 a is surrounded by an annular groove 5 c which emerges from the body of the take-up reel 5 on the side facing the toothed disc 11 b and has an axial depth which stretches over a large proportion of the width of the take-up reel 5 so that the bearing sleeve 5 a is connected to the radially outer body part of the take-up reel 5 by a side flange wall 17 measuring for example a few millimeters in size. [0024] The bearing sleeve 5 a has at least one free section which is separated from the other part of the bearing sleeve 5 a by a radial gap. This can for example be formed by the wall of the bearing sleeve 5 a being slit by at least one slot 5 d extending in an essentially axial direction which can extend as far as the bottom region of the annular groove 5 c and thus to the proximity of or to the flange wall 17 . The bearing sleeve 5 a is preferably axially split into segments 5 e by several slits 5 d distributed along the periphery. These segments are integrally connected to the take-up reel 5 or the flange wall 17 in the region of their lower ends so that the top ends are radially resiliently flexible. [0025] The bearing sleeve 5 a is radially biased against the inner bearing member, in this case the bearing sleeve 11 d , by a tensioning element 18 so that the inner shell surfaces of the segments 5 e form slide faces which press against the associated bearing member, in this case the inner bearing sleeve 11 d , with the tensional force exerted on it by the tensioning element 18 . This forms the sliding clutch 12 with torque-limiting force transmission between the take-up reel S and the bearing sleeve 11 d forming a rotary drive part. [0026] The tensioning element 18 can be a pressure element which acts in a radially elastic way and resiliently deforms the bearing sleeve 5 a at at least one position, for example at a point-focal position, and presses the bearing sleeve 5 a against the bearing sleeve 11 d . The tensioning element 18 can also be formed to be annular, exerting a radial force on at least one section of the circumference of the bearing sleeve 5 a. [0027] In the functioning mode, the driven drive connection part, in this case the toothed disc 11 b, is driven by the supply reel 4 driven by the tape detachment wherein it carries the take-up reel 5 with it in the rotational direction as a result of the frictional slaving between the bearing sleeves 11 d, 5 a . When the take-up reel 5 confronts the frictional slaving with torque resistance exceeding the tape tension, the sliding clutch activates or goes into action and slides through so that the take-up reel 5 is only carried with a carrying force corresponding to the permissible tape tension and at the tape speed. [0028] The annular tensioning element 18 a exerts an essentially uniform radial pressure on all the segments 5 e. This tensioning element 18 can be formed by a tension or compression element which is elastic in its longitudinal direction, for example a helical spring in the form of an open or closed ring according to FIG. 4 , the spring ends of which are connected to one another, for example are hooked to one another (tension spring) or are preferably supported on one another (compression spring). The radial force acted upon the segments 5 e is achieved by a thus formed tensioning ring 18 a pressing the segments 5 e together or spreading them apart by virtue of the tensioning ring 18 a contracting or stretching in the peripheral direction. [0029] The tensioning ring 18 can also be formed by a spring ring which acts in an elastic manner in a radial direction rather than in a circumferential direction. A spring ring made of resilient material as shown in FIG. 6 is particularly suitable for this use, this ring having a slot 18 b running in the transverse direction. [0030] The radial size of the tensioning element 18 in a relaxed state is to be measured such that the tensioning element 18 exerts the desired tension in a mounted and taut state. [0031] The tensioning element 18 is preferably located in the outer lengthways half of the bearing sleeve 5 a or in the free end region thereof, as is shown in FIG. 2 . To position the tensioning ring 18 a axially, an annular groove 19 can be disposed in the outer shell surface of the bearing sleeve 5 a or the segments 5 e . To make it easier to push the tensioning ring 18 a onto the bearing sleeve 5 a , the bearing sleeve has a slanted or rounded insertion surface 21 on its free end, which, on the segments 5 e , are insertion surface parts. The radial width of the annular groove 5 c is of such a size that there is a gap between the tensioning ring 18 a and the groove wall surrounding it. [0032] The embodiment exemplified in FIG. 4 , in which the same or similar parts are provided with the same reference numbers, differs from the exemplified embodiment described above in that the bearing sleeve 5 a and the segments 5 e are elastically biased radially outwards rather than radially inwards by the tensioning ring 18 a . In this embodiment, the bearing sleeve 5 a or the segments 5 e work together with a bearing part surrounding them, this bearing part being formed by a hollow cylindrical bearing sleeve 11 e which projects axially in a concentric manner from the toothed disc 11 b and submerges into the annular groove 5 c made to be the appropriate size with radial play. In this embodiment, the bearing sleeve 5 a or the segments 5 e and the bearing sleeve 11 e form the pivot bearing 14 for the take-up reel 5 . [0033] In this exemplified embodiment, the annular groove 19 and the insertion surface 21 are arranged on the inside of the bearing sleeve 5 a or segments 5 e . Between the bearing sleeve 11 e and the bearing sleeve 11 d there is arranged an annular groove 22 open at one side. Groove 22 has such a radial width that there is a free space between the tensioning element 18 and the outer shell surface of the bearing sleeve 11 d. [0034] In the embodiment exemplified in FIG. 3 , the tensioning ring 18 a can be formed by a resilient pressure element which acts in its longitudinal direction, for example a compression spring in the form of a helical spring ( FIG. 5 ) or a spring ring ( FIG. 6 ) slit with a slot 18 b , this spring being radially biased outwards. [0035] The sliding surfaces of the sliding clutch 12 used in the invention abut one another at a round or hollow cylindrical joint 12 a either directly or with a small amount of play. Only a very small radial movement—or in the case of abutment just the exertion of pressure—is required to achieve the rotational slaving based on the frictional action. Due to the low amount of radial movement, the material of the bearing sleeve 5 a is stressed just slightly or not at all. No material fatigue or reduction of the frictional action as a result of material fatigue or aging therefore has to be expected. The tension F of a long life is made clear by FIG. 7 given lifetime t. [0036] All the parts of the invention, including tensioning ring 18 a and the tensioning element 18 , can be made of plastic. The tensioning ring 18 a is preferably made of flexible metal, especially spring steel, so that the favorable spring constants can be exploited. [0037] To prevent the reels 4 , 5 from rotating backwards, for example as a result of tensions in the backing tape 2 , one of the two reels 4 , 5 has an associated return stop (not illustrated) which can for example be formed by a locking pawl (not illustrated) which works together with one of the toothed wheels 11 a , 11 b. [0038] In all the exemplary embodiments, it is possible and, with a view to improving the alignment of the slide faces, favorable to arrange an annular recess in the central portion of one and/or the other of the sliding surfaces of the joint 12 a or to contrast the sliding surfaces Z-shaped to one another as shown by FIG. 4 . In the latter embodiment, the joining together of the bearing parts is also simplified.
The invention relates to a sliding clutch for torsion-limiting force transmission between a reel and a rotating part which have two bearing members disposed concentrically within one another. One of the bearing elements is formed by a circular bearing sleeve which is radially resiliently deformable transverse to its rotational axis. The bearing sleeve and the opposing bearing member abut each other in the region of a circular joint and the force transmission is effected by frictional slaving in the region of the joint. With a view to improving the frictional slaving, a tensioning element is provided on the side of the bearing sleeve opposite the side adjacent the bearing member such that the tensioning element presses against the bearing sleeve to bias the bearing sleeve against the opposing bearing member.
1
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation in part application claiming priority from commonly owned and invented application Ser. No. 11/369,133 filed on Mar. 6, 2006 which has now issued as U.S. Pat. No. 8,084,525. FIELD OF THE INVENTION This invention pertains to the field of monitoring and controlling a creping cylinder/Yankee dryer coating. BACKGROUND OF THE INVENTION The Yankee coating and creping application is arguably the most important, as well as, the most difficult to control unit operation in the tissue making process. For creped tissue products, this step defines the essential properties of absorbency, bulk, strength, and softness of tissue and towel products. Equally important, is that efficiency and runnability of the creping step controls the efficiency and runnability of the tissue machine as a whole. A common difficulty with the tissue making process is the non-uniformity in characteristics of the coating on the creping cylinder in the cross direction. The coating is composed of adhesives, modifiers, and release agents applied from the spray boom, as well as, fibers pulled from the web or sheet, organic and inorganic material from evaporated process water, and other chemicals added earlier to the wet end of the tissue manufacturing process. Inhomogeneity in the coating characteristics is often related to variations in temperature, moisture, and regional chemical composition across the face of the dryer. The variation is often quite significant and can result in variable sheet adhesion, deposits of different characteristics and/or a lack of material on the cylinder that can result in excess Yankee/creping cylinder and creping blade-wear. Degradation of final sheet properties, such as absorbency, bulk, strength, and softness can also result from this variation and/or degradation. As a result of these drawbacks, monitoring and control methodologies for the coating on the creping cylinder surface are therefore desired. SUMMARY OF THE INVENTION The present invention provides for a method of monitoring and optionally controlling the application of a coating containing a Performance Enhancing Material (PEM) on a surface of a creping cylinder comprising: (a) applying a coating to the surface of a creping cylinder; (b) measuring the thickness of the coating on the surface of a creping cylinder by a differential method, wherein said differential method utilizes a plurality of apparatuses that do not physically contact the coating; (c) optionally adjusting the application of said coating in one or more defined zones of said creping cylinder in response to the thickness of said coating so as to provide a uniform thick coating on the surface of the creping cylinder; and (d) optionally applying an additional device(s) to monitor and optionally control other aspects of the coating on a creping cylinder aside from the thickness of the coating. The present invention also provides for a method of monitoring and optionally controlling the application of a coating containing a Performance Enhancing Material (PEM) on a surface of a creping cylinder comprising: (a) applying a coating to the surface of a creping cylinder; (b) providing an interferometer probe with a source wavelength that gives adequate transmission through a coating on the creping cylinder surface; (c) applying the interferometer probe to measure the reflected light from a coating air surface and a coating cylinder surface of the creping cylinder to determine the thickness of the coating on the creping cylinder; (d) optionally adjusting the application of said coating in one or more defined zones of said creping cylinder in response to the thickness of said coating so as to provide a uniform thick coating on the surface of the creping cylinder; and (e) optionally applying an additional device(s) to monitor and optionally control other aspects of the coating on a creping cylinder aside from the thickness of the coating. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 : Schematic showing a combination of an eddy current and optical displacement sensor mounted in a common module. FIG. 2 : Schematic of a sensor module mounted on a translation stage for cross direction monitoring of the Yankee dryer coating. FIG. 3 : Dynamic data collection using an Eddy current plus triangulation sensor configuration. FIG. 4 : Data regarding dynamic bare metal monitoring. FIG. 5 : Data regarding corrected dynamic bare metal monitoring. FIG. 6 : Data regarding dynamic displacement monitoring in the coated region. FIG. 7 : Data regarding dynamic film thickness monitoring in the coated region. FIG. 8 : Data regarding dynamic displacement monitoring in the coated region that contains a defect in the coating (bare spot). FIG. 9 : Data regarding dynamic film thickness monitoring in the coated section that contains a defect in the coating (bare spot). The sharp spike that approach −10 μm identifies the presence of a defect in the coating. FIG. 10 : Schematic showing the combination of Eddy current, optical displacement, capacitance, and IR temperature mounted in a common module. FIG. 11 : Schematic illustrating the general use of interferometry for coating thickness monitoring on the crepe cylinder. All interferometer measurements are based on constructive and destructive interference of waves. Film thickness is determined from fringe pattern. The advantages are: probe head adaptable to harsh environments; sensitive electronics located far from measurement point; dynamic monitoring (sampling rates up to 200 Hz); large dynamic range (100 nm-12 mm); and multiplexing. FIG. 12 : Data regarding dynamic film thickness profile around a selected circumference zone. LHS (left handed side) shows non-uniformity in coating thickness. RHS (right handed side) shows the same coating with chatter marks from interaction with a doctor blade. DETAILED DESCRIPTION OF THE INVENTION The methodologies and control strategies of the present disclosure are directed to the coating on the creping cylinder surface. Various types of chemistries make up the coating on the creping cylinder surface. These chemistries impart properties to the coating that function to improve the tissue making process. These chemistries will be collectively referred to as Performance Enhancing Materials (PEM/PEMs). An exemplary description of these chemicals and a method to control their application are discussed in U.S. Pat. No. 7,048,826 and U.S. Patent Publication No. 2007/0208115, which are herein incorporated by reference. In one embodiment, one of said plurality of apparatuses utilized is an eddy current sensor. The differential method can involve an eddy current and an optical displacement sensor. In one embodiment, the differential method comprises the steps of: applying the eddy current sensor to measure the distance from the sensor to a surface of the creping cylinder and applying an optical displacement sensor to measure the distance from the coating surface to the sensor. In a further embodiment, the optical displacement sensor is a laser triangulation sensor or a chromatic type confocal sensor. FIG. 1 depicts an illustration of the sensor combination consisting of an eddy current sensor and an optical displacement sensor. The eddy current (EC) sensor operates on the principle of measuring the electrical impedance change. The EC produces a magnetic field by applying an alternating current (AC) to a coil. When the EC is in close proximity to a conductive target, electric currents are produced in the target. These currents are in the opposite direction of those in the coil, called eddy currents. These currents generate their own magnetic field that affects the overall impedance of the sensor coil. The output voltage of the EC changes as the gap (d e ) between the EC sensor and target changes, thereby providing a correlation between distance and voltage. In this application the EC sensor establishes a reference between the sensor enclosure and the creping cylinder surface. The second sensor mounted in the enclosure optically measures the displacement of the sensor (d o ) with respect to the film surface. The optical displacement sensor can be either a triangulation type such as Micro-Epsilon (Raleigh, N.C.) model 1700-2 or a chromatic type such as Micro-Epsilons optoNCDT 2401 confocal sensor. These sensors work on the principle of reflecting light from the film surface. When variations in the coating optical properties exist due to process operating conditions, sensor monitoring location, or properties of the PEM itself, then a high performance triangulation sensor such as Keyence LKG-15 (Keyence—located Woodcliff Lake, N.J.) may be warranted. The Keyence triangulation sensor provides a higher accuracy measurement with built in algorithms for measuring transparent and translucent films. Variation in the transmission characteristics in both the cross direction (CD) and machine direction (MD) may warrant a sensor adaptable to the different coating optical characteristics and the higher performance triangulation sensor can switch between different measurement modes. In general the majority of commercial triangulation sensors will produce a measurement error on materials that are transparent or translucent. If the film characteristics are constant, angling the triangulation sensor can reduce this error. However, sensor rotation for measurements on processes that have a high variability in the film characteristics is not an option. Both the optical and EC sensors provide the required resolution to monitor PEM films with expected thickness>50 microns. The film thickness is obtained by taking the difference between the measured distances from the EC and optical displacement sensor. The sensors are housed in a purged enclosure, as shown in FIG. 1 . Purge gas (clean air or N 2 ) is used for sensor cooling, cleaning, and maintaining a dust free optical path. Cooling is required since the enclosure is positioned between 10-35 mm from the steam-heated creping cylinder. Additional cooling can be used, if needed, by using a vortex or Peltier cooler. Purge gas exiting the enclosure forms a shielding gas around the measurement zone to minimize particulate matter and moisture. Particulate matter can impact the optical measurement by attenuating both the launched and reflected light intensity. Whereas moisture condensing on the light entrance and exit windows of the enclosure will cause attenuation and scattering. The EC sensor is immune to the presence of particulate matter and moisture. For industrial monitoring on a creping cylinder (also known as a Yankee Dryer), the sensor module shown in FIG. 1 would be mounted on a translation stage as illustrated in FIG. 2 . Before installation, the positioning of the sensors must be calibrated on a flat substrate to obtain a zero measurement reading. This is necessary since the positioning of the EC and optical displacement sensor can be offset differently relative to the substrate surface. The calibration step is necessary to adjust the position of each sensor to insure a zero reading when no film is present. Installation of the sensor module on the industrial process involves mounting the module at a distance in the correct range for both sensors to operate. By translating the module in the CD as the cylinder rotates a profile of the film thickness and quality can be processed and displayed. The processed results are then used for feedback control to activate the appropriate zone(s) for addition of PEM, other chemicals, or vary application conditions, e.g., flow rate, momentum, or droplet size. In addition, if the film quality (thickness or uniformity) cannot be recovered, then an alarm can be activated to alert operators of a serious problem, e.g., cylinder warp, doctor blade damage or chatter, severe coating build-up, etc. Finally, three measurement locations are identified in FIG. 2 . Measurements on the film thickness and quality can be made between the doctor and cleaning blade ( 1 ), after the cleaning blade ( 2 ), or before the web is pressed on to the cylinder ( 3 ). A single location or multiple locations can be monitored. Laboratory results using the combination of EC and optical displacement (triangulation) sensor are shown in FIG. 3 . In this case dynamic measurements are made on a 95 mm diameter cast iron cylinder rotating at ˜16-20 RPM (revolutions per minute). Half of the cylinder was coated with PEM. In the PEM coated portion of the cylinder a bare spot (˜20 mm dia.) was made to simulate a defect region. FIG. 3 shows the corrected signal (Eddy-Triangulation) starting in the bare metal region. Translating the sensor combination to the coated region shows an average offset of ˜27 microns due to the coating. Here the signal is negative, which represents a decrease in distance of 27 microns between the sensor and cylinder due to thickness of the coating. At 300 seconds the sensor combination was translated back to the bare metal area. Initially the signal appears higher, (˜5 microns) requiring further adjustment to position the sensors closer to the original measurement location. This anomaly is likely an artifact of the laboratory system because of the sensors not measuring the exact same area and the small radius of curvature with the small-scale setup. Industrial monitoring on 14-18 ft diameter cylinders should minimize these effects, since the sensors would essentially view the cylinder as a flat plate. Finally, a demonstration to detect the coating defect was made by translating the sensors at ˜375 seconds to the region containing the bare spot. Here the average coating thickness measured was ˜30 microns. This is within 3 microns of the results from the region between 200-300 seconds. The appearance of a spike in the signal that approaches −10 microns identifies the presence of a coating defect. As the bare spot rotates through the measurement zone the signal approaches 0 microns. The 10 micron offset measured is attributed to residual coating in the defect area. The results from FIG. 3 are summarized in Table 1 for corrected data as well as raw triangulation and EC data. TABLE 1 Processed mean and standard deviation for different sensors and measurement locations. Corrected sensor is the film thickness measurement from the difference between the Eddy current and Triangulation. Mean Sensor Location (m) STD Corrected Bare Metal −0.33 3.41 Coating −27.48 4.30 Coating + Spot −30.97 6.47 Triangulation Bare Metal 4.89 16.78 Coating −49.86 15.82 Coating + Spot −44.93 13.19 Eddy Current Bare Metal −5.23 15.07 Coating 22.37 13.38 Coating + Spot 13.96 11.44 Recorded measurements from the EC and triangulation sensor are shown in FIG. 4 for monitoring the bare metal region. The 40-50 micron oscillations observed in the measurement reflect the wobble in the cylinder rotation. By applying the correction (EC-Triangulation) the wobble is reduced to ˜10 microns, as shown in FIG. 5 . For industrial monitoring this variation will likely be reduced as the spatial location of the EC sensor approaches the optical displacement measurement spot and reduces the curvature effects. Similarly FIGS. 6 and 7 show results for monitoring the coated region. In this case, the corrected data shown in FIG. 7 has a variation between 15-20 microns. This larger variation in the data is likely due to surface non-homogeneities of the film. Both frequency and amplitude analysis of the signal can provide information on the quality of the coating. The measurement spot size of the triangulation sensor is ˜30 microns. Therefore, the triangulation sensor easily resolves non-uniformities in the surface. Monitoring results from the coated region with the defect are shown in FIGS. 8 and 9 . The eddy current signal in FIG. 8 does not show evidence of the defect. Whereas the triangulation measurement indicates the presence of a defect by the sharp narrow spike. In the corrected signal shown in FIG. 9 the sharp spike from the coating defect is easily resolved. Another example showing the detection of uniformities is shown in FIG. 12 . In this case, synchronous data collection was performed with a coated cylinder rotating at 59 RPM. The LHS figure shows a profile of the coating relative to the cylinder surface. The non-uniformity in the coating thickness is evident, but the surface is relatively smooth. The RHS figure shows the same coating subjected to chattering conditions through the interaction of a doctor blade and coating. Comparing the two cases clearly shows the sensor system's ability to capture degradation in the surface quality of the coating. Detecting chattering events is critical on the Yankee process to perform corrective maintenance that minimizes the impact on product quality and asset protection. Moisture, which may affect the differential calculation, can also be accounted for; specifically moisture can be calculated from the dielectric constant derived from a capacitance measurement. This data can be utilized to decide whether any change in thickness is a result of moisture or the lack of a coating. Another way of looking at the capacitance is that it is a safeguard for a measurement obtained by the described differential method; it provides a more in-depth analysis of the coating itself, e.g. behaviors of the coating such as glass transition temperature and modulus, which is useful in monitoring and controlling the coating on the creping cylinder surface. One method of accounting for moisture content in the coating is by looking at capacitance and another way is to utilize a moisture sensor. Other techniques may be utilized by one of ordinary skill in the art. In one embodiment, the method incorporates a dedicated moisture sensor such as the one described in WO2006118619 based on optical absorption of H 2 O in the 1300 nm region, wherein said reference is herein incorporated by reference. This will give a direct measurement of the moisture level in the film without interferences that the capacitance monitor could experience due its dependence on the dielectic constant of both the coating and moisture. In another embodiment, the method additionally comprises: applying a capacitance probe to measure the moisture content of the coating; comparing the capacitance measurement with the differential method measurement to determine the effect of moisture on the coating thickness; and optionally adjusting the amount and distribution of the coating on the creping cylinder surface in response to the effect moisture has on thickness as determined by the differential method and/or adjust the amount of the coating. The method can use a module that houses multiple sensors as shown in FIG. 10 . The module is similar to the one presented in FIG. 1 , but with additional sensor elements. The module in FIG. 10 includes a capacitance probe and an optical infrared temperature probe. Capacitance probes such as Lion Precision, St. Paul, Minn. are widely used in high-resolution measurements of position or change of position of a conductive target. Common applications in position sensing are in robotics and assembly of precision parts, dynamic motion analysis of rotating parts and tools, vibration measurements, thickness measurements, and in assembly testing where the presence or absence of metallic parts are detected. Capacitance can also be used to measure certain characteristics of nonconductive materials such as coatings, films, and liquids. Capacitance sensors utilize the electrical property of capacitance that exists between any two conductors that are in close proximity of each other. If a voltage is applied to two conductors that are separated from each other, an electric field will form between them due to the difference between the electric charges stored on the conductor surfaces. Capacitance of the space between them will affect the field such that a higher capacitance will hold more charge and a lower capacitance will hold less charge. The greater the capacitance, the more current it takes to change the voltage on the conductors. The metal sensing surface of a capacitance sensor serves as one of the conductors. The target (Yankee drum surface) is the other conductor. The driving electronics induces a continually changing voltage into the probe, for example a 10 kHz square wave, and the resulting current required is measured. This current measurement is related to the distance between the probe and target if the capacitance between them is constant. The following relationship applies: C = ɛ ⁢ ⁢ A d ( 1 ) where C is the capacitance (F, farad), ∈ is the dielectric property of the material in the gap between the conductors, A is the probe sensing area, and d is the gap distance. The dielectric property is proportional to the material's dielectric constant as ∈=∈ r ∈ 0 , where ∈ r is the dielectric constant and ∈ 0 is the vacuum permittivity constant. For air, ∈ r =1.006 and for water, ∈ r =78. Depending on which two parameters are being held constant, the third can be determined from the sensor's output. In the case of position, d is measured where air is usually the medium. For our application in Yankee systems, the variability of ∈ r in the total gap volume is the measured parameter. In this case, the gap is composed of three main components air, film or coating that could also contain fibrous material, and moisture. A mixture dielectric constant can be expressed as ∈ r =∈ f Φ f ∈ w Φ w ∈ a Φ a   (2) where φ is the volume fraction with the subscript and superscript referencing the component material (a=air, w=water, f=film). Using Eq 1 and 2 the change in capacitance due to the presence of moisture is given by C fw - C f = ɛ 0 ⁢ ɛ f Φ f ⁢ ɛ w Φ w ⁢ ɛ a Φ a ⁢ A d - ɛ 0 ⁢ ɛ f Φ f ⁢ ɛ a Φ a ⁢ A d ( 3 ) where C fw is the capacitance for film containing moisture and C f is the dry film. Taking the log and rearranging Eq. 3 an expression for the volume fraction on moisture is given by Φ w = Log ⁡ ( C fw C f ) Log ⁡ ( ɛ w ) ( 4 ) For monitoring the Yankee film, the mixture capacitance C fw is measured directly with the capacitance probe. The temperature dependent dielectric constant for water is obtained from literature values. The volume fraction of moisture is then obtained by knowing the dry film capacitance, which can be determined from the film thickness measurement d c using the optical sensor and knowing the dielectric constant of the film. The average dielectric constant for the gap volume is proportionally composed of that for air and the coating. The more coating in the gap, the larger the average dielectric constant is. By controlling d and A, any sensitivity and range can be obtained. Because capacitance is sensitive to the moisture content of the coating, it may be difficult to separate out variation in coating thickness from changes in moisture content. By incorporating the set of sensors (EC, optical displacement, and capacitance) in the module shown in FIG. 10 , this information provides a means of cross checking the film thickness and information on the moisture content of the coating. The EC sensor provides a baseline reference distance for real-time correction used in both the optical displacement d d and capacitance. The capacitance averages over a much larger area compared to the optical probe. For example, a capacitance probe using a gap distance of 0.005 m would use a 19 mm diameter sensing probe head. The measurement area would be 30% larger than the probe head. Whereas optical displacement probes measure an area of 20 microns to 850 microns depending on the probe used. The higher resolution measurement from the optical probes will show sensitivity to smaller variation on the coating surface. However, the average measurement from the optical probe over a larger area will give similar results as the capacitance. Differences between the capacitance and optical probe reading can then be attributed to moisture content in the film provided the dielectric constant of the coating is known. An infrared (IR) temperature probe such as OMEGA (Stamford, Conn.) model OS36-3-T-240F can provide useful information on the temperature profile of the creping cylinder. Since PEM's will respond differently depending on temperature, temperature information can be used to adjust the chemical composition and level of PEMs applied to the cylinder. In one embodiment, the method further comprises: (a) applying an IR temperature probe to measure the temperature profile of the creping cylinder; (b) applying an IR temperature probe to measure the coating temperature needed to correct for the temperature dependent moisture dielectric constant; and (c) applying the corrected moisture dielectric constant to the capacitance measurement to determine the correct coating moisture concentration. The addition of the IR temperature probe in the sensor module provides information on the temperature profile of the crepe cylinder. This is useful in identifying temperature non-uniformities on the crepe cylinder. In addition, the temperature can be used to correct the dielectric constant of the coating. For example, the dielectric constant for water can vary from 80.1 (20° C.) to 55.3 (100° C.). An ultrasonic sensor may be incorporated into the monitoring methodology. In one embodiment, the method further comprises applying an ultrasonic sensor to measure the modulus of the coating, and optionally wherein the modulus value is used to measure the hardness of the coating. The ultrasonic sensor is used to detect the viscoelastic property of the coating. The propagation of sound wave (reflection and attenuation) through the film will depend on the film quality, e.g., hard versus soft. Information on the film properties can be used for feedback to a spray system for controlling the spray level or adjusting the spray chemistry, e.g., dilution level, to optimize the viscoelastic film property. As stated above, an interferometer may be utilized in measuring thickness. Other analytical techniques, such as the ones described in this disclosure can be utilized in conjunction with an interferometry method. In addition, the differential method can be used in conjunction with a methodology that utilizes an interferometer to measure thickness of the coating. In one embodiment, the method uses interferometry to monitor the coating thickness. If the coating has sufficient transmission, then the use of multiple sensors can be reduced to a single probe head as illustrated in FIG. 11 . In this case, light is transported to the probe by fiber optic cable. Reflected light from both surfaces of the film is collected back into the fiber probe for processing to extract coating thickness information. Several different techniques can be used for processing the collected light. Industrial instruments such as Scalar Technologies Ltd. (Livingston, West Lothian, UK) uses a spectral interferometry technique based on measuring the wavelength dependent fringe pattern. The number of fringes is dependent on the film thickness. Alternatively, Lumetrics Inc. (West Henrietta, N.Y.) instrument based on a modified Michelson interferometer determines thickness based on the difference in measured peaks resulting from each surface. Monitoring the coating on the crepe cylinder with an interferometry probe can be made at any of the locations illustrated in FIG. 2 . The main requirement is that the film has sufficient transmission for the light to reflect off the internal surface, i.e., near the substrate. One unique feature of the interferometry measurement is the ability to measure coating layers. This capability can be utilized at monitoring location 3 shown in FIG. 2 . At this location the coating is not fully dry and is free from process disturbances such as from the pressure roll that applies the tissue sheet to the creping cylinder, direct contact with the web, doctor blade, and cleaning blade. An interferometry sensor at this location provides the thickness of the freshly applied coating. This aids in knowing the spatial distribution of the coating prior to any disturbances. For example, knowing the coating thickness before and after process disturbances can identify inefficiencies in the spray system, areas experiencing excessive wear, or other dynamic changes. As stated above, the methodologies of the present disclosure provide for optionally adjusting the application rate of said coating in one or more defined zones of said creping cylinder to provide a uniformly thick coating in response to the thickness of said coating. Various types of apparatuses can carry out this task. In one embodiment, the method controls the spray zones based on measurements collected during normal operating conditions. For example, measurements from the sensor or sensor(s) discussed above are used to establish a baseline profile on the crepe cylinder. The baseline data is then used to track process variances. Upper and lower control limits established around the baseline profile data (film thickness, film quality, moisture level, viscoelasticity, temperature, etc.) is used to track when process deviations occur. If any of the process monitoring parameters falls outside the limits, then corrective action is taken with the zone control spray application system. In another embodiment, the plurality of apparatuses are translated across the Yankee dryer/creping cylinder to provide profiles of thickness and/or moisture content and/or temperature, and/or modulus. In another embodiment, the plurality of apparatuses are located between a crepe blade and a cleaning blade, after the cleaning blade, or prior to a tissue web being pressed into the coating, or any combination of the above. In another embodiment, the plurality of apparatuses are purged with a clean gas to prevent fouling, mist interference, dust interference, overheating, or a combination thereof
A method for monitoring and controlling the thickness of coating on a creping cylinder is disclosed. The methodologies involve a coordinated scheme of apparatuses that function to monitor various aspects of a creping cylinder coating so that the thickness of the coating can be determined.
3
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit under 35 U.S.C. §119(a) of a U.S. Patent Application No. 61/496790, filed on Jun. 14, 2011, and a Korean Patent Application No. 10-2012-0063898, filed on Jun. 14, 2012,the entire disclosure of which is incorporated herein by reference for all purposes. BACKGROUND [0002] 1. Field [0003] The following description relates to a seismic imaging technology for imaging a subsurface structure by processing measured data reflected from the subsurface structure after a wave from a source wave has been propagated to the subsurface structure. [0004] 2. Description of the Related Art [0005] Technologies for imaging a subsurface structure through waveform inversion have been studied and developed. An example of such technologies is disclosed in a Korean Patent Registration No. 1,092,668 registered on Dec. 5, 2011, filed on Jun. 17, 2009 with the Korea Intellectual Property Office. The Korean Patent Registration has been filed as U.S. patent application Ser. No. 12/817,799 with the U.S. Patent and Trademark Office. [0006] According to the disclosures, a low-frequency signal from a source is sent to a subsurface structure, a wave reflected from the subsurface structure is measured as measured data by a receiver such as a hydrophone array, and then the measured data is used to obtain a modeling parameter of the corresponding subsurface structure. The coefficients of a wave equation consist of modeling parameters such as the density, etc. of the subsurface space to which the wave is propagated. The modeling parameters of the wave equation are calculated by waveform inversion. According to the waveform inversion, the modeling parameters are calculated while being continuously updated in the direction of minimizing a residual function regarding the difference between modeling data and measured data, wherein the modeling data is a solution of the wave equation. [0007] According to the disclosures above, a modeling parameter for a wave equation is obtained by updating the modeling parameter iteratively in the direction of minimizing a residual function regarding an error between modeling data and measured data, wherein the modeling data is a solution of the wave equation to which a coefficient matrix obtained from the modeling parameter has been applied. Further, to obtain the modeling parameter, firstly a coefficient matrix of the wave equation should be calculated from a modeling parameter. Then, solving the wave equation with the coefficient matrix and given source data yields the modeling data. is Next, a residual function regarding a residual between the measured data and the modeling data is calculated. If the value of the residual function is greater than a predetermined value, the modeling parameter of the wave equation is updated in the direction of minimizing the residual function. If the value of the residual function is smaller than the predetermined value, the modeling parameter at that iteration is outputted as a final output value. Conventional waveform inversion was performed on global grid basis and hence the sea bottom is modeled in conformity with these coarse grid points. This resulted in inaccurate estimation of signals reflected on or transmitted through the sea bottom. SUMMARY [0008] The following description relates to a seismic imaging method that calculates a coefficient matrix of a wave equation according to a contour of the sea bottom within a global grid. This method can be used to accurately estimate signals reflected on or transmitted through the sea bottom because it accurately reflects more detailed contours of the sea bottom within the global grid. Moreover, computational overburden is minimized. [0009] In one general aspect, the coefficient matrix is calculated from a mass matrix which is obtained by applying a numerical integration method to two domains, the first domain being an upper medium above the sea bottom and the second domain being a lower medium below the sea bottom. [0010] According to another aspect, the numerical integration method is Gaussian Quadrature Integration Method. Other features and aspects will be apparent from the following detailed description, the drawings, and the claims. BRIEF DESCRIPTION OF THE DRAWINGS [0011] is FIG. 1 is a flow chart illustrating an example of a seismic imaging method. [0012] FIG. 2 illustrates a 2D cross-sectional diagram of two cubic elements divided by the sea bottom. [0013] Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience. DETAILED DESCRIPTION [0014] The following description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses, and/or systems described herein. Accordingly, various changes, modifications, and equivalents of the methods, apparatuses, and/or systems described herein will be suggested to those of ordinary skill in the art. Also, descriptions of well-known functions and constructions may be omitted for increased clarity and conciseness. [0015] An example of a seismic imaging method includes waveform inversion. According to an aspect, an embodiment of the waveform inversion obtains a modeling parameter for a wave equation by updating the modeling parameter iteratively in the direction of minimizing a residual function regarding an error between modeling data and measured data, wherein the modeling data is a solution of the wave equation to which a coefficient matrix obtained from the modeling parameter has been applied, and the measured data has been measured by a plurality of receivers, [0016] An exemplary but not limiting waveform inversion in the Laplace domain is disclosed in Shin, C. S., & Cha, Y. H., 2008. Waveform inversion in the Laplace domain, Geophys. J. Int., is 173, 922-931. According to the papers above, the Laplace-transformed wavefield in the time domain is expressed by [0000] {tilde over ( u )}( s )=∫ 0 ∞ u ( t ) e −st dt   (1) [0000] where {tilde over (ũ)}(s) is the wavefield in the Laplace domain, u(t) is the wavefield in the time domain, t is time, and s is the Laplace damping constant. Then wave equation in the Laplace domain can be obtained by transforming a wave equation in the time domain into the Laplace domain: [0000] s 2 c 2  ∂ 2  u ~ ∂ t 2 = ∂ 2  u ~ ∂ x 2 + ∂ 2  u ~ ∂ y 2 + ∂ 2  u ~ ∂ z 2 + f ~ , ( 2 ) [0017] where c (x, y, z) is the p-wave velocity, u (x, y, z, t) is the pressure field, and f (x, y, z, t) is the source function, and hat notation above a letter indicates a Laplace transformed variable. [0018] The wave equation in the Laplace domain above can be solved by the finite element method. We apply the weighted residual method to derive a modified formula equivalent to the wave equation. We define the residual to apply the weighted residual method in equation (2) as [0000] r = s 2 c 2  ∂ 2  u ~ ∂ t 2 - ∇ 2  u ~ - f ~ , ( 3 ) [0019] where ∇ is the Laplace operator defined as [0000] ∂ 2 ∂ x 2 + ∂ 2 ∂ y 2 + ∂ 2 ∂ z 2 . [0020] We change equation (3) to the weak form by multiplying it by an arbitrary weighting function, v and integration in a given domain, Ω. [0000] ∫ Ω  [ s 2 c 2  u ~ - ∇ 2  u ~ - f ~ ]  v   Ω = 0 , ( 4 ) [0021] By integration by parts of Equation (4) and applying the natural boundary condition, equation (4) becomes : [0000] ∫ Ω  [ s 2 c 2  u ~  v - ∇ u ~  ∇ v - f ~  v ]   Ω = 0 ( 5 ) [0022] The Laplace-transformed wavefields, ũ and v are approximated by summation of weight functions α j (s) and β i (s), and basis functions, φ j (x, y, z) and φ i (x, y, z) by the Galerkin approximation as follows: [0000] u  ( x , y , z , s ) = ∑ j = 1 N  α j  ( s )  φ j  ( x , y , z ) , and   v  ( x , y , z , s ) = ∑ i = 1 N  β j  ( s )  φ i  ( x , y , z ) , ( 6 ) [0023] By substituting equation (6) into equation(5), assuming the arbitrary function ν=1 and rearranging, we obtained [0000] ∑ j = 1 N  s 2  α j c 2  ∑ i = 1 N  ∫ Ω  ( φ j  φ i )   Ω + ∑ j = 1 N  α j  ∑ i = 1 N  ∫ Ω  ( ∂ φ j ∂ x  ∂ φ i ∂ x + ∂ φ j ∂ y  ∂ φ i ∂ y + ∂ φ j ∂ z  ∂ φ i ∂ z )   Ω = f ~  ∑ i = 1 N  ∫ Ω  φ i   Ω ( 7 ) [0024] Letting the coefficients of the basis functions, α j be a vector, ũ, because these coefficients fundamentally represent wavefields, we can convert equation (7) to a matrix multiplication form as follows: [0000] S   u ~ = f ~   where   S = K + s 2  M   K = K ij = ∫ Ω  ( ∂ φ j ∂ x  ∂ φ i ∂ x + ∂ φ j ∂ y  ∂ φ i ∂ y + ∂ φ j ∂ z  ∂ φ i ∂ z )   Ω , and ( 8 ) M = M ij = ∫ Ω  ( 1 c 2  φ j  φ i )   Ω ( 9 ) [0025] In equation (9)Error! Reference source not found., M is a mass matrix and K is a is stiffness matrix. We can obtain the wavefield in the Laplace domain by solving equation (8) as described in equation (10). [0000] ũ=S −1 {tilde over (f)}   (10) [0026] FIG. 1 is a flow chart illustrating an example of a seismic imaging method. As described in U.S. patent application Ser. No. 12/817,799, a modeling parameter for a wave equation is obtained by updating the modeling parameter iteratively in the direction of minimizing a residual function regarding an error between modeling data and measured data, wherein the modeling data is a solution of the wave equation to which a coefficient matrix obtained from the modeling parameter has been applied. As shown in FIG. 1 , to obtain the modeling parameter, firstly a coefficient matrix of the wave equation should be calculated from a modeling parameter(steps 100 ˜ 300 ). Then, solving the wave equation with the coefficient matrix and given source data yields the modeling data(step 400). Next, a residual function regarding a residual between the measured data and the modeling data is calculated(step 500). [0027] Disclosed in detail is the calculation of the residual function in Pyun, S. J., Shin, C. S. & Bednar, J. B., 2007. Comparison of waveform inversion, part3: amplitude approach, Geophys. Prospect., 55, 465-475. Also, Shin, C. S., & Min, D. J., 2006. Waveform inversion using a is logarithmic wavefield: Geophysics, 71, R31-R42. Discloses a logarithmic residual function. [0028] Next, the value of the residual function is compared with a reference value R ref (step 600). If the value of the residual function is greater than a predetermined value, the modeling parameter of the wave equation is updated in the direction of minimizing the residual function(step 700). [0029] To determine the direction of minimizing the residual function, a gradient of the residual function is calculated. The Gauss-Newton method, the Marquardt-Levenverg method, the steepest decent method and other least-square methods that seek to minimise the cumulative squared residuals with respect to changes in the parameter can be applied to this minimisation problem. A back-propagation algorithm may be used to calculate the direction of the gradient of the k-th element more effectively (Shin & Min 2006 above). Again, the coefficient matrix of the waveform equation is calculated using the updated modelling parameter(step 200 ). These iteration continues until the value of the residual function becomes smaller than the predetermined reference value R ref . If the value of the residual function is smaller than the predetermined value, the modeling parameter at that iteration is outputted as a final output value(step 800 ). [0030] According to an aspect, the coefficient matrix is calculated from a mass matrix obtained according to the contour of the sea bottom within a global grid near the sea bottom. According to another detailed aspect, the mass matrix is obtained by applying a numerical integration method to two domains, the first domain being an upper medium above the sea bottom and the second domain being a lower medium below the sea bottom. [0031] FIG. 2 illustrates a 2D cross-sectional diagram of two cubic elements divided by the sea bottom. Each of the cubic elements are identified by global grids. The obliquely inclined lines or interfaces that connect the three square dots represent the assumed sea bottom and these is lines divide the extended numerical integration points (circles) into the different two groups (Ω 1 and Ω 2 ). The element mass matrix can be calculated by a numerical integration method using two different model velocities assigned to each group, Ω 1 and Ω 2 . [0032] As for the cubic elements above the sea bottom, corresponding medium is water and the modeling parameter, for example, concentration or the propagation velocity for the cubic elements is assumed to be constant. Hence numerical integration method disclosed herein does not need to be applied. For at least some of the cubic elements along the sea bottom surface, especially for obliquely interfaced cubic elements where signal propagation may be distorted, numerical integration method disclosed herein need to be applied. This greatly reduces the number of cubic elements where extended numerical integration should be applied at each iteration, hence reduces greatly the errors caused by irregular sea bottom surface with minimum added computational burden of the whole seismic imaging. For 3-dimensional seismic imaging where computational burden is already high and affected more sensitively by the sea bottom configuration, these aspects are more important compared to 2-dimensional or 1-dimensional seismic imaging. [0033] According to another aspect, the numerical integration method may be the Gaussian Quadrature Integration Method. The Gaussian quadrature integration method is a numerical integration method that expresses the one-dimensional integration of an (2n+1) -th order arbitrary function as a linear combination of n integration point coordinates and their corresponding weights. [0034] According to an aspect, the Gaussian quadrature integration method is applied to calculate the element mass matrices that constitute the impedance matrix in the Laplace-domain modelling and inversion algorithm at elements along the sea bottom. By the Gaussian quadrature integration method, we can express the element mass matrix of equation (9) as equal is to the right side of equation (11) as follows: [0000] M ij e = ∫ Ω e  φ i  φ j   Ω e = ∫ - 1 1  ∫ - 1 1  ∫ - 1 1  h 3 8  c 2  φ i  φ j   ξ   η   ζ = ∑ p = 1 n  ∑ q = 1 n  ∑ r = 1 n  w p  w q  w r  F  ( ξ p , η q , ζ r ) ( 11 ) [0035] In equation (11), M ij e is an element mass matrix, p,q,r is indices of the Gaussian quadrature points in 3-dimensional domain, h is a grid interval. Φ i , Φ j are values of shape function at i-th and j-th nodes. Each of the shape functions has a value of ‘1’ at a grid point and has values of ‘0’ at all the other points. All of the shape functions have values of ‘1’ at different grid points. The local coordinates of an integration point are ξ p , η q , and ζ r , and F(ξ p , η q , ζ r ) is the value of the multiplication of shape functions at the local coordinates. [0036] Because the velocity, c is a function of space, it is not constant within an element at the sea bottom when the grid interval is coarse enough for the sea bottom to pass through the element. However, the conventional 3D Laplace-domain modelling technique has a resolution problem because it describes the different velocities in a single element as one velocity. To reflect two velocities in one element, we use different F (ξ p , η q , ζ r ) values corresponding to the velocity of each Gaussian quadrature point (ξ p , η q , ζ r ) when integrating the mass matrix of the element at the sea bottom as follows: [0000] F  ( ξ p , η q  ζ r ) = { h 3 8  c Ω   1 2  φ i  φ j if   ( ξ p , η q , ζ r ) ⋐ Ω   1 h 3 8  c Ω2 2  φ i  φ j if   ( ξ p , η q , ζ r ) ⋐ Ω   2 ( 12 ) [0037] where Ω 1 and Ω 2 are domains containing elements divided by the sea bottom. This method can be interpreted as a kind of weighting using the spatial distribution of velocity as weighting for the velocity component. If we apply only one component in an element at the sea bottom, whether we select the water velocity or the subsurface velocity, the value of the mass matrix is one of the two extremes. Thus, instead of taking an extreme value, we use a moderate value reflecting the two velocities. [0038] A number of examples have been described above. Nevertheless, it will be understood that various modifications may be made. For example, suitable results may be achieved if the described techniques are performed in a different order and/or if components in a described system, architecture, device, or circuit are combined in a different manner and/or replaced or supplemented by other components or their equivalents. Accordingly, other implementations are within the scope of the following claims.
A seismic imaging method for imaging a subsurface structure is provided. The seismic imaging method calculates a coefficient matrix of a wave equation according to a contour of the sea bottom within a global grid. This method can be used to accurately estimate signals reflected on or transmitted through the sea bottom because it accurately reflects more detailed contours of the sea bottom within the global grid. Moreover, computational overburden is minimized.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention The subject invention relates to switched-mode power supply circuits for television receivers. 2 . Description of the Related Art Switched-mode power supply circuits are used in television receivers to provide main operating power and stand-by power to the various circuit in the television receiver. A particular type of switched-mode power supply circuit provides stand-by power using a burst mode of operation. Although power consumption during this stand-by burst mode is low, there is still an appreciable amount of power being consumed. Thus, the television receiver also includes a main power switch for terminating all power to the television receiver when a user anticipates that the television receiver will not be used for a significant period of time. This main power switch is usually in the form of a mechanical switch which is bulky and expensive. SUMMARY OF THE INVENTION It is an object of the present invention to provide a functional ON/OFF switch for a switched-mode power supply circuit in a television receiver, which is low-cost and small in size, and which is capable of very low power consumption during an OFF state. The above object is achieved with a switched-mode power supply circuit having an operating mode and a stand-by mode, said switched-mode power supply circuit comprising means for generating a d.c. supply voltage having a first output terminal and a second output terminal; a transformer having a primary winding, an auxiliary primary winding, a first secondary winding and a second secondary winding, said primary winding having a first terminal coupled to the first output terminal of said generating means, and a second terminal; a controllable switch connected in a series with the second terminal of said primary winding and the second output terminal of said generating means; a main output capacitor coupled across output terminals of said first secondary winding for providing a first main output voltage in the operating state and a second main output voltage in the stand-by mode, said second main output voltage being lower than said first main output voltage; a control output capacitor coupled across output terminals of said second secondary winding for providing a control output voltage; means for selectively coupling one of the output terminals of said first secondary winding to said second secondary winding during said stand-by mode; an opto-coupler having light emitting means and light detecting means optically coupled to said light emitting means; means for selectively coupling the light emitting means of said opto-coupler across said control output capacitor during said stand-by mode; means for causing said light emitting means to emit light to said light detecting means when the control output voltage across said control output capacitor exceed a predetermined value during said stand-by mode; a controller having an output for supplying switching signals to said controllable switch, an auxiliary voltage sensing input coupled, via a shunting auxiliary capacitor, to said auxiliary primary winding of said transformer, and a stand-by mode detecting input coupled to an output of said light detecting means, said light detecting means having an input coupled to receive said auxiliary voltage, said controller comprising a start-up current source for charging said auxiliary capacitor during start-up of said switched-mode power supply, whereby, during said stand-by mode, said stand-by current source is used to intermittently charge the auxiliary capacitor when said controllable switch is not switching; and means for selectively coupling said stand-by mode detecting input of said controller to said first output terminal of said generating means, wherein said controller further comprises means for turning off said start-up current source and means for stopping said switching signals, thereby turning off said switched-mode power supply circuit, when said first output terminal is not coupled to said stand-by mode detecting input. In the above switched-mode power supply circuit, when the OFF mode is desired, the coupling of the first output terminal of the generating means to the stand-by mode detecting input of the controller is removed. The drop in voltage at the stand-by mode detecting input is detected by the turning off means which, in response, turns off the start-up current source and activates the means for stopping the switching signals. This then effectively turns off the switched-mode power supply circuit, in that it now only consumes approximately 300 μA of current. Applicants have found that when replacing the main mechanical switch with the functional ON/OFF switch of the subject invention, it is necessary to ensure that the switched-mode power supply circuit consumes a minimum amount of power, e.g., 15 watts, even in the event of faults. To that end, the switched-mode power supply circuit as described above, is characterized in that the controller further comprises means for limiting power consumption when said coupling means selectively uncouples the first output terminal of said generating means from said stand-by detecting input of said controller. BRIEF DESCRIPTION OF THE DRAWINGS With the above and additional objects and advantages in mind as will hereinafter appear, the invention will be described with reference to the accompanying drawings, in which: FIG. 1 shows a schematic diagram of a prior art switched-mode power supply circuit having a mechanical ON/OFF switch; FIG. 2 shows a schematic block diagram of a first embodiment of a switched-mode power supply circuit according to the subject invention; FIG. 3 shows a schematic block diagram of a second embodiment of a switched-mode power supply circuit according to the subject invention; and FIG. 4 shows a block diagram of the start-up current source and Vcc management circuit as well as the over-current protection circuit contained in the controller. DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a schematic block diagram of a known switched-mode power supply using primary control. In particular, a diode rectifier bridge REC is connected to a line voltage source through a master switch SWM. An output from the rectifier bridge REC is connected to ground through a capacitor C11 and to one end of a primary winding L11 of a transformer TR. The other end of primary winding L11 is connected to one terminal of a controllable switch Tr11, the other terminal of which being connected to ground through a sense resistor R SENSE . A first secondary winding L12 of the transformer TR has a first end and a second end connected to each other through a series arrangement of a diode D11 and a main output capacitor C12, the second end of the first secondary winding L12 also being connected to ground. A load (not shown) may be connected across the main output capacitor C12. The transformer TR also includes a second secondary winding L13 having a first end and a second end connected to each other through a series arrangement of a diode D12 and a control output capacitor C13, the second end of the second secondary winding L13 also being connected to ground. A microprocessor (not shown), for controlling, for example, a television receiver in which the switched-mode power supply circuit is installed, is connected across the control output capacitor C13 to receive operating power. The first end of the first secondary winding L12 is also connected, via a diode D13 and a controllable switch Sw1, to one end of the control output capacitor C13, while the control output capacitor C13 is shunted by a series arrangement of a light emitting diode D14 of an opto-coupler, a Zener diode Z1 and a controllable switch Sw2. The controllable switches Sw1 and Sw2 are controlled by a signal from the microprocessor to initiate the stand-by mode of the switched-mode power supply circuit. The transformer TR further includes an auxiliary primary winding L14 which has one end connected to a diode D15, and then to ground through a V AUX capacitor C14, to a V AUX input of a controller IC, and to one terminal of a light sensor Tr12 of the opto-coupler, the other terminal of the light sensor Tr12 being connected to a stand-by mode detecting input (OOB) of the controller IC. The other end of the auxiliary primary winding L14 is connected to ground. The controller IC also has a V IN input connected to the output of the rectifier bridge REC, a DEMAG input connected through a resistor R11 to the one end of the auxiliary primary winding L14, a driver output connected to the control input of controllable switch Tr11, and an I SENSE input connected to the resistor R SENSE . In order to turn off the switched-mode power supply circuit, one merely activated the switch SWM which cut off power to the rectifier bridge REC. However, this type of switch is costly and bulky due to the amount of power that it must handle. FIG. 2 shows the switched-mode power supply circuit of FIG. 1 in which the subject invention has been incorporated. In particular, the series arrangement of two resistors R12 and R13 and a Zener diode Z2 is connected between the first output terminal of the rectifier bridge REC and ground. The junction between the Zener diode Z2 and resistor R13 is connected to the OOB input of the controller IC via a switch Sw3, which is further connected to ground via a resistor R14. When it is desired to turn off the switched-mode power supply circuit, switch Sw3 is opened, removing the voltage across the Zener diode Z2 from the OOB input of the controller IC. The controller IC detects this drop in the voltage on the OOB input and stops the controllable switch Tr11 from switching. In this state, the controller IC draws less than 300 μA thereby effecting the OFF state. The embodiment shown in FIG. 2 uses a separate opto-coupler in primary sensing to signal the controller IC that burst mode stand-by is desired. However, in most switched-mode power supplies, an opto-coupler is already being used to regulate the control voltage during normal operation. FIG. 3 shows a second embodiment of the switched-mode power supply circuit of the subject invention in which the already existing opto-coupler is additionally used in secondary sensing to signal burst mode standby operation. In particular, the light emitting diode D14 of the opto-coupler is connected through resistors R15 and R16 to the anode of a Zener diode Z3, the cathode of which being connected to ground. A series combination of a resistor R17 and a capacitor C15 connects the anode of the Zener diode Z3 to a control terminal of the Zener diode Z3 and to junction point between resistors R18 and R19 connected between the output of the first secondary winding L12 and ground. Switch Sw2 connects the anode of Zener diode Z1 to the output of the second secondary winding L13, the cathode of Zener diode Z1 being connected to ground through the series arrangement of resistors R20 and R21. The junction between resistors R15 and R16 is connected to the collector of an NPN transistor Tr13, having an emitter connected to ground and a base connected to the junction between resistors R20 and R21. On the primary side, the junction between the light sensor Tr12 of the opto-coupler and the diode D16 is further connected through a resistor R22 to a V CNTL input of the controller IC which is also connected to ground through the parallel arrangement of a resistor R23 and a capacitor C16. During normal operation, transistor Tr13 is off and the intensity of the light being emitted by the light emitting diode D14 of the opto-coupler is controlled by the circuit R16-R19, C15 and Z3. This variable light intensity causes a corresponding response in the light sensor Tr12 which applies a portion of the V AUX voltage to the V CNTL input of the controller IC for regulating the duty cycle of the controllable switch TR11, which is beyond the scope of the present invention and will not be described further. However, when the microprocessor signals burst mode stand-by operation by closing switches Sw1 and Sw2, due to the increased control output voltage across the control output capacitor, transistor Tr13 turns on fully causing the light emitting diode D14 to emit a much increased light output, which, in turn, causes the light sensor Tr12 to apply the whole of the V AUX voltage to the OOB input of the controller IC. As shown in FIG. 4, the controller IC includes a start-up current source 30 coupled to the V IN input and a Vcc management circuit 32 connected to the V AUX input. The OOB input is connected to a resistor R24 and then to a first comparator 34 for comparing the voltage thereon to +2.4V, and generating an "OFF/ON" signal. This OFF/ON signal is applied to an input of the Vcc management circuit 32. The resistor R24 is also connected to the collector of an NPN transistor Tr15. The base of transistor Tr15 is connected to a voltage source Vcca, and to ground via a Zener diode Z4. The emitter of the transistor Tr14 is connected to a second comparator 36 for comparing the voltage thereon to +1.4V, for generating a "Burst Mode Stand-by" signal S6. This signal S6 is applied to the start-up current source 30 and to one input of an OR-gate 38. An output (S5) from the Vcc management circuit 32 is also applied to the start-up current source 30 and to an inverting input of OR-gate 38. An output from OR-gate 38 is applied to the reset input of an RS flip-flop 40, the set input being connected to an output of an oscillator 42. The Q output from the RS flip-flop 40 is connected to one input of an AND-gate 44 which has an output connected to a driver 46 for driving the controllable switch Tr11. The operation of the switched-mode power supply circuit will now be described. When line voltage is applied to the rectifier bridge REC, with switch Sw3 open, the controller IC is in a "sleep mode" and the current consumption is less than 300 μA. Once switch Sw3 is closed, the voltage on the OOB input is then equal to the Zener diode Z2 voltage (i.e., higher than +2.4V) causing the output from the OFF/ON comparator 34 to go "high". This commences a start-up sequence and Vcc management circuit 32 turns off the S5 signal causing the start-up current source 30 to generate a current I1 for charging the V AUX capacitor C14. Once the V AUX voltage rises above a predetermined level, the Vcc management circuit 32 turns on the signal S5 and the controller IC (at t 2 <t<t 4 ) now starts causing the controllable switch Tr11 to switch which then causes the transformer TR to start transferring energy from the primary winding. L11 to the secondary windings L12 and L13, and also to the auxiliary primary winding L14 which then takes over supplying the V AUX capacitor C14. The switched-mode power supply circuit is now in normal operation. When burst mode stand-by operation is desired, the microprocessor closes switches Sw1 and Sw2 thereby coupling the first secondary winding L12 to the second secondary winding L13 thereby removing energy from the main output capacitor C12. In addition, switch Sw2 connects the light emitting diode D14 of the opto-coupler and the Zener diode Z1 across the second secondary winding L13. The coupling of the first and second secondary windings L12 and L13 now causes an increase in the control output voltage across the control output capacitor C13. When the control output voltage exceeds the Zener diode Z1 voltage, the light emitting diode D14 is energized. This causes the light sensor Tr12 to couple the V AUX voltage to the OOB input of the controller IC. Since the V AUX voltage is in excess of, for example, +5.6V, the comparator 36 generates the signal S6 resetting the flip-flop 40 which stops the controllable switch Tr11 from switching. Once the controllable switch Tr11 stops switching, transformer TR ceases transferring energy form the primary winding L11 to the first and second secondary windings L12 and L13 and to the auxiliary primary winding L14. As a result, the control output capacitor C13 and the V AUX capacitor C14 begin to drain causing the control voltage and the V AUX voltage to begin to drop. When the control voltage drops below the Zener diode Z1 voltage, the light emitting diode D14 stops emitting light, the light sensor Tr12 removes the V AUX voltage from input OOB of the controller IC, and the comparator 36 stops generating the signal S6. The V AUX voltage has been dropping during this time and when the V AUX voltage has dropped to an under-voltage V UVLO level, the Vcc management circuit 32 stops generating the signal S5 thereby maintaining the reset condition of the flip-flop 40, and activating the start-up current source 30 for charging up the V AUX capacitor C14 thereby raising the V AUX voltage. Once the V AUX voltage is at a start-up voltage V START level, the Vcc management circuit 32 generates the S5 signal which turns off the start-up current source 30 and allows the controllable switch Tr11 to commence switching. The switching of the controllable switch Tr11 allows the transformer TR to transfer energy from the primary winding L11 to the first and second secondary windings L12 and L13 and to the auxiliary primary winding L14. This cycle then repeats itself until the microprocessor opens switches Sw1 and Sw2 indicating an end to the burst mode stand-by operation and a return to normal operation. When using the functional switch Sw3, it is important that the power consumption of the switched-mode power supply circuit be kept to a minimum level, e.g., 15 watts, even in the event of a fault. The circuit of resistors R14, R24 and R25, and transistor Tr15 provide this protection. In particular, when switch Sw3 is open, resistor R14 ensures that the voltage at the OOB input is close to ground. The first comparator 34 then senses an OFF state and the controller IC goes into a "sleep" mode where it does not start the switched-mode power supply circuit. Burst mode is initiated by the light sensor Tr12 of the opto-coupler. When activated, the light sensor Tr12 forces a voltage greater than +5.6V at the OOB input and at the same time, provides a current large enough to force a voltage greater than the reference voltage, i.e., +1.4V, of the second comparator 36 on the resistor R25. The output of second comparator 36 then goes high and causes the switched-mode power supply circuit to go into burst mode stand-by operation. Resistor R24 is chosen based on a fault condition where the input OOB is shorted to the V AUX input. In such a situation, the system should then go into burst mode operation thereby keeping the dissipation in the switched-mode power supply circuit below 15W. To this end, R24 acts as a current limiter. Transistor Tr13 is chosen to be a bipolar NPN transistor, instead of a PMOS type transistor, because of the high threshold voltage of a PMOS transistor (2.1V). Due to this higher threshold voltage, the burst mode trip level would be raised. The higher trip level would then make it impossible to put the switched-mode power supply into burst mode stand-by operation when a fault occurred. When there is a short circuit between the OOB input and the V AUX input, the voltage V AUX is applied to the OOB input causing the second comparator 36 to detect burst mode stand-by operation. The controllable switch Tr11 is turned off and the Vcc management circuit 32 monitors the V AUX voltage. Due to the short circuit, the V AUX voltage gets clamped at a voltage level V CLAMP , where: V.sub.CLAMP =V.sub.CCA +0.6 +(I.sub.start *R24) The voltage V CLAMP has a dependence on the value of R24, I START from the start-up current source 30, and temperature. Depending on the value of V CLAMP , the V AUX voltage can get clamped at a voltage which is lower than the start-up voltage for the controller IC. In such a state, the controller IC "hangs" and never initiates a start-up. If V CLAMP is higher than the start-up voltage, the controller IC starts up and immediately senses a burst mode condition. Numerous alterations and modifications of the structure herein disclosed will present themselves to those skilled in the art. However, it is to be understood that the above described embodiment is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
A switched-mode power supply circuit having an operating mode and a stand-by mode, includes a functional ON/OFF switch. The switched-mode power supply circuit includes a transformer and a controllable switch connected to a primary winding of the transformer for switchably connecting the primary winding to a source of d.c. voltage. In the stand-by mode, based on a detected voltage level at an input of a controller IC, the switched-mode power supply circuit is arranged to switchable connect the primary winding to the d.c. voltage source in bursts which occur at a low frequency. By switchably connecting this input to a power source for the switched-mode power supply circuit, the controller IC detects the absence of this power source, and turns off the switched-mode power supply circuit allowing a minimum current consumption by the switched-mode power supply circuit.
8
This application is a continuation of Ser. No. 08/269,232, now abandoned, filed Jun. 6, 1994. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates generally to financial market data processing systems and specifically to a fault-tolerant computer-implemented system for assembling world-wide financial market data for regional distribution. 2. Discussion of the Related Art The continuous reporting from the major exchanges (e.g., New York Stock Exchange, Chicago Board of Options Exchange, et al.) of financial market data such as stock trades, option premiums, securities transaction volume and the like, is denominated in the art as the "ticker data feed", which normally includes transaction price and volume data associated with a trade keyed to a "ticker symbol" representing the security traded. Ticker feed data are created when a trade is actually made on the floor of the exchange. As such, the ticker data feed includes only the raw trading information reported by floor brokers and does not usually include derivative financial data such as accumulated volume, price extremes over selected time intervals, statistical trends, and consolidated data for securities traded on several independent exchanges. Moreover, the ticker data feed is unresponsive to requests for current financial market data for specific securities, which are available only from some database in which the ticker feed data are stored and updated. Recent advances in telecommunications technology have encouraged the proliferation of world-wide trading of securities through regional exchanges and through "virtual" exchanges that exist only in the amalgamation of computer systems denominated "cyberspace". This proliferation has given rise to new problems for the securities trader, such as fragmented markets for single securities, continuous 24-hour daily trading activity, and rapid market response to world-wide events. These new problems add to the long-felt problems in the art arising from delayed availability of derivative financial market data, individual portfolio valuation data and specific trading activity indicators or alarms. Although the effects of improved telecommunication technology operate to improve reporting of financial market data, they also exacerbate the effects of existing obstacles to the rapid collection, integration and distribution of world-wide financial market data. Although the present art is replete with systems and procedures for the collection, assembly, processing, storage and distribution of financial market data, the existing techniques neither anticipate nor solve the newer problems arising from rapid escalation of world-wide security trading on many different physical and virtual exchanges. For instance, tens of thousands of different financial instruments are traded on several dozen physical and virtual exchanges in the United States alone. In addition, several thousand mutual fund shares are traded in the United States alone. Thousands of additional financial instruments are traded on many dozens of other exchanges in Europe and the Far East. Other exchanges include Canadian, Mexican, South American, virtual government bond markets, etc. There is a market wherever a trade is made that generates financial market data of interest to the securities trader. Because financial market data accuracy and timeliness are directly quantifiable in monetary terms, there is a clearly-felt need in the art for a financial market data reporting system that collects world-wide security trading data wherever available and delivers such data in consolidated derivative form to regional users without failures such as error or delay. Because of the directly-quantifiable monetary value of financial market data quality, the art is replete with systems and procedures proposed by practitioners to overcome the accuracy and timeliness problems associated with reporting financial market data. For instance, in U.S. Pat. No. 4,677,552, H. C. Sibley, Jr., discloses an automated international commodity trade exchange having several local computerized trade exchanges located in at least two different countries and interconnected by satellite communication. Sibley's invention provides consolidated market data to the trader by means of user terminals, thereby permitting trades based on knowledge of the consolidated market instead of the local market. However, Sibley does not consider the collection, processing and distribution of data from scores of world-wide exchanges trading in tens of thousands of different securities involving hundreds of financial instrument types other than commodity contracts. Other practitioners have disclosed improvements in local trading systems. For instance, in U.S. Pat. No. 5,101,353, William A. Lupien et al. disclose an automated system for improving market liquidity through computer-implemented trading apparatus. Their system uses data processing equipment to place trading orders in external securities markets and through automated "brokers" (in cyberspace) that execute trades directly between system users. Lupien et al. consider solutions to the external market liquidity problems arising from large institutional trades and do not consider the collection and distribution of world-wide financial market data. Similarly, in U.S. Pat. No. 4,674,044, Leslie P. Kalmus et al. disclose an automated securities trading system that operates as a "virtual" trading floor for selected securities. Their system reports executed trade details to the customer and to national stock price reporting systems and responds to changes in security trading prices by updating all relevant internal parameters. Kalmus et al. provide a solution to the automated trade-quality problem known for virtual exchanges but neither consider nor suggest methods for rapid and accurate accumulation of world-wide exchange transaction data for distribution to regional users. Also, in U.S. Pat. No. 5,038,284, Robert M. Kramer discloses a method and apparatus for conducting trading transactions in a network of portable trading stations. Kramer teaches a computer-assisted "pit" trading system that uses portable computer terminals to automatically report and reconcile all trades without the usual risk of confusion or error associated with the loud and boisterous "pit" environment of commodity exchange floors. Some practitioners propose solutions to the "derivative market data" distribution problem, otherwise denominated the "portfolio tracking" problem in financial market data systems. For instance, in U.S. Pat. No. 4,989,141, Richard J. Lyons et al. disclose a computer system for financial analysis and reporting of individualized market portfolio performance. Lyons et al. ignore the problem of accurate trading reports. Similarly, in U.S. Pat. No. 4,566,066, Frederic C. Towers discloses a securities valuation system that employs a general purpose digital computer to produce securities portfolio valuation schedules for many simultaneous users. Like Lyons et al., Towers merely assumes accurate daily updates to the basic financial market data without considering the above-described quality problems. More pertinently to the global financial data quality problem, numerous practitioners suggest improved local market quotation systems. For instance, in U.S. Pat. No. 4,473,824, Richard N. Claytor discloses a price quotation system for distributing financial market data. Claytor's system includes a transceiver for receiving financial market data and for broadcasting selected data to users possessing handheld portable receiving and display devices. Claytor essentially discloses a "ticker-tape" transmitter with portable receiving terminals suitable for tracking trading activity related to a few user-selected securities and neither considers nor suggests techniques suitable for compiling and distributing world-wide financial market data for tens of thousands of different securities. Earlier, in U.S. Pat. No. 3,611,294, Jerry D. O'Neill et al. disclose a system of disseminating financial market data from a central broadcasting station to a plurality of portable radio receivers. Again, O'Neill et al. merely disclose a method for transmitting raw exchange "ticker data feeds" to individual users who may then accumulate data for a few user-selected securities. Also, in U.S. Pat. Nos. 4,677,434 and 5,045,848, Anthony C. Fascenda discloses a similar system for encoding and broadcasting financial market data by commercial radio transmitter to a plurality of specially-equipped portable radio receivers. Fascenda employs commercial FM broadcast spectra to transmit ticker data interleaved with a repeated stream of derivative financial market data. Fascenda considers data encoding and compression together with encryption methods to control access and improve channel efficiency but neither considers nor suggests methods for the accumulation, processing and distribution of high-quality world-wide financial market data. Early practitioners in the art considered the limited problem of ticker data feed distribution to regional centers by land-line. For instance, in U.S. Pat. No. 3,082,402, J. R. Scantlin discloses a securities quotation apparatus that uses telephone lines to distribute exchange ticker data to regional customers who may then accumulate, process and distribute data to their clients. In U.S. Pat. Nos. 3,513,442 and 3,689,872, Frank W. Sieracki discloses a financial market data retrieval and quoteboard multiplex system that permits regional users to request and receive specific financial market data on demand from a central ticker data stream using telephone lines. In U.S. Pat. No. 4,942,616, Thomas Linstroth et al. disclose an interactive synthesized-speech quotation system for brokers that is suitable for automated response to clients who call in telephone price quote requests for individual securities. Their system offers human-speech response to such requests without human intervention. Nothing in the present art is readily suitable for accumulating, processing and distributing financial market data of the quality and the scale required to satisfy demands arising from the recent improvements in world-wide trading technology. Such a system must be completely reliable and therefore tolerant of any possible system element failures. Data distribution must occur through the system without significant delay. Data errors must be detected and corrected, either automatically or with cued manual intervention. Finally, such a central ticker plant system must provide for adding ticker data streams from new physical and virtual exchanges and must provide for customized distribution that is responsive to user command. Nothing in the related art is suitable for resolving all of these problems. These unresolved problems and deficiencies are clearly felt in the art and are solved by this invention in the manner described below. SUMMARY OF THE INVENTION The system of this invention solves the above problems by making and combining several improvements to the art. These improvements include (a) a new three-level system architecture, (b) a new redundant multi-platform hardware protocol, (c) a new broadcast feed data blocking protocol, (d) the use of multi-thread processing techniques and (e) a new Data Quality Assurance (DQA) procedure for error detection and correction. This invention combines these and other selected elements to create a new Central Ticker Plant (CTP) system for accumulating financial market data from scores of exchanges throughout the world, for processing these data to correct errors and to calculate derivative financial market data and for distributing these financial market data to a plurality of regional users, who may each submit interactive requests for customized data services. It is an object of this invention to provide continuous CTP system operation without downtime for hardware or software repairs. It is a feature of this invention that redundant hardware architecture, including redundant database processors and redundant input data feeds, ensure continuous system operation during failures. It is another object of this invention to provide rapid distribution of error-free financial market data without substantial accumulation, processing and distribution delays. It is an advantage of a preferred embodiment of this invention that incoming data are made available for output in less than 500 milliseconds. It is another advantage of the system of this invention that all incoming data is guaranteed delivery to the system output. Finally, it is a feature of this invention that all incoming ticker data correction messages from financial market data sources are automatically processed to correct financial market data errors. It is yet another feature of this invention that a cued manual DQA interface is provided for analyzing and correcting all "exceptions" flagged by error-detection devices within the CTP system. It is yet another object of this invention to provide output data feeds that adapt to user commands. It is a feature of this invention that output data feeds can be configured responsive to user requests and broadcast data can be selected for repetition responsive to user request. The foregoing, together with other objects, features and advantages of this invention, will become more apparent when referring to the following specification, claims and the accompanying drawing. BRIEF DESCRIPTION OF THE DRAWING For a more complete understanding of this invention, reference is now made to the following detailed description of the embodiments as illustrated in the accompanying drawing, wherein: FIG. 1 is a functional block diagram showing an exemplary financial market data system embodiment including the Central Ticker Plant (CTP) system of this invention; FIG. 2 is a functional block diagram illustrating a data flow architecture of the CTP system of this invention; FIG. 3 is a functional block diagram illustrating the market data flow for the CTP system of this invention; FIG. 4 is a functional block diagram illustrating the custom output feed management data flow for the CTP system of this invention; FIG. 5 is a functional block diagram illustrating the Data Quality Assurance (DQA) data flow for the CTP system of this invention; FIG. 6 is a functional block diagram illustrating the output feed recovery data flow for the CTP system of this invention; FIG. 7 is a functional block diagram illustrating the system control data flow for the CTP system of this invention; FIG. 8 is a functional block diagram showing an illustrative hardware embodiment of a financial market data center that includes the CTP system of this invention; FIG. 9 is a functional block diagram showing an implementation of the input bin feed processing data flow in the exemplary CTP system embodiment of FIG. 8; FIG. 10 is a functional block diagram showing an implementation of the Options Price Reporting Authority (OPRA) input processing data flow in the exemplary CTP system embodiment of FIG. 8; FIG. 11 is a functional block diagram showing an implementation of the DQA processing data flow in the exemplary CTP system embodiment of FIG. 8; and FIG. 12 is a functional block diagram showing an implementation of the retransmission recovery processing data flow in the exemplary CTP system embodiment of FIG. 8. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The system of this invention can be appreciated in the context of the embodiment of the financial market data system 20 shown in FIG. 1. The Central Ticker Plant (CTP) 22 receives financial market data on a plurality of input feeds exemplified by input feed 24. CTP 22 produces an output data stream on a broadcast feed 26, which is coupled to a Local Area Net (LAN) 28 for distribution to a variety of message destinations. For instance, broadcast feed 26 provides data messages destined to an "underlying network" of customers, exemplified by the remote site 30 and destined to a plurality of Query Response Centers (QRCs) exemplified by QRC 32. All output data messages include information specifying the message destination. Typically, a single broadcast feed output is received by all QRC systems, which are preferably physically collocated with CTP 22. As used herein, a "feed" denominates a stream of financial market data messages transferred from a single source to one or more message destinations. Broadcast feed data and customer inquiry responses are communicated by way of a Wide Area Network (WAN) 34, which may include any suitable telecommunication system known in the art. LAN 28 communicates with WAN 34 by means of the network Point of Presence (POP) 36. Remote site 30 includes, for example, a similar network POP 38, which couples WAN 34 to the customer local area network (LAN) 40. Broadcast feed data are transferred from CTP 22 through LAN 28 and POP 36 to WAN 34, and therefrom to POP 38 and through LAN 40 to the destination premises system 42, where the financial market data messages are processed by the customer. Customer inquiry commands retrace this path through WAN 34 to LAN 28 and therefrom to a Query Response Center, exemplified by QRC 32. QRC 32 then produces local commands and sends them to LAN 28 and therefrom to CTP 22, which responsively provides the appropriate financial data output messages to LAN 28. These customer inquiry response messages are also transmitted through POP 36 to WAN 34 and therefrom to the customer system at remote site 30. Financial data system 20 includes an assigner 44, which accepts reports of the "state" of CTP 22 by way of LAN 28. Assigner 44 is responsible for maintaining the internal states of "primary" CTP 22 and a backup or "secondary" CTP 45 and for sending state transition commands to both. Primary CTP 22 and backup or secondary CTP 45 are identical in every respect, with backup CTP 45 giving fault-tolerant redundancy to the financial market data system of this invention. Although both CTPs need not be physically collocated, it is preferred that secondary CTP 45 be coupled to LAN 28 substantially as shown. Financial market data system 20 is managed by a System Management Facility (SMF) 46 that responds to system-level events and alarms related to local failures, application errors, activation and deactivation, and the like. Finally, the customer service system (CSS) 48 maintains customer records and gives authorization for responding to incoming customer inquiries. CSS 48 also provides the message destination details required in all broadcast feed data messages. Financial market data system 20 is fully redundant in hardware and software. Two redundant CTP systems, exemplified by CTP 22 and CTP 45, are maintained concurrently so that processing continues uninterrupted in the event of any single component failure. System 20 operates continuously 24 hours per day seven days per week. All maintenance and repair functions are performed without interrupting continuous system operation. These features are further described below. During normal operation, CTP 22 collects, validates, normalizes and enhances financial market data received from many financial exchanges throughout the world and produces output data messages having a standardized message format for delivery to customer destinations throughout the region. CTP 22 also provides special custom feeds carrying financial data to specified customers that are modifiable responsive to commands received from the message destination. As used herein, CTP 22 is said to be in "CTP online-primary" status under these circumstances. While in such status, CTP 22 is capable of receiving and spooling and processing financial market data from data sources, is capable of communication with the "underlying network" of message destinations, creates and broadcasts output feeds and is capable of providing feed recovery to the underlying network. While CTP 22 is in online-primary state, backup CTP 45 is in one of four alternate states. These four alternate states are "CTP offline", "CTP rebuild", "CTP secondary", and "CTP online-contingency" state. While in "offline" state, backup CTP 45 is incapable of receiving and broadcasting market data and does not communicate with the financial market data sources or the underlying destination network of customers. While in the "rebuild" or the "secondary" state, backup CTP 45 is capable of receiving and spooling financial market data from the data sources and can receive processed market data from "primary" CTP 22, but backup CTP 45 cannot communicate with the underlying destination network. Finally, when in the "online-contingency" state, backup CTP 45 can receive and spool input feed data from the financial market data sources, can receive processed market data from "primary" CTP 22 and can communicate with local QRCs and other remote financial market data systems exemplified by system 20, but cannot communicate with the underlying destination network. Upon failure within CTP 22 while in the primary state, a message is sent to assigner 44, which then arbitrates a switchover from primary CTP 22 to backup CTP 45. This switchover is accomplished by changing state within CTPs 45 and 22 responsive to commands from assigner 44. For example, CTP 22 is switched from primary state to secondary state responsive to a command from assigner 44, which disconnects CTP 22 from the underlying destination network before another command from assigner 44 switches CTP 45 from online-contingency state to primary state, which connects CTP 45 to the underlying network. Upon catastrophic hardware or software crash in CTP 22, the CTP state is automatically switched from primary to offline. Such state change may also occur responsive to a command from assigner 44. In switching to offline status, CTP 22 disconnects from the underlying destination network, disconnects from the financial data input feeds, saves a checkpoint copy of the market database onto a disk and sends an acknowledgment to assigner 44. Upon failure of CTP 22, backup CTP 45 must be switched from "secondary" or "online-contingency" state to "online primary", which is managed merely by connecting backup CTP 45 to the underlying destination network responsive to a command from assigner 44. This is sufficient because backup CTP 45 maintains a concurrent database copy while in the secondary state by processing data received on the input feeds and from primary CTP 22. Of course, following repair of a catastrophic hardware or software failure, the repaired CTP must be transitioned from "offline" state to either the "secondary" or the "online-contingency" state by rebuilding a concurrent database. When rebuilding, the recovering CTP is assigned to the "rebuild" state discussed above. Either CTP is transitioned from the offline state to the rebuild state responsive to a "power-up" by first booting the system, establishing links to SMF 46 and assigner 44, checking software and database integrity, establishing communication with the primary CTP and requesting data recovery. After rebuilding, the recovering CTP is switched from the rebuild state to the secondary state responsive to completion of the rebuild procedure. This is accomplished when the two redundant databases are synchronized in concurrency. The transition to secondary state occurs by first starting input data spooling, switching to secondary state and finally reporting status to SMF 46 and assigner 44. The transition from secondary state to online-primary state is initiated by command from assigner 44 and requires that both CTP databases be synchronized and that both CTPs have input data spooling in progress. The transition to primary state occurs by first establishing the connection to the underlying destination network, then synchronizing data with the input spool files, starting input data processing at the market data feeds, creating custom and broadcast output data feeds and finally reporting status to SMF 46 and assigner 44. Duplication of the CTP hardware and software element provides the redundancy necessary to ensure continuous operation during maintenance and repair of either CTP 22 or 45. Moreover, each of the important CTP software elements also provide internal fault-tolerant redundancy. These fault-tolerant features are discussed in connection with the detailed description of CTP subsystems (FIGS. 3-7) after the following introductory overview in connection with FIG. 2. In summary, FIG. 1 shows that CTP 22 accepts data from financial market input feeds, cleanses the data, enhances the data, saves the data and broadcasts the data to the underlying destination network, which includes local Query Response Centers as well as regional customers. CTP 22 and the underlying destination network communicate by way of the wellknown Transmission Control Protocol/Internetworking Protocol (TCP/IP) communications standard to perform broadcast, retransmission/recovery, feeds management, customer entitlement validation and system control. CTP 22 and the QRCs exemplified by QRC 32 are preferably collocated physically. CTP 22 provides market data broadcast and retransmission recovery functions for financial market data system 20. CTP 22 communicates with SMF 46 over LAN 28 to monitor performance, configuration and system control. CTP 22 communicates with Customer Service System (CSS) 48 to validate entitlement of users requesting feed recovery and feed manipulation services. CTP 22 communicates with the backup or contingency site system exemplified by backup CTP 45 using LAN 28 to synchronize the two CTP databases and exchange status information. The internal operation of CTP 22 is shown in FIG. 2, which summarizes the dataflow architecture of CTP 22. Input feed 24 is coupled to an input feed subsystem 50, which includes multiple concurrent instances of the processing logic necessary for receiving financial market data feeds (ticker streams) from exchanges throughout the world. Each processing logic instance includes threads for receiving one or more input feeds from one exchange having a single input feed message protocol. Thus, CTP 22 accommodates the differing ticker stream protocols from the various exchanges by including an input feed processing logic instance for each known input feed message protocol. Redundant input feeds are also accommodated to improve input feed data accuracy and assist recovery from errors. For instance, FIG. 2 shows input feed 24 as a dual feed having input lines 24a and 24b, both of which provide identical ticker stream data. Some input feeds provide consolidated ticker stream data from many different exchanges. For instance, the Securities Industry Automation Corporation (SIAC) provides two ticker streams identified as the Consolidated Tape System (CTS) and the Consolidated Quote System (CQS). The CTS feed conforms to the latest revision of the Consolidated Tape System (CTS) Vendor Communications Interface Specifications of Jun. 10, 1986. The CQS stream conforms to the latest revision of Consolidated Quotation Service (CQS) Vendor Communications Interface Specifications of Apr. 15, 1987. Both the CTS and CQS input feeds provide ticker stream data from the New York Stock Exchange, American Stock Exchange, Midwest Stock Exchange, Pacific Stock Exchange, Philadelphia Stock Exchange, Cincinnati Exchange, Boston Stock Exchange, Third Market Exchange, Instinet Exchange, Consolidated File Exchange and the Chicago Board of Options Exchange Equities Stream. As another example, the Options Price Reporting Authority (OPRA) input feed conforms to the latest version of the Specification for Interface between OPRA Processor and Vendor dated Apr. 20, 1989 and includes ticker stream data from the American Options Exchange, the New York Options Exchange, the Chicago Board of Options Exchange, the Pacific Options Exchange and the Philadelphia Options Exchange. Up to four independent but redundant input feeds are accepted from each such financial data source to ensure fault-tolerance and continued operation during random telecommunication failures. Other domestic input feeds include ticker streams such as the National Association of Securities Dealers (NASD) Systems Stream, the Automated Bonds System High Speed Quotes (BQS) Stream, the Interexchange Technical Committee (ITC) Format Commodity Feeds (which include nine important commodity exchanges) and the Commodity Options Center Exchange Stream. Foreign input feeds include the European Options Input Feed, the London Metals Exchange (LMEX) Stream, the Tokyo Stock Exchange Stream,, the Osaka Stock Exchange Stream and streams from Hong Kong, Singapore, Amsterdam, Brussels, Paris, Frankfurt, Luxembourg, Milan, the Australian Stock Exchange and many other sites. Each of these ticker stream input feeds consists of a stream of input messages each conforming to a specific predetermined input message protocol. As used herein, an input message consists of a packet of financial market data organized according to an input message protocol. For example, a single input message may include a ticker symbol identifying a particular security, a bid price, an ask price, a trade price, a trade volume, a timestamp and other header and error correction data. Input feed subsystem 50 accumulates each such input message and passes the complete input message to the message conversion subsystem 52. Message conversion subsystem 52 includes multiple concurrent instances of the processing logic needed to convert an input message to an internal message having a normalized internal message protocol. Each instance of message conversion subsystem 52 verifies input message sequence number (where provided) and data consistency within the input message envelope. Each input message received during the past 24 hours is permanently stored in a 24-hour input spool 54, which is dumped to an archive and reset every 24 hours. Message conversion subsystem 52 converts the input message data to the CTP internal format and sends the resultant internal message to the message validation system 56. When an input message is found to be inconsistent with the corresponding protocol or when a message sequence number is missing, message conversion subsystem 52 automatically requests retransmission from the corresponding financial market data source where supported. Message conversion subsystem 52 also identifies and arbitrates removal of duplicate input messages from the incoming data stream. When one of two duplicate input messages is incomplete or otherwise in error, the valid copy is identified and retained for use by the CTP system. Message validation subsystem 56 provides multiple concurrent instances of the message validation logic each receiving a stream of internal messages each conforming to a normalized internal message protocol or format. Subsystem 56 provides for the processing of different classes of security instruments and for the storage of the market data changes (updates) into separate market data files. As used herein, financial market data includes trading information for a plurality of securities that are classified according to predetermined security classes or types. For instance, such security classes include stocks (equities), bonds, options, commodity contracts, and many others. Within each security class, many different securities are traded on many different exchanges. Message validation subsystem 56 is organized according to major security class, as are the market data file 58 and the market data history file 60. Message validation system 56 tests the incoming internal message data for consistency with the related financial market data values stored in market data file 58. When these consistency tests are satisfied, the appropriate derivative data are calculated from the incoming message data and the market data file 58 and history file 60 are changed (updated). A corresponding transaction message is then created and sent to the broadcast feeds subsystem 62. Market data history file 60 stores a full 24-hour series of such transaction messages for each financial market data source. When a consistency test fails, an exception message is produced in subsystem 56 and sent to the Data Quality Assurance (DQA) subsystem 64 and to the kickout file 65, which stores all such exception messages for manual processing. Message validation subsystem 56 also provides logic necessary for the automated processing of correction messages received from the source exchanges. The market statistics computing subsystem 66 provides internally generated financial market statistics and indices that are updated periodically responsive to the incoming financial data stream. These statistics are calculated from the contents of market data file 58 and market data history file 60 and are forwarded to broadcast feeds subsystem 62 after storage in market data file 58. Broadcast feeds subsystem 62 saves the transaction messages received from message validation subsystem 56 in a transaction log file 68, organizes the transaction messages into data blocks and assigns block sequence numbers in each feed, performs data compression and transmits the resulting broadcast feeds data to LAN 28 on line 26. Transaction log file 68 retains up to 48 hours of broadcast feeds data. The oldest 24 hours of these data are dumped to an archive daily, thereby maintaining a minimum of 24 hours of broadcast feed data with which to respond to retransmission requests received from users in the underlying network. Each broadcast data block is transmitted once for each feed. CTP 22 provides on line 26 a full (broadcast) feed of all data blocks for each destination in the underlying network. A number of independent customized data feeds each including a stream of blocked transaction messages for customer-selected securities are also interleavedly transmitted on line 26 responsive to requests received on the custom feed line 72. Broadcast feeds subsystem 62 spools the last 24 hours of output data blocks in the broadcast feeds history file 70. Feed recovery subsystem 74 processes requests for retransmissions received from the underlying network and arranges for resending the requested data blocks, first locating them in broadcast feeds history file 70 and then transferring them to LAN 28 on line 76. DQA subsystem 64 provides an interface for manual processing of corrections, errors, exceptions and administrative messages that cannot be automatically processed. DQA subsystem 64 also provides an interface for manual maintenance of market data file 58. Although data records for new securities can be added to market data file 58 as updates for new ticker symbols are received, this process is manually monitored through DQA subsystem 64, which also provides for the manual addition, deletion and adjustment to data content needed to accommodate financial market circumstances such as stock splits and dividend payments that are unreported in the input ticker streams. Custom feeds management subsystem 78 receives requests from the underlying network by way of interface 72 to LAN 28 for the addition or deletion of security ticker symbols to one of several feed lists in a custom feed definition file. All such requests are first referred to CSS 48 (FIG. 1) for verification before modifying custom feed content. Custom feeds subsystem 78 permits dynamic reconfiguration of a plurality of custom feeds tailored to individual customer requirements. The system control subsystem 80 provides configuration management, system initialization, system state management, and collects and reports statistics and alarms. System control subsystem 80 communicates to System Management Facility (SMF) 46 (FIG. 1) by way of the SMF Agent subsystem 82, which provides the primary interface between internal CTP applications and SMF 46. The CTP subsystems discussed above in connection with FIGS. 1 and 2 are now described in more detail. FIG. 3 shows the financial market data flow diagram for CTP 22 (FIG. 1). Input feed subsystem 50 accepts input feed data from the financial data sources as discussed above in connection with FIG. 2. Some input feeds, exemplified by input feed 24, are provided twice (e.g., 24a and 24b) over diverse paths from the source exchange to improve fault tolerance at the input feed. Processing of duplicate input lines produces redundant input messages because both identical input messages are processed except when one input message is discarded for error. Duplicate input messages are removed in message conversion subsystem 52. Each concurrent input processing logic instance in input feed subsystem 50 performs several functions. These include validating the input feed protocol envelope, ascertaining and reporting line status and statistics and controlling incoming line communications. Most input feed messages are enclosed in a specific line protocol envelope. Each message is checked for protocol validity. Messages that do not satisfy the validity checking logic are flagged as errors and forwarded to message conversion subsystem 52 for logging and additional error processing. Some input feed lines provide a line status or heartbeat message when no input data are being sent by the corresponding source exchange. These heartbeat messages serve to assure input feed subsystem 50 that the line is active and functional. When heartbeat messages are received, they are forwarded to message conversion subsystem 52 for logging. Input lines that do not provide line status or heartbeat messages are monitored with a configurable timer to provide an error message when the timer "times-out" between messages. These "time-out" error messages are also forwarded to message conversion subsystem 52 for logging. Several statistics and line status indicators are maintained for each input line. These include the current line and communications board status, the number of correct messages received since start-of-day or session (correct messages are those messages that satisfy the link level Cyclic Redundancy Checksum (CRC) error detection logic), the current and maximum correct-message rates (messages per second), the number of protocol errors found since start-of-day or session, and the current and maximum protocol error rates (errors per unit time). These line statistics are maintained for reference by SMF agent 82 (FIG. 2). A separate alarm indicator is set if an error rate reaches a predetermined threshold value. Input feed subsystem 50 also responds to commands issued by the System Management Facility 46 (FIG. 1) forwarded by way of SMF agent subsystem 82. These commands relate to the physical input/output parameters and line operation, including the "enable input line" and "disable input line" commands, which are merely representative of the types of hardware commands used. Input feed subsystem 50 communicates with message conversion subsystem 52 over the interface 84. Complete input messages are passed from subsystem 50 to subsystem 52. Message conversion subsystem 52 spools the input messages, performs header and data field validation activities and normalizes each input message to a common CTP internal format or protocol. A single concurrent conversion logic instance within message conversion subsystem 52 communicates with one or more concurrent logical instances within input feed subsystem 50, provided that all received input messages conform to the same input protocol requiring a similar header, data field validation and normalization actions. Messages sent by way of the communications interface 84 are received by message conversion subsystem 52 in sequential order. Interface 84 does not support priority queuing or any other method of message manipulation. A single concurrent logical instance of input feed subsystem 50 communicates with only one concurrent logical instance of message conversion subsystem 52. The relationship between subsystems 50 and 52 is governed by a predetermined input line configuration file. Message conversion subsystem 52 generates a retransmission request to input feed subsystem 50 over interface 84 when an out-of-sequence condition in the feed is detected, provided that automatic retransmission is supported by the corresponding market data feed source. Message conversion subsystem 52 receives incoming input messages from input feed subsystem 50 and timestamps them. This timestamp permits internal throughput monitoring. Subsystem 52 then spools the complete input messages and performs input arbitration, header and field validation, message normalization and message accounting procedures. This process also spools input feed data received outside the normal trading hours but normally does not otherwise process the data because doing so could contaminate the database with test data provided by the exchanges. Subsystem 52 spools all input message data to input spool 54 in a format as close as practical to the original input feed message protocol. Input spool 54 provides a record for use in auditing errors later found in market data file 58 and can be dumped and replayed for system diagnosis and testing purposes. Because duplicate input feeds are processed by input feed subsystem 50 for most market data sources, message conversion subsystem 52 receives duplicate copies of input messages from most sources. Duplicate input messages are identified and removed from the data stream in a process herein denominated as input message arbitration. Where duplicate input message feeds are processed, the input arbitration logic passes the first occurrence of each message regardless of its source. Neither duplicate input port is designated as a primary or secondary data source. After the first message has been processed, any later duplicate message is detected and removed from the data stream by arbitration logic (not shown) within the instance of message conversion subsystem 52. Complete input line statistics and error reporting is maintained for each redundant input feed. Where the redundant input feeds provided by the financial data source do not provide precisely identical messages, provision is made for manual assignment of the redundant input feeds as the "master" source, thereby forcing message conversion subsystem 52 to ignore all data from the secondary input feed. Input message header validation processing logic within each instance of message conversion subsystem 52 determines the message type, financial instrument class and the necessary processing. Data field validation logic within each instance compares the data format within each data field for consistency with the corresponding input message protocol field definition. The specific details of these functions are potentially different for each of the market data feeds arriving at CTP 22. An input message parser is provided for each financial data feed protocol and new protocols can be accommodated by adding the necessary corresponding parsing logic. Messages that fail the header validation test are forwarded, along with messages tagged as having failed the input feed envelope validation test received from input feed subsystem 50, to message validation subsystem 56 by way of the interface 86. Input messages that pass header validation logic testing and which have no earlier-appended fault flags are first normalized to a standard internal protocol and then forwarded to message validation subsystem 56. Message normalization logic within each logical instance of subsystem 52 converts each valid input message to the CTP internal record format. The resulting output on interface 86 is a normalized internal message conforming to the internal protocol for each valid input message. Message conversion subsystem 52 maintains statistics in each instance reporting the number of processed input messages, characters and errors by type, maintains a message sequence number independently for each market data feed and generates an alarm if a message sequence number is missed or if errors are detected at a rate above a predetermined threshold value. Also, subsystem 52 generates automatic retransmission requests to the market data source when message sequence numbers are missed, provided that the source accepts such requests. All normalized internal messages are tagged with a passed/failed validation indication to the appropriate logical instance within message validation subsystem 56 using an Instrument-to-Validation Routing Table. Message validation subsystem 56 first refers to market data file 58 to ensure the presence of the financial security class and instrument referenced in an internal message and performs range checking on the appropriate data fields. Each logical instance of subsystem 56 also calculates derivative data, generates market data file 58 entries and 24-hour history file update entries and finally creates a corresponding transaction message for transfer to broadcast feeds subsystem 62 over interface 88. A single logical instance within message conversion subsystem 52 can communicate with one or more logical instances within message validation subsystem 56. A single logical instance within subsystem 56 can communicate with one or more logical instances within message conversion subsystem 52. The particular financial market data source and the relevant financial instrument class together determine the relationship between concurrent instances of subsystems 52 and 56, as represented in the Instrument-to-Validation Routing Table. Internal messages sent over interface 86 are received by message validation subsystem 56 in sequential order and interface 86 does not support priority queuing or any other method of message manipulation. Each instance of message validation subsystem 56 performs several fundamental functions, including validating the existence of the security class and instrument, range check validation, sales condition processing, derivative data calculation, market and history file update and maintenance, automated corrections processing, periodic refresh cycle generation and feed list modification. Subsystem 56 spools all internal messages that fail validation to kickout file 65. Validated internal messages are converted to transaction messages and forwarded to broadcast feeds subsystem 62 together with an attached list of message destinations within the underlying network. Internal messages that fail the validation testing are forwarded as transaction messages to broadcast feed subsystem 62 with attached fault-indication data and a list of message destinations. Each logical instance of message validation subsystem 56 reads market data file 58 searching for the existence of the security named in an incoming internal message particular security is not found, subsystem 56 adds the security to data file 58 using a predefined parameter set for new data records. Additionally, the subsystem 56 instance generates a message to kickout file 65 indicating that the particular security was not found and providing information necessary to locate the newly created record keyed to the "ticker symbol" for that security. This procedure permits manual override of the automated procedure by a data quality administrator should the "new" security symbol arise because of error at the source of the incoming message. Because some financial data sources transmit messages conveying symbol additions, deletions and changes, message validation subsystem 56 automatically updates market data file 58 to reflect these changes. These automatic ticker symbol additions, deletions and changes also generate messages to kickout file 65 to permit the manual entry of any additional information required. Range checking logic within each instance of subsystem 56 automatically compares certain data fields with predetermined thresholds to detect errors. For example, range checking applicable to security classes such as equities includes reviewing data fields corresponding to "bid price", "ask price", and "trade price". Such range checking is done for each trade or quotation update message. That is, each of these fields is checked against previous values transmitted and, if the change in value is found to be beyond a predetermined magnitude, the entire message is flagged as an exception and diverted to kickout file 65 for manual processing. Of course, range checking parameters for the first trade of a session must differ from those of subsequent trades. Such range checking parameters are provided for each financial data source within each input feed. When there is more than one class of instrument traded at an exchange (having the same exchange identifier), the necessary plurality of range check parameters are provided for each class of instrument traded at the exchange. Range checking logic operates in an OVERRIDE mode, an OFF mode or an ON mode. OVERRIDE range checking logs all range check failures but permits application of the message data to market data file 58. OFF range checking applies all message data to market data file 58 and performs no range checking. ON range checking performs range checking on all data and permits only qualified message data to be applied to market data file 58. All failing messages are assembled into message blocks and transferred to kickout file 65. The range check values are freely modifiable for application to the next processing update message received. For instance, the first trade of a session is checked against the previous close and must be less than a defined increment or delta. Subsequent trades use thresholds exemplified by a fixed percentage of price within fixed ranges. If the price is out of range, a bid/ask range check is then performed and an exception message is generated and transmitted to kickout file 65 as well as forwarded with the appropriate rejection error code to broadcast feed subsystem 62. Additionally, internal messages received by message validation subsystem 56 from message conversion subsystem 52 that are flagged as having failed the feed envelope validation test or the header and data field validation tests are logged to kickout file 65 and forwarded to broadcast feed subsystem 62 with the appropriate rejection error code. Specific sale conditions require a special processing logic within each instance of message validation subsystem 56. For instance, equities processing requires a special provision for delayed opens, cancelling of last transaction, and sales where the price is not for the current last period. Processing of an unrecognized sale condition causes generation of an exception message that is logged to kickout file 65 for manual processing by the DQA operator. Because CTP 22 passes all sales conditions from the financial market data sources through to the underlying network of user destinations, two sale condition data fields are provided to broadcast feeds subsystem 62. The first of these is the original sale condition information received from the exchange and the second uses a mapped sale condition created by the special sales condition processing logic. Message validation subsystem 56 also performs the derivative data calculations stored in market data file 58. Additional to the current derivative data such as "day high", "day low" and "net change from previous close", CTP 22 maintains an update sequence number for each ticker symbol in addition to independent trading session derivative data, true 52-week highs and lows, contract life high/low, and a tally of new highs/lows for the day. A separate consolidated record is updated to provide these derivative data for issues that trade in a consolidated market over many different exchanges, such as many of the equities listed in the primary U.S. markets. Subsystem 56 updates market data file 58 and history file 60 and adds broadcast feed information, which includes a bit map of the message destinations for the particular security data within each transaction message. The broadcast feed information is stored with each ticker symbol in market data file 58. The transaction message enhanced by a broadcast feed bitmap is then retrieved from market data file 58 by subsystem 56 and transmitted to broadcast feeds subsystem 62 over interface 88. The appropriate statistics are then updated in market data file 58, which maintains a current record for each ticker security symbol. History file 60 maintains a history of updates applied to the current security record throughout the trading day for every security ticker symbol, which information is maintained primarily for error correction processing. Automated error corrections processing logic within each instance of message validation subsystem 56 processes exchange-generated correction messages automatically whenever possible. These exchange messages provide data to correct previously-reported trades and affect both market data file 58 and history file 60. The following is an example of the logic associated with processing exchange-generated correction messages as received from message conversion subsystem 52: (1) Based on the exchange-generated correction message type (error, cancel or correction), automatically perform: (a) error processing: adjustments to be made to volume (plus/minus) and optionally to price, e.g., changes to last price, high/low/open; (b) cancellation processing: adjustments to be made to volume (plus/minus) and/or price; or (c) correction processing: compare original trade data to correction data and, accordingly adjust volume, price or both. For symbol correction processing, adjust volume and price per symbol. (2) Retrieve market data file record and update it with adjustments. (3) Format and send an adjustment message to broadcast feeds subsystem 62. (4) If, for any reason, the correction message cannot be processed automatically, place the message in a kickout log file for manual processing by the DQA operator. A periodic refresh cycle generation logic within each instance of message validation subsystem 56 automatically generates refresh messages that are transmitted on the broadcast feed at a priority lower than the primary data update messages. The refresh cycle provides a second level of assurance that all message destinations have the same data as the CTP. The refresh cycle is the only source for correcting customer systems that elect not to use the retransmission recovery service discussed below. Messages in the refresh cycle contain all "dynamic" data fields maintained for each security type. Logic provides for "intelligent" refresh that permits tracking of specific issues that experience recent activity in the market. The intelligent refresh option is normally active during the active issuend, when active, only the active issues are transmitted during the refresh cycle. The refresh cycle processing logic also transmits updates needed to prepare the remote system (CTP 45 in FIG. 1) files for the next market open of exchanges where trading is not continuous around the clock. Messages in the market-open cycle contain both dynamic (updated by market activity) and static (not updated by market activity) data fields. The transmitted static data fields include any defined system-wide "alias" symbols for the security issue. Message validation subsystem 56 receives requests from custom feeds management subsystem 78 (FIG. 2) for the addition or deletion of ticker symbols from specified custom feed lists. These requests are validated before transmission from custom feeds management subsystem 78 for both entitlement to modify the feed and entitlement for the data. Subsystem 78 also verifies that the requested data will not cause the custom feed to exceed its allocated bandwidth. Message validation subsystem 56 updates the Market Data File 58 record for each security affected by the custom feed request and adds/deletes the feed from the list of feeds to which the symbol is a member. Whenever a symbol is added to a feed, message validation subsystem 56 generates a summary message for that symbol and marks it for transmission on the feed to which it has been added. Messages are passed from validation subsystem 56 to DQA subsystem 64 (FIG. 2) in CTP internal protocol by way of kickout file 65 over the interface 90. Interface 90 handles several types of messages, including exchange-generated correction messages, exchange-generated administrative messages, exception messages and invalid messages that failed header/field validation tests within subsystems 52 and/or 56. Each of these messages has the logical contents necessary to support the subsequent processing logic. For example, an exchange-generated correction message can include a correction header, correction source, message type (cancellation, error or correction), timestamp, original security data (exchange ID, symbol ID, symbol sequence number, volume size, last price), and corrected security data (exchange ID, symbol ID, volume size, last price). The resulting transaction message created by an instance of subsystem 56 and transmitted over interface 90 is herein denominated an adjustment message. Adjustment messages are created following the update of market data file 58 and history file 60 and are sent by subsystem 56 over interface 88 to broadcast feeds subsystem 62 for distribution to the underlying network destinations. An exemplary adjustment message includes the adjustment type (volume adjustment or volume and low price or volume and high price or price adjustment), security data (exchange ID, symbol ID, symbol sequence number), and trade data (volume size, last price). Adjustment messages that cannot be processed by message validation subsystem 56 are forwarded to kickout file 65 for manual processing in DQA subsystem 64 (FIG. 2). Administrative messages are received from input feed subsystem 50 and processed by message conversion subsystem 52. An exemplary administrative message includes administrative header, administrative source, network ID, CTP ID, message type, timestamp, exchange ID, and administrative text. Responses to such administrative messages create updates to market data file 58 and, in some cases, history file 60. Such updates may include an adjustment or transmission of a response to broadcast feeds subsystem 62. An exemplary response to an administrative message includes message type, security data, exchange ID, symbol ID, symbol sequence number, optional flags, administrative data, creation date, termination date, and action (new security/issue, termination of security/issue, earnings data modifications, trade history update, X-dividend, stock split, etc.) Administrative messages that cannot be processed by message validation subsystem 56 are forwarded to kickout file 65 for manual processing in DQA subsystem 64. Exception messages are those messages that are rejected by message validation subsystem 56. Exception messages require manual intervention by a data quality administrator who must analyze the exception message and enter the corrected data. An exemplary exception message includes exception header, exception source (network ID, CTP ID), message type (no find, price kickout, volume kickout or text message), timestamp, exception code, security data (exchange ID, symbol ID, symbol sequence number) and trade data (volume size, last price). Each exception message demands a manual response, which may result in message rejection or correction by updates transmitted to market data file 58. A manual adjustment or other response to each exception message is transmitted by message validation subsystem 56 to broadcast feeds subsystem 62 and therefrom to the underlying destination network. Any message that is rejected by either input feed subsystem 50 or message conversion subsystem 52 is herein denominated an "invalid message", which is forwarded to message validation subsystem 56 for action. Invalid messages require manual intervention by a data quality administrator who must analyze the message and enter the corrected data. An exemplary invalid message includes message header, reason for invalidity, network ID, CTP ID, message type (redundancy check, invalid field, invalid message type or invalid format), timestamp, invalidity code, security data and trade data. Each invalid message requires manual message rejection or manual updates to market data file 58 and history file 60. Any adjustment or response message is formatted and transmitted from message validation subsystem 56 to broadcast feeds subsystem 62 for distribution to the underlying destination network. Message validation subsystem 56 communicates with DQA subsystem 64 (FIG. 2) by way of the direct interface 92 (FIG. 5) and the indirect kickout file interface 90. Data messages are passed from subsystem 56 to subsystem 64 as internal messages conforming to internal protocol and include record request/response, record update/confirmation, record add/delete, and the like. Market statistics computing subsystem 66 accepts trade, quote and correction messages from broadcast feeds subsystem 62 and performs application-dependent calculations for every transaction message or block of transaction messages received within a predetermined time interval. Market statistics subsystem 66 updates the statistics data in market data file 58 and history file 60 and forwards the resulting statistics as transaction messages to broadcast feeds subsystem 62 on an interface 94. The frequency of statistical updates is application-dependent and configurable. Market statistic subsystem 66 also receives, processes and responds to requests for the addition, deletion, listing and correction of statistics forwarded from DQA subsystem 64. A plurality of logical applications within market statistics subsystem 66 includes statistics logic for creating market-related statistics such as volumes, averages, trends and the like, options volatility indices (OVIs) as used by Dynamic Options Class Display (DOCD) systems, and the creation, maintenance and distribution of security instrument lists of related symbols such as option class lists for all option series traded. Broadcast feeds subsystem 62 provides data spooling, feed creation and broadcast functions. It also uses the internal timestamp in each transaction message received to calculate transit time for internal throughput monitoring. Subsystem 62, in primary CTP mode, also transmits feed information to the contingency CTP backup system 45 discussed above in connection with FIG. 1 to keep the contingency database files current. In contingency or secondary CTP mode, broadcast feeds subsystem 62 receives feed information from the primary CTP site and stores the data in the transaction log file 68 and broadcast feeds history file 70. Broadcast feeds subsystem 62 receives data from message validation subsystem 56 and market statistics subsystem 66. These data contain both transaction information such as trade quote, correction, text and the like, and feed identification information that specifies the output message destination. Both the transaction and feed information is spooled to transaction log file 68. A pointer to the spool file record in transaction log 68 is stored in broadcast feeds history file 70 as described below. A Feed Definition and Network Configuration Table is used by subsystem 62 to map the feed identification information within the received transaction message to the underlying network address or addresses or to a local process such as market statistics subsystem 66. The transaction message information is extracted and duplicated for every specified feed destination. These transaction message data for each feed are formatted for transmission and stored into a transmission block maintained individually for each output feed message destination. Broadcast feeds subsystem 62 maintains the block sequence number and a transmitted broadcast feeds history file for each such feed generated. Broadcast feeds history file 70 contains a series of records each containing the block number, symbol ID and a pointer to the transaction log file 68 location for each transaction message in the block. Broadcast feeds history file 70 data are used to reconstruct a block for retransmission to any of the feed message destinations. The history file 70 record is completed and saved when a transmission block is filled and sent or when no more data are available for transmission and the block is closed and sent partially full. Partially-filled transmission blocks are sent when sufficient transaction data are not available to keep the transmission current (e.g., within 500 ms of transaction timestamp). FIG. 4 shows the feed management data flow diagram for CTP 22 (FIG. 1). Custom feeds management subsystem 78 accepts feeds manipulation requests from DQA subsystem 64 on an interface 96. Subsystem 78 also accepts feed manipulation requests from users in the underlying destination network on interface 72. Subsystem 78 validates user entitlement by requesting it from CSS system 48 (FIG. 1). If the user is entitled to manipulate the feed definition and the feed is not at its bandwidth capacity limit, subsystem 78 forwards the request as an internal message to the appropriate instance of message validation subsystem 56 on an interface 98. Message validation subsystem 56 adds or removes the feed indicator for the symbols in the request, generates a refresh-summary transaction message for adding the symbol to the feed request and forwards the message to broadcast feeds subsystem 62 for distribution to the requested feed only. Message validation subsystem 56 responds to custom feeds management subsystem 78, which responds to the requester specifying a completion code. The custom feeds are limited in number to the system hardware capacity provided for CTP 22. A custom feed change request includes the feed identifier, the action to be taken (add, delete or display) and the ticker symbol or list of symbols (including wild-card designations). Because each record (symbol) in market data file 58 includes a list of feeds (message destinations) to which it is a member, custom feeds management subsystem 78 manipulates market data file 58 records by way of message validation of system 56. If a change cannot be permitted, a message is sent to the requesting system denying the request and a rejection is produced and transmitted to kickout file 65 for monitoring and follow-up by the DQA operator. The requested change takes effect before the next update is received by message validation subsystem 56 for the relevant symbol. The feed list change also causes subsystem 56 to generate a summary message for broadcast by subsystem 62 to the underlying network. A response to the request is also sent to the requesting customer system by the same route. Custom feeds management subsystem 78 processes requests as described above without logic for mediating conflicting requests. Where more than one terminal is entitled to send custom feed update requests for a single custom feed, no attempt is made to keep the symbol in the feed until all terminals have requested that it be removed, for instance. FIG. 5 provides a schematic view of the DQA data flow of the CTP 22 from FIG. 1. DQA subsystem 64 receives copies of the messages from kickout file 65 that have failed testing by message conversion subsystem 52 or message validation subsystem 56. DQA subsystem 64 may request the entire current record for the symbol requiring correction by way of message validation subsystem 56 and then may perform correction and forward the corrected record to subsystem 56 for storage in market data file 58 and history file 60. All manual operator activity is logged to a corrections log file 100. Subsystem 64 also requests that market statistics subsystem 66 add/delete or modify statistics or may request that custom feeds management subsystem 78 add or delete symbols and so forth. This corrections function includes making online adjustments to the market data responsive to data received in correction messages from the exchanges (when these cannot be automatically processed), exception messages from message validation subsystem 56, administrative messages from the exchanges and data from a number of other sources such as reports and newspapers. DQA subsystem 64 also permits database editing, including revising data fields not associated with transaction data, addition and deletion of securities from market data file 58, and adjustment of transaction data to reflect dividends, stock splits and other related changes. Generally, such editing updates should be collected and applied as a group in preparation for a future trading session. Corrections messages conform to the internal protocol and are sent to message validation subsystem 56 for incorporation in market data file 58 and history file 60. Internal messages generated by DQA subsystem 64 are not subject to the validation checking procedures imposed on incoming financial data messages. DQA subsystem 64 provides an audit log of all manual activity and maintains statistics to monitor performance at the group and individual level. Daily performance and market activity reports are created automatically. A manual interface is provided to permit setting of the message validation parameters and changing of the mode to enable or disable the validation testing by security type within each exchange. DQA subsystem 64 also provides an interface to the Exchange Definition Table to permit trading schedule modification for any of the exchanges that source financial data to the CTP system. The Exchange Definition Table is used to schedule the maintenance processes that are periodically performed on the CTP system files. Subsystem 64 also provides manual interface for the custom feeds administration function that supports the display, addition and deletion of symbols from individual custom feeds. Finally, DQA subsystem 64 provides a manual interface to market statistics management subsystem 66 that permits definition, monitoring and adjustment of the internally-calculated market statistics. DQA subsystem 64 communicates with custom feeds management subsystem 78 on interface 96. Subsystem 78 processes DQA requests and responds to DQA subsystem 64 after feed manipulation is complete. Messages are sent and received in sequential order and interface 96 does not support priority queuing or any method of message manipulation. Messages between subsystems 64 and 78 include add/delete symbol to/from a feed, add/delete feed, and modify symbol/feed parameters. DQA subsystem 64 communicates with market statistics calculation subsystem 66 by way of interface 102. Subsystem 64 forwards statistics manipulation messages to subsystem 66 which processes and responds following completion of the requested statistics manipulation. Message are sent and received in sequential order and interface 102 does not support priority queuing or any method of message manipulation. Interface 102 handles messages including add/delete market statistics, add/delete symbol to/from statistics, modify market statistics parameters and modify statistics value. Custom feeds management subsystem 78 communicates with message validation subsystem 56 through interface 88. Subsystem 78 forwards feeds manipulation messages to message validation subsystem 56, which processes the requests and responds following completion of the feed manipulation. Messages sent on interface 88 are received in sequential order and interface 88 does not support priority queuing nor any method of message manipulation. The types of messages sent between subsystems 56 and 78 include add/delete symbol to/from a feed and response to add/delete symbol request. FIG. 6 shows the feed recovery data flow for CTP 22 (FIG. 1). Feed recovery subsystem 74 processes all retransmission requests received from the underlying destination network by way of interface 76 to LAN 28. Upon receiving a retransmission request, subsystem 74 confirms that the number of concurrent retransmission requests is below a predetermined maximum, issues a message to CSS 48 (FIG. 1) asking for entitlement information and, if the request is valid, builds a retransmission-positive response and performs "last price" or "tick-by-tick" recovery depending on the request. Finally, subsystem 74 notifies the requesting destination when recovery is completed. If the request validation fails, a retransmission-negative response containing the error code is returned to the requesting receiver system. The number of concurrent retransmission sessions is a configurable system parameter. The maximum number is empirically determined and every retransmission request, source of the request, session start/end time and amount of data is logged. A virtual connection on bus 76 is maintained separately from the normal broadcast feed on bus 26 (FIG. 2). These virtual connections remain for the duration of each recovery session, which begins with a recovery-start message sent by subsystem 74 and ends with a recovery-end message also sent by subsystem 74. Each recovery retransmission message is the same format and contains the same sequence numbers as were provided in the original broadcast feed data. The retransmission request identifies the specific feed, the range of missed output data blocks and type of recovery desired, whether tick-by-tick or current data. For tick-by-tick recovery, subsystem 74 uses data from broadcast feeds history file 70 and transaction log file 68 to reconstruct the original blocks of transaction messages and sends the blocks in sequence over interface 76 with a flag to indicate "tick-by-tick" recovery. For current data recovery, subsystem 74 uses broadcast feeds history file 70 and knowledge of the missing block range to obtain a list of symbols that were updated during the missed sequence. This "missed" symbol list is then used to obtain data for each symbol from market data file 58 and recreate current market data record summary messages for each "missed" symbol. These summary messages are transmitted on the virtual recovery circuit (interface 76) with a flag to indicate "current data" recovery. Current data recovery transmission blocks contain new block sequence numbers assigned at the time of the recovery session and have no relation to the original update transmission blocks or sequence numbers. FIG. 7 shows the system control data flow for CTP 22. System control subsystem is responsible for system configuration control, control, monitoring and administration of the tasks performed by CTP 22. The monitoring function includes periodic collection of task-specific statistics and reporting to SMF system 46 (FIG. 1) by way of SMF Agent subsystem 82. The reporting interval is configurable with a preferred value of five seconds. Subsystem 80 manages and monitors the tasks required by SMF system 46. Command messages entered at SMF 46 are received by SMF agent 82 and forwarded to system control subsystem 80 for command processing. Remote configuration messages received from SMF 46 are forwarded to a download process. Subsystem 80 also processes SMF operator commands such as get/set data structure/lists, demand specific event reporting, inquire about status, bring about a change of state, change program version, fall back to previous program version, and the like. SMF agent subsystem 82 maintains status information regarding tasks requested by SMF 46 related to overall system supervision. Agent subsystem 82 also maintains alarm and statistics filters requested by SMF 46 responsive to alarm and statistics messages entered at SMF 46. Some examples of messages forwarded to SMF 46 by SMF agent subsystem 82 include alarm messages (e.g., indicating errors, communications problems, exceeded thresholds, etc.), informational messages indicating exceptional conditions (e.g., change in system state of health, failure to receive market-open message from exchange, etc.), and statistics messages. System control subsystem 80 communicates with input feed subsystem 50 by way of an interface 104. The types of messages on interface 104 include load or reload software, make line primary/secondary, start/stop input feed process, modify line parameters (e.g., baud rate, etc.), and perform periodic processes (e.g., end-of-day, etc.). Subsystem 80 communicates with message conversion subsystem 52 on an interface 106. Interface 106 messages include make input feed processes primary/secondary, modify input feed to message conversion routing, start/stop message conversion process, modify conversion table parameters (e.g., exchange indicators, etc.), modify message conversion to message validation routing, and perform periodic processes. System control subsystem 80 communicates with message validation subsystem 56 on interface 108. The types of messages on interface 108 include start/stop validation process and perform periodic process. System control subsystem 80 communicates with DQA subsystem 64 on an interface 110. Communications on interface 110 include those required to update the instrument/validation routing table and to report correction file 100 statistics. System control subsystem 80 communicates with custom feeds subsystem 78 on an interface 112. Messages carried by interface 112 include add/delete feed to the feeds management table, start/stop custom feeds management process, modify feed parameters (.e.g., total bandwidth capacity, etc.) and perform periodic processes. Subsystem 80 communicates with market statistics subsystem 66 on an interface 114. Messages carried by interface 114 include start/stop market statistics process and perform periodic processes. Subsystem 80 communicates with broadcast feeds subsystem 62 on an interface 116. Messages on interface 116 include add/delete broadcast/point-to-point routing information, start/stop broadcast process and perform periodic processes. Subsystem 80 interfaces with feed recovery subsystem 74 on an interface 118, which carries start/stop recovery process and modify recovery parameters (e.g., number of concurrent recoveries, etc.) messages. Finally, subsystem 80 communicates with SMF agent subsystem 82 on an interface 120. Message types on interface 120 include command messages from SMF 46, data messages from SMF 46 (software, configuration files, etc.), alarm messages to SMF 46, statistics reporting messages to SMF 46, and status reporting to SMF 46. FIG. 8 shows an exemplary implementation of a financial market data center 220 embodying the CTP of this invention. System 220 includes a primary CTP system 222 (Cluster A) and a secondary CTP system 245 (Cluster B). Each CTP cluster includes associated support equipment such as communication processors and manual X-stations. CTPs 222 and 245 operate in duplex mode with either one functioning as primary at any time. The primary components of each CTP are now described. The numerals designating each CTP component are modified with "A" or "B" to designate an element in CTP 222 (cluster A) or CTP 245 (cluster B). When designation of either or both is intended, the corresponding numeral is used alone without a letter appended. The components include input communication processors 114A and 116A in CTP 222 and input communication processors 114B and 116B in CTP 245. Each of these input communication processors 114 and 116 consists of Simpact Model 9000 Terminal Servers. Each processor 114 and 116 handles up to eight input lines operating at 19.2 kbps. Four OPRA lines are supplied into processor 114, exemplified by line 115. Each OPRA line operates at 19.2 kbps. Three binfeed lines exemplified by line 117 are supplied into processor 116 at the same rate. After processor 114 reads the OPRA lines and processor 116 reads the binfeed lines, each processor forwards a copy of the input messages to Local Area Network (LAN) 118 and therefrom to the Central Ticker Plant Processing Computers (CTPs) 120, 122 and 124. Each of the processors 120-124 consists of one IBM RS/6000 Model 360/550 series computer. Processor 120 contains executables for all three CTP processors, configuration files and operator interface code. Processors 122 and 124 each retrieve the executables and configuration files from processor 120 by NFS mounting file systems and directories. Processor 120 also collects performance statistics for all three processors 120-124, drives the manual operator interface at X-station 126 and processes the binfeed line messages. Processor 122 processes the OPRA line messages, performs input processing, validates the data and maintains the OPRA database. Also, processor 122 maintains the CTP Market Statistics Database. Processor 124 controls data distribution and output. A CTP broadcast data output feed is delivered to the output system and update lines for transmitting to other financial market data systems are output on four lines (exemplified by line 130) operating at 14.4 kbps. Processor 124 also performs data feed recovery for the two broadcast feeds A and B (not shown) to the underlying network. Each of the Output Communications Processors (OCPs) 128 consists of one Simpact Model 9000 Terminal Server that generates the four Update Lines exemplified by line 130 for feeding the underlying network. Each of the DQA systems 132 consists of a single IBM RS6000 Model 360 computer coupled to at least one X-station 134 that provides the necessary manual access to the Data Quality Assurance system of this invention. The Model 360 computer 132 serves as the boot host and X-station manager for X-station 134 and contains the DQA executable code. System 132 maintains local correction logs and operator activity log files but does not mount file systems containing kickout and validation files on processors 120-124. These kickout and validation file systems are mounted by NFS. The System Management Facility (SMF) 246 provides network management and general financial market data center management functions. SMF system 246 also provides operational windows for startup, shutdown, operation and monitoring of all CTP system components, provides an arbitrator function for determining the primary/secondary state of CTPs 222 and 245, contains the Ticker Plant Configuration System for maintaining CTP configuration files and drives the configurator interface and the arbitrator interface. Each arbitrator (ARB) 136 resides on its own dedicated LAN 138. The two ARBs are duplexed with one as the primary ARB and the other as the secondary ARB. ARBs 136A-B are a control point of CTP clusters 222 and 245, respectively, where the one Primary ARB collects state-of-health information from each of the two CTPs 222 and 245 and always knows which CTP is assigned to be the primary CTP. Upon failure in the primary CTP, the primary ARB assigns the secondary CTP to be primary and switches the primary CTP to be secondary. Data center 220 contains this pair of Arbitrators for fault-tolerance. Both ARBs 136A-B communicate with each other by sending the other state-of-health information. Upon primary Arbitrator failure, the secondary ARB will become the primary ARB. Financial market data center 220 is organized according to a Local Area Network (LAN) architecture. There are two LANs within each CTP cluster 222 and 245. LAN 118 contains all CTP processors 120-124 and DQA system 132, input communication processors 114 and 116 and DQA X-station 134. CTP 124 is connected to a second LAN 119 and therefrom to OPC 128. SMF system 246 resides on a separate administrative LAN (not shown) to provide coupling with X-stations 126A-B and router 140A. Routers 140A, 140B and 140C provide interconnectivity among the several LANs. Routers 140A-C are not a dedicated part of the CTP system but do form part of the financial market data center 220 architecture. Router 140C interconnects the arbitrator LANs 138A-B substantially as shown. The CTP embodiment discussed above in connection with FIG. 8 consists mainly of several UNIX application processes that interact together to receive, process and distribute financial information. The major processing and control function embodied in system 220 are now described in terms of the particular hardware elements on which each of the processes are hosted for operation in the exemplary system environment shown in FIG. 8. The CTP architecture is modular and the processes may be relocated to accommodate growth and improved technology by updating the hardware system architecture. Therefore, the following discussion of hosted processes (FIGS. 9-12) is intended merely as an exemplary demonstration of one useful implementation of the CTP of this invention. FIG. 9 shows the processing flow for data received from the binfeed input lines exemplified by line 117. The input process 250 resides in input communications processor 116 to forward input messages to LAN 118 and therefrom the CTP processor 120. The message conversion (cnbin) process 252 resides in CTP processor 120 to convert the input messages to transaction messages and to output these transaction messages to LAN 118, wherefrom they are forwarded to CTP processor 124. The broadcast (bdm) process 262 resides in CTP 124 to receive the transaction messages from LAN 118. Process 262 has access to broadcast history file 270 and transaction log file 268 within CTP 124 and assembles the transaction messages into blocks in the manner discussed above in connection with FIGS. 2-5 and forwards them to LAN 119 for distribution to the appropriate underlying network output process (not shown). FIG. 10 shows the processing flow for financial market data messages received from the exchanges, exemplified by the OPRA lines such as OPRA line 115. Input process 250 on input communication processor 114 receives the incoming messages and performs the validation and statistical procedures discussed above in connection with FIGS. 2-3 and 7, forwarding the annotated input messages to LAN 118. From LAN 118 the input messages are forwarded to the message conversion (cn) process 252 within processor 122 to log the messages into the input log 254 internal to processor 122. Following input message conversion to internal protocol, the internal protocol messages are forwarded to the message validation (val) process 256 and to the market statistics (ms) process 266 in processor 122. Validation process 256 and market statistics process 266 both have access to the market database file 258 and the kickout file 265 both internal to processor 122. Validation process 256 converts the internal messages to transaction messages and forwards them to LAN 118. Market statistics process 266 computes the requisite derivative data, formats it as transaction messages, and forwards it to LAN 118. From LAN 118, the transaction messages from validation process 256 and statistics process 266 are forwarded to the broadcast (bdm) process 262 within CTP processor 124. Broadcast process 262 has access to broadcast history file 270 and transaction log file 268, both internal to processor 124. The transaction messages are accumulated into blocks and the output blocks are forwarded to second LAN 119. These same blocks now contain destination address information for routing to customer destinations in the underlying network, which is forwarded by the update line (upd) process 142 in CTP processor 124 to processor 128. Finally, the output process 144 in output communications processor 128 receives the output transaction message blocks and destination addresses from LAN 119 and formats these as serial data for transfer over to the underlying update lines exemplified by update line 130. FIG. 11 shows the processing flow for the Data Quality Assurance (DQA) process of this invention. The DQA subsystem 264 incorporates a DQA processor 132 and a DQA X-station 134 coupled to LAN 118. DQA processor 132 retrieves exception messages and the like stored in the kickout file 265 internal to processor 122 by way of LAN 118. Manually-initiated correction messages are forwarded from DQA processor 132 to message validation (val) process 256 and market statistics (ms) process 266, both in processor 122, by way of LAN 118. Both processes 256 and 266 have access to the market database file 258 to make the necessary database updates responsive to the DQA correction messages. Also responsive to the DQA correction messages from DQA processor 132, both processes 256 and 266 generate related transaction messages and forward them to broadcast (bdm) process 262 in processor 124 by way of LAN 118. These transaction messages (containing correction data from DQA subsystem 264) are then formatted into output blocks and forwarded to files 268 and 270 and to LAN 119 for the underlying network in the usual manner as discussed above in connection with FIG. 10. FIG. 12 shows the processing flow for data recovery through retransmission incorporated in the CTP of this invention. Recovery requests are received from the underlying network on line 146 coupled to LAN 119 and therefrom forwarded to the feeds recovery (recov) process 274 within processor 124 to draw the necessary blocks from the broadcast history file 270 and the transaction log file 268, both internal to processor 124. However, as discussed above in connection with FIGS. 2 and 6, process 274 must first obtain information from market database 258 within processor 122 necessary to identify which output blocks from files 268 and 270 must be retransmitted. This is accomplished through message validation (val) process 256 and market statistics (ms) process 266, both within processor 122, by way of LAN 118. Processes 256 and 266 retrieve the trading data from market database 258 necessary to identify the output blocks to be retransmitted. This information is forwarded to feeds recovery process 274 to extract and transmit the output blocks stored in files 268-270. The extracted output is forwarded to LAN 119 and therefrom to the underlying network by way of output process 144 within output communications processor 128. Clearly, other embodiments and modifications of this invention occur readily to those of ordinary skill in the art in view of these teachings. Therefore, this invention is limited only by the following claims, which include all embodiments and modifications that are related in view of the above specification and accompanying drawing.
A central ticker plant system for distributing financial market data that receives ticker feed data from many exchanges throughout the world, processes and formats the received data and then distributes or broadcasts the data to regional customers in the form of securities transactional data denoting the security identity and related transactional data. The central ticker plant system is fault-tolerant because of novel hardware redundancy and multi-thread software processing architecture and operates continuously during hardware and software maintenance and repair, ensuring that every financial market data message received from the exchanges is included within 500 milliseconds in broadcast output.
6
TECHNICAL FIELD [0001] The disclosure relates to the field of communication, and in particular to a terminal, network locking and network unlocking methods thereof, and a storage medium. BACKGROUND [0002] Along with rapid popularization of mobile networks on a global scale, in particular rapid growth of 3-Generation (3G) networks, each operator attracts users in manners of communication fee subsidy or mobile terminal bundling in terms of selling modes of mobile terminals such as mobile phones, tablets and data cards to increase and consolidate the number of users. In order to prevent user loss and reward early subsidy investment of operators, the operators usually protect own customer resources and expect their own customers to use their own specified network resources only by network locking. In a prior art, a network locking on a mobile terminal is implemented by limiting the mobile terminal to use only a specified data card such as a Subscriber Identity Module (SIM) card. An existing network locking solution mainly includes the following steps: [0003] Step 1, when producing a terminal, a mobile terminal manufacturer writes a legal Public Land Mobile Network (PLMN) number segment, a locking identifier and an unlocking code value into a flash of the terminal; [0004] Step 2, when a terminal user inserts a card into the terminal, the terminal reads a PLMN number segment from the SIM card or acquires the PLMN number segment from a network where the SIM card gets successfully registered, and then compares the read or acquired PLMN number segment with the preset PLMN number segment of the terminal, all functions of the terminal are enabled if they are consistent, and if they are inconsistent, all the functions of the terminal are disabled; and [0005] Step 3, when the terminal user sends an unlocking code to the terminal, the terminal compares the sent unlocking code with a preset unlocking code of the terminal by virtue of a certain algorithm and the like, clears a network locking identifier if they are consistent, and determines that unlocking fails if they are inconsistent. [0006] In the existing network locking solution, the unlocking code value is directly obtained merely according to a set network locking parameter, and is easy to be tampered and cracked illegally, which may make the terminal easy to be unlocked illegally and lower security of network locking of the terminal. SUMMARY [0007] In order to solve the problem of the prior art, the embodiment of the disclosure provides a terminal, network locking and network unlocking methods thereof, and a storage medium, which may solve the problems of easily illegal unlocking and poor security of network locking of an existing terminal. [0008] In order to solve the technical problem, the embodiment of the disclosure provides a network locking method for a terminal, which may include that: [0009] a network locking parameter is written into a first storage unit of the terminal; [0010] network locking parameter verification information and an unlocking code are obtained according to unique identification information of hardware of the terminal and the network locking parameter; and [0011] the obtained network locking parameter verification information is stored into a second storage unit of the terminal, and the unlocking code is stored. [0012] In an embodiment of the disclosure, the step that the network locking parameter verification information is obtained according to the unique identification information of the hardware of the terminal and the network locking parameter may include that: [0013] a first digest value for the unique identification information of the hardware of the terminal and the network locking parameter is calculated; and [0014] the first digest value is encrypted using a private key in a preset asymmetric encryption key pair to obtain first network locking parameter verification information. [0015] In an embodiment of the disclosure, the step that the network locking parameter verification information is obtained according to the unique identification information of the hardware of the terminal and the network locking parameter may further include that: [0016] a second digest value for the unique identification information of the hardware of the terminal and a public key in the asymmetric encryption key pair is calculated; and the second digest value is encrypted using the private key in the asymmetric encryption key pair to obtain second network locking parameter verification information. [0017] In an embodiment of the disclosure, the unique identification information of the hardware of the terminal may be unique identification information, which can be acquired only through an internal program of the terminal, of the hardware. [0018] In an embodiment of the disclosure, the unique identification information of the hardware of the terminal may be unique identification information of a baseband chip of the terminal. [0019] In order to solve the problem, the embodiment of the disclosure also provides a network unlocking method for a terminal, which may include that: [0020] a first unlocking code input by a user is received; [0021] a local unlocking code of the terminal is calculated according to a network locking parameter stored in the terminal and unique identification information, adopted for network locking, of hardware of the terminal; and [0022] comparison is performed to determine whether the first unlocking code is consistent with the local unlocking code, and if YES, it is determined that network unlocking succeeds. [0023] In an embodiment of the disclosure, the method may further include: before the step that comparison is performed to determine whether the first unlocking code is consistent with the local unlocking code, the first unlocking code and a first unlocking code ciphertext are received, wherein [0024] the first unlocking code ciphertext is a ciphertext obtained by encrypting the first unlocking code input by the user using a private key in an asymmetric encryption key pair adopted for network locking of the terminal; [0025] the first unlocking code ciphertext is unlocked according to a public key in the asymmetric encryption key pair adopted for the network locking of the terminal to obtain a first check unlocking code; and [0026] comparison is performed to determine whether the first unlocking code is consistent with the first check unlocking code, and if YES, comparison is performed to determine whether the first unlocking code is consistent with the local unlocking code. [0027] In an embodiment of the disclosure, the method may further include: before the step that the first unlocking code input by the user is received and when the terminal is started, [0028] integrity check is performed on the network locking parameter stored in a first storage unit of the terminal; or [0029] integrity check is performed on the public key in the asymmetric encryption key pair adopted for the network locking of the terminal. [0030] In an embodiment of the disclosure, the step that integrity check is performed on the network locking parameter stored in the first storage unit of the terminal may include: [0031] first network locking parameter verification information stored during the network locking is read from a second storage unit of the terminal, decryption processing is performed on the first network locking parameter verification information according to the public key in the asymmetric encryption key pair adopted for the network locking of the terminal to obtain a first check digest value, and a check network locking parameter is acquired from the first check digest value; and [0032] the check network locking parameter and the network locking parameter stored in the first storage unit are compared to determine whether the two parameters are consistent, and if YES, it is determined that the network locking parameter is complete; [0033] the step that integrity check is performed on the public key in the asymmetric encryption key pair adopted for the network locking of the terminal may include: [0034] second network locking parameter verification information stored during the network locking is read from the second storage unit of the terminal, decryption processing is performed on the second network locking parameter verification information according to the public key in the asymmetric encryption key pair adopted for the network locking of the terminal to obtain a second check digest value, and a check public key is acquired from the second check digest value; and [0035] the check public key and the public key stored in the second storage unit are compared to determine whether the two keys are consistent, and if YES, it is determined that the public key is complete. [0036] In an embodiment of the disclosure, the method may further include that: after network unlocking of the terminal is successfully performed, [0037] the network locking parameter stored in a first storage unit of the terminal is updated into an unlocking parameter; [0038] a third digest value for the unique identification information of the hardware of the terminal and the unlocking parameter is calculated; and [0039] the third digest value is encrypted using the private key in the asymmetric encryption key pair adopted for the network locking to obtain third network locking parameter verification information, and the third network locking parameter verification information is stored into a second storage unit of the terminal. [0040] In an embodiment of the disclosure, the method may further include: [0041] when the terminal is started after successful unlocking, the third network locking parameter verification information is read from the second storage unit of the terminal, decryption processing is performed on the third network locking parameter verification information according to the public key in the asymmetric encryption key pair adopted for the network locking of the terminal to obtain a third check digest value, and a check unlocking parameter is acquired from the third check digest value; and [0042] the check unlocking parameter and the unlocking parameter stored in the first storage unit are compared to determine whether the two parameters are consistent, and if YES, it is determined that the unlocking parameter is complete. [0043] In order to solve the problem, the embodiment of the disclosure further provides a terminal including a first storage unit, a second storage unit, a sending unit, a receiving unit and a processing unit, in which: [0044] the receiving unit may be configured to receive a network locking parameter and store the network locking parameter in the first storage unit; [0045] the processing unit may be configured to obtain network locking parameter verification information and an unlocking code according to unique identification information of hardware of the terminal and the network locking parameter, and store the obtained network locking parameter verification information into the second storage unit of the terminal; and [0046] the sending unit may be configured to send out the unlocking code for storage. [0047] In an embodiment of the disclosure, the second storage unit may be a One Time Programmable (OTP) storage unit. [0048] In an embodiment of the disclosure, the operation that the processing unit obtains the network locking parameter verification information according to the unique identification information of the hardware of the terminal and the network locking parameter may include that: [0049] a first digest value for the unique identification information of the hardware of the terminal and the network locking parameter is calculated; and [0050] the first digest value is encrypted using a private key in a preset asymmetric encryption key pair to obtain first network locking parameter verification information. [0051] In an embodiment of the disclosure, the operation that the processing unit obtains the network locking parameter verification information according to the unique identification information of the hardware of the terminal and the network locking parameter may further include: [0052] a second digest value for the unique identification information of the hardware of the terminal and a public key in the asymmetric encryption key pair is calculated; and [0053] the second digest value is encrypted to using the private key in the asymmetric encryption key pair obtain second network locking parameter verification information. [0054] In an embodiment of the disclosure, the unique identification information of the hardware of the terminal may be unique identification information, which can be acquired only through an internal program of the terminal, of the hardware. [0055] In an embodiment of the disclosure, the receiving unit may further be configured to receive a first unlocking code input by a user; and [0056] the processing unit may further be configured to calculate a local unlocking code according to the network locking parameter stored in the terminal and the unique identification information, adopted for network locking, of the hardware of the terminal, perform comparison to determine whether the first unlocking code is consistent with the local unlocking code, and if YES, determine that network unlocking succeeds. [0057] In order to solve the problem, the embodiment of the disclosure further provides a computer storage medium having stored therein a computer-executable instruction configured to execute the abovementioned network locking method for a terminal and/or the network unlocking method for a terminal. [0058] The embodiment of the disclosure achieves the following beneficial effects: during network locking of the terminal, the network locking parameter is written into the first storage unit of the terminal, and the network locking parameter verification information and the unlocking code are obtained on the basis of the unique identification information of the hardware of the terminal and the network locking parameter; and when network unlocking of the terminal is performed, the unlocking code is obtained according to the network locking parameter stored in the terminal and the unique identification information of the hardware of the terminal; and comparison is performed to determine whether the unlocking code is consistent with the unlocking code input by the user, and when the two codes are consistent, it is determined that network unlocking is successfully performed. It is clear that the technical solutions provided by the disclosure may implement unique binding of the network locking parameter of the terminal and the unique identification information of the hardware of the terminal, and network unlocking can be smoothly performed only according to the unique identification information of the hardware of the terminal, so that difficulty in illegal cracking of the unlocking code can be increased to a greater extent and thus security of network locking of the terminal can be improved. BRIEF DESCRIPTION OF THE DRAWINGS [0059] FIG. 1-1 is a flowchart of network locking of a terminal according to embodiment 1 of the disclosure; [0060] FIG. 1-2 is a flowchart of obtaining network locking parameter verification information by adopting an asymmetric encryption algorithm according to embodiment 1 of the disclosure; [0061] FIG. 2-1 is a flowchart of releasing network locking of a terminal according to embodiment 1 of the disclosure; [0062] FIG. 2-2 is a flowchart of performing integrity check on a first unlocking code input by a user according to embodiment 1 of the disclosure; [0063] FIG. 3 is a flowchart of performing integrity check on a network locking parameter according to embodiment 1 of the disclosure; [0064] FIG. 4 is a flowchart of performing integrity check on a public key according to embodiment 1 of the disclosure; [0065] FIG. 5 is a flowchart of updating an unlocking parameter after network unlocking is successfully performed according to embodiment 1 of the disclosure; [0066] FIG. 6 is a flowchart of performing integrity check on an unlocking parameter according to embodiment 1 of the disclosure; [0067] FIG. 7 is a structure diagram of a terminal according to embodiment 1 of the disclosure; [0068] FIG. 8 is a flowchart of network locking of a terminal according to embodiment 2 of the disclosure; and [0069] FIG. 9 is a flowchart of releasing network locking of a terminal according to embodiment 2 of the disclosure. DETAILED DESCRIPTION [0070] The embodiment of the disclosure is intended to solve the problem of poor security of network locking of an existing terminal caused by easily illegal cracking of network locking of the terminal; during network locking of the terminal, an unlocking code is obtained by virtue of unique identification information of hardware of the terminal and a network locking parameter, that is, the unlocking code is uniquely bound with the hardware of the terminal during network locking, the unique identification information of the hardware of the terminal in the embodiment of the disclosure may only be obtained through an internal application program of the terminal, and the unique identification information of the hardware may not be obtained through an external program or tool, so that security of the unlocking code may further be improved, and may be prevented from being illegally cracked, and network locking of the terminal is further prevented from being illegally cracked. The technical solutions of the disclosure will be further described below with reference to specific implementation modes and the drawings in detail. Embodiment 1 [0071] Referring to FIG. 1-1 , a network locking method for a terminal provided by the embodiment includes the following steps: [0072] Step S 101 , a network locking parameter is written into a first storage unit of the terminal. [0073] The network locking parameter written in Step S 101 may be a PLMN number segment, and may also be selected according to a specific application scenario. [0074] In the embodiment, before Step S 101 , the method may further include: a step of determining whether the terminal supports a network locking function, and subsequent Step S 101 is executed only when the terminal supports the network locking function; and an existing terminal, such as a mobile phone terminal, usually supports the network locking function. [0075] Step S 102 , network locking parameter verification information and an unlocking code are obtained according to unique identification information of hardware of the terminal and the network locking parameter. [0076] In Step S 102 , the network locking parameter verification information may include one or more pieces of network locking parameter verification information according to a specific encryption algorithm and a specific application scenario; for example, an asymmetric encryption algorithm such as an asymmetric Rivest-Shamir-Adleman (RSA) public key encryption algorithm may be adopted in the embodiment; then, the network locking parameter verification information in Step S 102 includes first network locking parameter verification information and second network locking parameter verification information, and as shown in FIG. 1-2 , the step that the network locking parameter verification information is obtained according to the unique identification information of the hardware of the terminal and the network locking parameter includes: [0077] Step S 1021 , a first digest value for the unique identification information of the hardware of the terminal and the network locking parameter is calculated, [0078] wherein the digest value may be represented by a Message Digest (MD) value, and the first digest value is represented by MD 1 ; [0079] Step S 1022 , the first digest value is encrypted using a private key in a preset asymmetric encryption key pair to obtain the first network locking parameter verification information; [0080] Step S 1023 , a second digest value for the unique identification information of the hardware of the terminal and a public key in the asymmetric encryption key pair is calculated; and [0081] Step S 1024 , the second digest value is encrypted using the private key in the asymmetric encryption key pair to obtain the second network locking parameter verification information. [0082] It should be understood that the network locking parameter verification information may not include the second network locking parameter verification information obtained by Step S 1023 and Step S 1024 when the adopted encryption algorithm does not include the public key; the asymmetric encryption algorithm in the embodiment may specifically be provided by a Universal Serial Bus (USB) key, and the private key in the asymmetric encryption key pair may be stored in the USB key, so that security of network locking is further improved; and [0083] in the embodiment, the unlocking code may specifically be calculated according to keyword information of the network locking parameter and the unique identification information of the hardware of the terminal, and a specific algorithm may adopt the asymmetric RSA algorithm. [0084] In the embodiment, the unique identification information of the hardware of the terminal may be unique identification information, which may only be obtained through an internal application program of the terminal and may not be obtained by an external program or tool, so that security of the unlocking code is further improved. For example, the unique identification information may be unique identification information of a baseband chip of the terminal, and may specifically be a unique hardware key of the baseband chip; and of course, the unique identification information of the hardware of the terminal may also be information, which may be obtained through the external application program or tool, with lower security, and for example, may be an International Mobile Equipment Identity (IMEI) of the terminal. [0085] Step S 103 , the obtained network locking parameter verification information is stored into a second storage unit of the terminal, and the obtained unlocking code is stored. [0086] In Step S 103 , the obtained unlocking code may be stored in the terminal; and however, for improving security, the obtained unlocking code is preferably sent to a Personal Computer (PC) side to be stored with identification information of the terminal, such as the IMEI of the terminal, as an index in the embodiment, which may specifically be implemented by establishing a mapping table of identification information of a terminal and its unlocking code. [0087] The first storage unit and second storage unit in the embodiment may adopt the same storage unit, and may also adopt different storage units. In order to further improve security, the first storage unit is preferably a Random-Access Memory (RAM) storage unit of the terminal, and for example, may be a Non-Volatile Random Access Memory (NVRAM); the second storage unit may be a One Time Programmable (OTP) storage unit, and a written content may not be modified once the content is written into the OTP storage unit, so that the network locking parameter verification information written into the OTP storage unit may be prevented from being illegally tampered. [0088] Step S 103 further includes the operation that the public key in the asymmetric encryption key pair adopted for network locking is also stored into the second storage unit. [0089] Network locking of the terminal may be implemented by Step S 101 to Step S 103 , the unlocking code is bound with the unique identification information of the hardware of the terminal in a network locking process, and network unlocking may be correctly performed only after the unique identification information of the hardware is acquired; and data cloning may also be prevented to avoid an unlocked network locking parameter being copied from terminal A to network-locked terminal B for unlocking, so that security of network locking of the terminal may further be improved, and may be prevented from being illegally cracked. [0090] In addition, after the network locking parameter verification information and the public key in the asymmetric encryption pair key adopted for network locking are stored into the OTP storage unit in the embodiment, these data may not be illegally tampered and erased; and therefore, security of network locking may further be improved. [0091] Moreover, the asymmetric RSA algorithm is adopted for encryption calculation in the embodiment. Different operating companies may adopt different RSA key pairs for network locking parameter signing and subsequent authentication, and the private key of the key pair may be stored into the USB key; and the operating companies and hackers may smoothly implement unlocking only with the correct unlocking code and the corresponding private key, both of the two being indispensible, so that difficulty in illegal cracking is further increased. [0092] Correspondingly, a network unlocking method for a terminal provided by the embodiment, as shown in FIG. 2-1 , includes the following steps: [0093] Step S 201 , a first unlocking code input by a user is received; [0094] Step S 202 , a local unlocking code is calculated according to a network locking parameter stored in the terminal and unique identification information, adopted for network locking, of hardware of the terminal; [0095] Step S 203 , comparison is performed to determine whether the first unlocking code is consistent with the local unlocking code, Step 204 is executed if YES, otherwise Step 205 is executed; [0096] Step S 204 , it is determined that unlocking succeeds; and [0097] Step S 205 , it is determined that unlocking fails. [0098] In step S 201 , the user may specifically input the first unlocking code through a PC side; in addition, for ensuring reliability, integrity check may also be performed on the first unlocking code input by the user in the embodiment; then, before Step S 203 , the method may, as shown in FIG. 2-2 , further include the following steps: [0099] Step S 2021 , the first unlocking code input by the user is encrypted using a private key in an asymmetric encryption key pair adopted for network locking of the terminal to obtain a first unlocking code ciphertext; [0100] Step S 2022 , the first unlocking code and the first unlocking code ciphertext are sent to the terminal; [0101] Step S 2023 , the terminal unlocks the first unlocking code ciphertext to obtain a first check unlocking code according to a public key in the asymmetric encryption key pair in a network locking process; and [0102] Step S 2024 , comparison is performed to determine whether the first unlocking code is consistent with the first check unlocking code, and if YES, Step S 203 is executed. [0103] In the embodiment, before the terminal is unlocked, that is, before Step S 201 is executed, when the terminal is started, the method may further include a step that integrity check is performed on the network locking parameter in a first storage unit of the terminal; [0104] or the method may further include a step that integrity check is performed on the public key in the asymmetric encryption key pair adopted for the network locking process of the terminal. [0105] Specifically, the step that integrity check is performed on the network locking parameter stored in the first storage unit of the terminal, as shown in FIG. 3 , includes: [0106] Step S 301 , first network locking parameter verification information stored during network locking is read from a second storage unit of the terminal; [0107] Step S 302 , decryption processing is performed on the first network locking parameter verification information to obtain a first check digest value according to the public key in the asymmetric encryption key pair adopted for the network locking process of the terminal, and a check network locking parameter is acquired from the first check digest value; [0108] Step S 303 , the check network locking parameter and the network locking parameter stored in the first storage unit are compared to determine whether the two are consistent, Step S 304 is executed if YES, otherwise Step S 305 is executed; [0109] Step S 304 , it is determined that the network locking parameter is complete, and the terminal normally runs; and [0110] Step S 305 , it is determined that the network locking parameter is incomplete and may be tampered or damaged, and then the terminal may enter an offline state and disable functions such as a voice function and a network access function. [0111] Specifically, the step that integrity check is also performed on the public key in the asymmetric encryption key pair adopted for the network locking process of the terminal, as shown in FIG. 4 , includes: [0112] Step S 401 , second network locking parameter verification information stored during network locking is read from the second storage unit of the terminal; [0113] Step S 402 , decryption processing is performed on the second network locking parameter verification information to obtain a second check digest value according to the public key in the asymmetric encryption key pair adopted for the network locking process of the terminal, and a check public key is acquired from the second check digest value; [0114] Step 403 , the check public key and the public key stored in the second storage unit during network locking are compared to determine whether the two are consistent, Step S 404 is executed if YES, otherwise Step S 405 is executed; [0115] Step S 404 , it is determined that the public key is complete, that is, the terminal normally runs; and [0116] Step S 405 , it is determined that the public key is incomplete and namely may be tampered or damaged, and then the terminal may enter the offline state and disable the functions such as the voice function and the network access function. [0117] In the embodiment, after Step S 204 , a step that the network locking parameter into an unlocking parameter may further be executed, and is, as shown in FIG. 5 , specifically implemented as follows: [0118] Step S 501 , the network locking parameter stored in the first storage unit of the terminal is updated into the unlocking parameter; [0119] Step S 502 , a third digest value for the unique identification information of the hardware of the terminal and the unlocking parameter is calculated; [0120] Step S 503 , the third digest value is encrypted using the private key in the asymmetric encryption key pair adopted for network locking to obtain third network locking parameter verification information; and [0121] Step S 504 , the obtained third network locking parameter verification information is stored into the second storage unit of the terminal. [0122] At this moment, network unlocking of the terminal has been successfully performed, and when the terminal is restarted, integrity detection may be performed on the third network locking parameter verification information stored in the first storage unit of the terminal, as shown in FIG. 6 , specifically including the following steps: [0123] Step S 601 , when the terminal is started after successful unlocking, the third network locking parameter verification information is read from the second storage unit of the terminal; [0124] Step S 602 , decryption processing is performed on the third network locking parameter verification information to obtain a third check digest value according to the public key in the asymmetric encryption key pair adopted for the network locking process of the terminal, and a check unlocking parameter is acquired from the third check digest value; [0125] Step S 603 , the check unlocking parameter and the unlocking parameter stored in the first storage unit are compared to determine whether the two are consistent, Step S 604 is executed if YES, otherwise Step S 605 is executed; [0126] Step S 604 , it is determined that the unlocking parameter is complete, that is, the terminal normally runs; and [0127] Step S 605 , it is determined that the unlocking parameter is incomplete and namely may be tampered or damaged, then the terminal may enter the offline state and disable the functions such as the voice function and the network access function, and the current number of failed unlocking tries may further be updated to provide a basis for subsequently determining whether to perform unlocking. [0128] Referring to FIG. 7 , the embodiment further provides a terminal, which supports a network locking function and includes a first storage unit 701 , a second storage unit 702 , a sending unit 703 , a receiving unit 704 and a processing unit 705 , wherein [0129] the receiving unit 704 is configured to receive a network locking parameter and store the network locking parameter in the first storage unit 701 ; [0130] the processing unit 705 is configured to obtain network locking parameter verification information and an unlocking code according to unique identification information of hardware of the terminal and the network locking parameter, and store the obtained network locking parameter verification information into the second storage unit of the terminal; and [0131] the sending unit 703 is configured to externally send the unlocking code for storage, and a specific storage manner may adopt the abovementioned storage manner. [0132] From the above analysis, it can further be seen that the first storage unit 701 and second storage unit 702 in the embodiment may be the same storage unit, and may also be different storage units; and the second storage unit may preferably be an OTP storage unit. [0133] In the embodiment, the operation that the processing unit 705 obtains the network locking parameter verification information according to the unique identification information of the hardware of the terminal and the network locking parameter includes that: [0134] a first digest value for the unique identification information of the hardware of the terminal and the network locking parameter is calculated; [0135] the first digest value is encrypted using a private key in a preset asymmetric encryption key pair to obtain first network locking parameter verification information; [0136] the operation further includes that: [0137] a second digest value for the unique identification information of the hardware of the terminal and a public key in the asymmetric encryption key pair is calculated; and [0138] the second digest value is encrypted using the private key in the asymmetric encryption key pair to obtain second network locking parameter verification information. [0139] In the embodiment, the unique identification information of the hardware of the terminal may be unique identification information, which may only be acquired through an internal program of the terminal, of the hardware, so that security of network locking is further improved; and for example, the unique identification information may be unique identification information of a baseband chip of the terminal. [0140] In the embodiment, the receiving unit 704 is further configured to receive a first unlocking code input by a user; and [0141] the processing unit 705 is further configured to calculate a local unlocking code according to the network locking parameter stored in the terminal and the unique identification information, adopted for network locking, of the hardware of the terminal, perform comparison to determine whether the first unlocking code input by the user is consistent with the local unlocking code, determine that network unlocking succeeds if YES, otherwise determine current unlocking fails. After determining that unlocking succeeds, the processing unit 705 may update the unlocking parameter according to the methods shown in FIG. 5 to FIG. 6 , and verify the unlocking parameter when the terminal is started; and when determining that current unlocking fails, the current number of unlocking failures may be updated to provide a determination basis for subsequent unlocking. [0142] In the embodiment, before the receiving unit 704 receives the first unlocking code input by the user, the processing unit 705 may further perform integrity verification on the network locking parameter and the public key in the asymmetric encryption key pair adopted for a network locking process of the terminal in advance by virtue of the methods shown in FIG. 3 to FIG. 4 , which will not be elaborated herein. Embodiment 2 [0143] In order to better understand the technical solutions of the disclosure, the technical solutions of the disclosure will be further described below with reference to a network locking flow and network unlocking flow of a mobile terminal (which may not, of course, be limited to a mobile terminal, and may also be a non-mobile terminal). [0144] Referring to FIG. 8 , the network locking flow of the mobile terminal includes: [0145] Step S 801 , a PC side tool sends a network locking security handshake instruction to the mobile terminal; [0146] Step S 802 , the mobile terminal determines whether a network locking function is supported, [0147] wherein the mobile terminal specifically determines whether the network locking function is supported, Step S 803 is executed if the mobile terminal does not support the network locking function, otherwise Step S 804 is executed; [0148] Step S 803 , a handshake failure is returned; [0149] Step S 804 , a handshake success is returned; [0150] Step S 805 , the PC side tool sends a network locking parameter PLMN to the mobile terminal, [0151] wherein the PC side tool specifically sends the network locking parameter PLMN to the mobile terminal, and then the mobile terminal writes it into a first storage unit such as an NVRAM; [0152] Step S 806 , the PC side tool sends an instruction to the mobile terminal, [0153] wherein the instruction sent to the mobile terminal by the PC side tool is configured to request for network locking parameter verification information and public key parameter verification information, i.e. first network locking parameter verification information and second network locking parameter verification information respectively; [0154] Step S 807 , the mobile terminal determines whether the number of remaining pages of an OTP storage unit is more than 2, [0155] wherein the mobile terminal specifically determines whether the number of the remaining pages of the OTP storage unit (i.e. a second storage unit) of a flash is more than 2, namely determines whether a storage space is sufficient, Step S 808 is executed if the number of the remaining pages is less than 2, otherwise Step S 809 is executed; [0156] Step S 808 , a failure is returned; [0157] Step S 809 , a unique identifier of a baseband chip of the terminal is read, [0158] wherein the terminal specifically reads the unique identifier, such as an HW key, of the baseband chip of the terminal through an internal upper-layer application program; [0159] Step S 810 , the mobile terminal calculates a first digest value MD 1 of the network locking parameter and the unique identifier, [0160] wherein the mobile terminal specifically calculates MD 1 of the network locking parameter and the unique identifier, i.e. MD 1 of the HW key; [0161] Step S 811 , the mobile terminal calculates a second digest value MD 2 of an unlocking public key and the unique identifier, [0162] wherein the mobile terminal specifically calculates MD 2 of the network locking parameter and the unique identifier, i.e. MD 2 of the HW key; [0163] Step S 812 , the mobile terminal calculates an unlocking code according to a keyword of the network locking parameter and the unique identifier of the baseband chip, [0164] wherein the mobile terminal specifically calculates the unlocking code according to the keyword of the network locking parameter and the HW key; [0165] Step S 813 , the mobile terminal returns MD 1 , MD 2 and the unlocking code to the PC side tool; [0166] Step S 814 , the PC side tool locally stores the unlocking code and an IMEI of the terminal, [0167] wherein the PC side tool stores the IMEI of the terminal in a local database as an index of the unlocking code; [0168] Step S 815 , the PC side tool returns MD 1 and MD 2 to a USB key; [0169] Step S 816 , the USB key encrypts MD 1 and MD 2 using a private key to obtain DSP 1 and DSP 2 ; [0170] wherein the USB key performs digital signing on MD 1 and MD 2 using the RSA private key to generate the first network locking parameter verification information (DSP 1 ) and the second network locking parameter verification information (DSP 2 ); [0171] Step S 817 , the USB key returns DSP 1 and DSP 2 to the PC side tool; [0172] Step S 818 , the PC side tool sends DSP 1 and DSP 2 to the mobile terminal; [0173] Step S 819 , DSP 1 and DSP 2 are stored in the OTP storage unit, [0174] Wherein the mobile terminal writes DSP 1 and DSP 2 into the OTP storage unit of the flash respectively; and [0175] Step S 820 , the mobile terminal returns the network locking parameter and a network locking success. [0176] Integrity detection on the network locking parameter and the public key will not be elaborated herein, the technical solutions of the disclosure are further described herein directly with the unlocking flow of the mobile terminal as an example, and referring to FIG. 9 , the flow includes: [0177] Step S 901 , a user inputs a first unlocking code K 1 into the PC side tool; [0178] Step S 902 , the USB key encrypts the unlocking code K 1 using the private key to generate a first unlocking code ciphertext KC; [0179] Step S 903 , the PC side tool sends an unlocking request containing K 1 and KC to the mobile terminal; [0180] Step S 904 , whether an unlocking failure flag bit in the OTP storage unit is reset, [0181] wherein the mobile terminal specifically detects whether the unlocking failure flag bit in the OTP storage unit of the flash is reset, Step S 905 is executed if YES, otherwise Step S 906 is executed; [0182] Step S 905 , an unlocking failure message is returned to the PC side tool; [0183] Step S 906 , the mobile terminal determines whether the number of remaining unlocking times is more than 0, Step S 907 is executed if NO, otherwise Step S 908 is executed; [0184] Step S 907 , a failure is returned, that is, if the number of the remaining unlocking times is not more than 0, the terminal returns the unlocking failure message to the PC side tool; [0185] Step S 908 , K 2 is decrypted from KC using the public key, [0186] wherein the terminal decrypts a first check unlocking code K 2 from the ciphertext KC using the public key adopted for network locking; [0187] Step S 909 , comparison is performed to determine whether K 1 and K 2 are the same, Step S 910 is executed if NO, otherwise Step S 911 is executed; [0188] Step S 910 , the failure is returned, that is, the terminal returns the unlocking failure message to the PC side tool; [0189] Step S 911 , a local unlocking code is calculated according to the keyword of the network locking parameter and the unique identifier of the baseband chip of the terminal, [0190] wherein the terminal calculates the local unlocking code according to the keyword of the network locking parameter and the unique identifier, such as the HW key, of the baseband chip of the terminal; [0191] Step S 912 , comparison is performed to determine whether K 1 and the local unlocking code are the same, Step S 913 is executed if NO, otherwise Step S 914 is executed; [0192] Step S 913 , the failure is returned, and 1 is subtracted from the number of the remaining unlocking times, [0193] wherein the terminal returns the unlocking failure message to the PC side tool, simultaneously subtracts 1 from the number of the remaining unlocking times, and writes a result into the OTP storage unit of the flash; [0194] Step S 914 , the terminal modifies the network locking parameter into an unlocking parameter; [0195] Step S 915 , a third digest value MD 3 of the network locking parameter and the unique identifier is recalculated, [0196] wherein the terminal recalculates the third digest value MD 3 of the unlocking parameter and the unique identifier such as the HW key; [0197] Step S 916 , the terminal returns MD 3 to the PC side tool; [0198] Step S 917 , the PC side tool returns MD 3 to the USB key; [0199] Step S 918 , MD 3 is encrypted using the private key to obtain DSP 3 , [0200] wherein the USB key encrypts MD 3 using the private key to generate the first network locking parameter verification information DSP 3 ; [0201] Step S 919 , the USB key returns DSP 3 to the PC side tool; [0202] Step S 920 , the PC side tool sends DSP 3 to the mobile terminal; [0203] Step S 921 , the terminal writes DSP 3 into the OTP storage unit of the flash; and [0204] Step S 922 , an unlocking success is returned, that is, the terminal returns an unlocking success message. [0205] At this point, introduction about the specific implementation steps involved in the terminal hardware identifier-based security network locking and unlocking methods for a terminal have been finished. It can be seen that security of network locking of the terminal may be improved by the network locking method and corresponding network unlocking method provided by the embodiment of the disclosure. [0206] The sending unit, receiving unit and processing unit in the terminal provided by the embodiment of the disclosure may all be implemented by a processor in the mobile terminal, and may, of course, also be implemented by a specific logic circuit; and in a specific implementation process, the processor may be a Central Processing Unit (CPU), a Micro Processing Unit (MPU), a Digital Signal Processor (DSP), a Field Programmable Gate Array (FPGA) or the like. [0207] The network locking method for a terminal and/or the network unlocking method for a terminal in the embodiment of the disclosure may also be stored in a computer-readable storage medium if being implemented in form of software function module and sold or used as independent products. Based on such understanding, the technical solutions of the embodiment of the disclosure or the parts contributing to the prior art may be embodied in form of software product, and the computer software product is stored in a storage medium, and includes a plurality of instructions to enable a piece of computer equipment (which may be a PC, a server, network equipment or the like) to execute all or part of the methods of each embodiment of the disclosure. The storage medium includes: various media capable of storing program codes, such as a U disk, a mobile hard disk, a Read-Only Memory (ROM), a disk or a compact disc. Therefore, the embodiment of the disclosure is not limited to any specific hardware and software combination. [0208] Correspondingly, the embodiment of the disclosure further provides a computer storage medium having stored therein a computer-executable instruction configured to execute a network locking method for a terminal and/or a network unlocking method for a terminal in the embodiment of the disclosure. [0209] The above is only further detailed description made about the technical solutions of the disclosure with reference to specific implementation modes, and specific implementation of the disclosure may not be considered to be limited to the description. Those skilled in the art may further make a plurality of simple deductions or replacements without departing from the concept of the disclosure, and these deductions or replacements shall fall within the scope of protection of the disclosure. INDUSTRIAL APPLICABILITY [0210] In the embodiment of the disclosure, during network locking of the terminal, the network locking parameter is written into the first storage unit of the terminal, and the network locking parameter verification information and the unlocking code are obtained on the basis of the unique identification information of the hardware of the terminal and the network locking parameter; and when network unlocking of the terminal is performed, the unlocking code is obtained according to the network locking parameter stored in the terminal and the unique identification information of the hardware of the terminal; and comparison is performed to determine whether the unlocking code is consistent with the unlocking code input by the user, and when the two codes are consistent, it is determined that network unlocking is successfully performed. It is clear that the embodiment of the disclosure may implement unique binding of the network locking parameter of the terminal and the unique identification information of the hardware of the terminal, and network unlocking may be smoothly performed only according to the unique identification information of the hardware of the terminal, so that difficulty in illegal cracking of the unlocking code can be increased to a greater extent, and thus security of network locking of the terminal can be improved.
The present invention discloses a terminal, a network locking and network unlocking method for same, and a storage medium, said network locking method comprising: writing network-locking parameters in a first memory unit of the terminal; obtaining, in accordance with terminal hardware unique identification information and the network-locking parameters, network-locking parameter authentication information and an unlock code; storing the obtained network-locking parameter authentication information in a second memory unit of the terminal, and saving the unlock code.
7
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application is filed under 35 U.S.C. §120 and §365(c) as a continuation of International Patent Application PCT/IB2014/060422, filed Apr. 4, 2014, which application claims priority from German Patent Application No. 10 2013 103 693.7, filed Apr. 12, 2013, which application is incorporated herein by reference in its entireties. FIELD OF THE INVENTION [0002] The invention relates to a an apparatus and method for forming at least one structure on a surface of a substrate. The structure is formed as a layer from powder. BACKGROUND OF THE INVENTION [0003] For example, a low-temperature plasma spray method, “PlasmaDust”, of company Reinhausen Plasma is known for coating surfaces of substrates. Therein a powder is fed to a low-temperature plasma jet, is partially melted and chemically activated in this plasma jet, and applied by the plasma jet on a surface of a substrate to be coated. [0004] With this technique, it is only possible to achieve line widths of the applied layer not below about 1 millimeter without a mask. Thereby the edges of the lines are not shaped particularly clearly, which is caused by the inhomogeneous density profile of the plasma jet, which is similar to a Gaussian distribution. The usage of masks is laborious and therefore cost-intensive. In particular corresponding masks have to be provided for each desired shape of the layer, even if the number of substrates to be coated is small. [0005] It is known from German patent application DE 10 2008 001 580 A1 to apply the material for a layer as a dispersion of nanoparticles on a surface of a substrate. The nanoparticles applied this way are thermally post-processed by means of a CO 2 laser to achieve a desired electric conductivity and transparence of the layer. Regions of the layer, which have not been thermally post-processed, can be removed easily from the surface of the substrate, whereas the regions of the layer, which have been thermally post-processed, adhere very well, compare Zieris R et al., 2003, Characterization of coatings deposited by laser-assisted atmospheric plasma, Materials Park, Ohio: ASM International, pp. 567-572, ISBN: 0-87170-785-3. [0006] High laser power is required for such a thermal post-processing, which can lead to the damage of thermally sensitive substrates. [0007] It is known from the Russian patent application RU 2010 120 868 to illuminate the plasma beam, loaded with powder, by laser light within the plasma nozzle to achieve a better melting of the powder. Since the powder flows through the nozzle after laser irradiation, the laser irradiation does not contribute to the formation of finer structures. [0008] It is known from German patent application DE 10 2007 011 235 A1 to act simultaneously with a laser beam and a plasma jet on a surface. Therein both the laser beam and the plasma jet serve to clean the surface. Coating of the surface by the plasma jet, particularly in cooperation with the laser beam, is not mentioned. [0009] European patent application EP 0 903 423 A2 and German patent DE 197 40 205 B4 describe a method to apply a layer by means of plasma spraying. Thereby at least one continuous laser beam is directed through the spray jet with a given interaction time directly onto the surface of the substrate or the surface of a layer, which has already been applied there, and partially melts it. This method is a high-temperature method using a plasma torch, wherein the high-temperature method is directed at the processing of materials with melting points approximately in the range of 1500-2000° C. The laser beam impinges on the surface of the substrate within the incidence region of the spray jet. [0010] German patent application DE 199 41 563 A1 and German patent application DE 199 41 564 A1 each describe a method for plasma coating using a plasma torch together with a laser. The surface to be coated is locally melted by a laser beam, a plasma beam follows the laser beam and carries the coating material contained in the plasma into the melt. Alternatively the melting with the laser beam can also occur after applying the coating material with the plasma beam. [0011] An overview of the combination of using a laser with a method for plasma spraying can be found in S. E. Nielsen, “Laser fusing—combining laser and plasma spraying techniques for surface improvements”. SUMMARY OF THE INVENTION [0012] The present invention comprises a method for forming at least one structure from a powder on a surface of a substrate, the method having the steps of depositing the powder on the surface of the substrate by a low-temperature plasma jet during a relative movement between the low-temperature plasma jet and the substrate wherein the low-temperature plasma jet defines a plasma incidence region on the substrate, directing at least one laser beam onto the substrate and thereby defining a laser incidence region, wherein a defined relative position between the laser incidence region of the at least one laser beam and the plasma incidence region of the low-temperature plasma jet is given, and, causing a heat input in the substrate and/or the powder by the at least one laser beam in the laser incidence region. [0013] The present invention also comprises an apparatus for forming at least one structure on a surface of a substrate, the apparatus having a processing head, a nozzle of processing head for forming a low-temperature plasma jet and thereby defining a plasma incidence region of the low-temperature plasma jet on the substrate, a powder feed for feeding a powder into the low-temperature plasma jet or into the plasma for generating the low-temperature plasma jet, and, at least one laser emitter directed a laser beam onto the substrate and thereby defining a laser incidence region of the laser bean on the substrate, wherein the at least one laser emitter is arranged in such a way with respect to the processing head so that a defined relative position between the laser incidence region of the laser beam and the plasma incidence region of the low-temperature plasma jet is set on the substrate. [0014] A general object of the present invention is to provide a method, by which a structure can be formed easily and cost-effectively on a surface of a substrate. Therein structures shall also be possible, whose typical dimensions are significantly below 1 millimeter. [0015] Another object of the present invention is to provide an apparatus with which a structure can be formed easily and cost-effectively on the surface of a substrate. Therein structures shall also be possible, whose typical dimensions are significantly below 1 millimeter. [0016] In the plasma the powder particles exist in a partially or fully melted state, in the latter case, therefore, as a droplet. In order for a sufficient adhesion to form between such a powder particle and a surface of the substrate, it is necessary for material of the powder particle to spread on the surface; an increase of the contact area between the material of the powder particle and the surface of the substrate improves the adhesion of the powder particle on the substrate. In order to enable such a spreading of material of the powder particle on the surface of the substrate, the powder particle has to stay, after impact on the surface, in a partially or fully melted state for a sufficient time, so that material of the powder particle can spread on the surface. [0017] If the surface of the substrate is too cold, with at least thermal conductivities of the substrate and the melted powder material, a difference in temperature between the powder particle and the substrate, the heat transfer between the substrate and the melted powder material, the melting temperature of the powder as well as the heat capacity of the powder particle playing a role, the melted material solidifies too quickly, so that a sufficient spreading of this material is not possible. [0018] The basic idea of the invention is to cause a directed heat input into the surface of the substrate or into the powder applied on the surface of the substrate by at least one laser beam, so that a solidification of the melted material of powder particles on the surface is delayed. Directed heat input means here that only a defined, as the case may be spatially tightly limited, region of the surface of the substrate, which region is to be coated for forming the structure, is exposed to the laser beam, and that the laser irradiation occurs also in immediate temporal vicinity of the coating, so that damaging the substrate by an unnecessarily long exposure of a location on the substrate to the laser is avoided; likewise avoided in this way is so great a drain of the amount of input heat from the defined region before coating that the heat input can no longer show the desired effect. [0019] The application of the material for the structure on the surface of the substrate, on which the structure is to be built by coating the surface, occurs by a plasma jet, to which the material is added as a powder. This plasma jet is a low-temperature plasma jet. Feeding the powder to the plasma of the plasma jet can occur in any way known by the skilled person for plasma spray methods. The powder can also be fed to the plasma, before forming the plasma jet; feeding the powder to the gas from which a plasma is generated is also conceivable. For applying the powder on the surface of the substrate, the low-temperature plasma jet and the substrate are moved relatively to each other, so that at least the defined region of the surface of the substrate, which the structure is to be formed on, is impinged with the powder. [0020] For achieving a directed heat input into the defined region to be coated of the surface of the substrate, i.e. the defined region, on which the structure is to be formed, at least one laser beam is used, which is directed onto the substrate, as said before. This results in a laser incidence region of the at least one laser beam on the substrate; therein, the substrate also can already have been impinged with powder, in which case the laser beam primarily impinges on the powder on the substrate. The low-temperature plasma jet impinges on the substrate in a plasma incidence region. At any given point of time the laser incidence region on the substrate is that region of the substrate or of the powder applied on the substrate, which is impinged by laser radiation at this point of time. A location on the substrate or on the powder applied on the substrate, which is not impinged by laser light at the given point of time, is not included in the laser incidence region. An analogous definition applies for the plasma incidence region. The at least one laser beam is directed onto the substrate such that a defined relative position between the laser incidence region and the plasma incidence region is given. The laser incidence region is always located within the defined region to be coated and is moved across it. The amount of the heat input within the laser incidence region can be influenced for example by the power of the laser beam and the velocity, at which the laser is moved across the surface of the substrate. [0021] Outside of the defined region, i.e. where no heat input by the laser occurred, no sufficient adhesion can be formed between the surface of the substrate and the powder particles applied there by the plasma jet, for the reasons mentioned above. Consequently, these powder particles, which are located outside of the defined region, can be removed easily from the surface. In this way structures of reduced typical size scale, down to 50 micrometers, can be formed, even without using masks. An example for a typical size scale is the width of a coating applied as a line. Building a sufficient adhesion only within the defined region also results in more clearly shaped edges of these lines; the lines have a rectangular cross section, in contrast to the line profile similar to a Gaussian shape, which is obtained with the abovementioned PlasmaDust method. [0022] In one embodiment of the method, the defined relative position between the laser incidence region and the plasma incidence region is such that the laser incidence region is located outside of the plasma incidence region and is not impinged with powder. In this embodiment, the powder particles impinge in a partially or fully melted state on the surface of the substrate. A heat input occurred within the defined region to be coated of the surface by the laser beam, which causes a temperature rise of the substrate within the defined region, so that a difference in temperature between the powder particles and the substrate is reduced within the defined region. Therefore the heat drain from the powder particles to the substrate is reduced, and the solidification of melted material of the powder particles is delayed compared with powder particles applied outside of the defined region. A requirement for the method in this embodiment evidently is that the substrate absorbs the laser light in an extent, which is sufficient to achieve the required heat input into the substrate. [0023] In a further development of this embodiment, the at least one laser beam is directed such that it does not traverse the low-temperature plasma jet. The absorption characteristics of the powder particles for laser light are insignificant in this embodiment of the inventive method. [0024] In another further embodiment of the previously discussed embodiment, the at least one laser beam is directed such that it traverses the low-temperature plasma jet. Therefore in this development of the method an additional heat input can occur into powder particles passing through the laser beam in the plasma jet, insofar as these powder particles are able to absorb the laser light. The additional heat input into the powder particles contributes to delaying the solidification of the melted material of these powder particles after their impact on the defined region of the surface of the substrate. [0025] In a further embodiment the laser incidence region overlaps with the plasma incidence region. The laser incidence region may be fully or partially located within the plasma incidence region. Therefore, in this embodiment, at least a part of the laser radiation impinges on powder within the laser incidence region, which has already been applied on the surface of the substrate. It is a requirement for this embodiment that the powder particles absorb the laser light, and the method can also be applied if the substrate itself is transparent for the used laser light to such an extent that a sufficient heat input into a defined region of the surface of the substrate by direct absorption of laser light by the substrate is not possible. The powder within the laser incidence region absorbs the laser radiation. The heat input into a powder particle caused in this way counteracts the heat drain from the powder particle to the substrate. Thus, in this embodiment, too, the solidification of melted material of the powder particle is delayed compared with a powder particle applied outside of the defined region. [0026] If the relative position of the laser incidence region and of the plasma incidence region is such that the laser incidence region is located partly within and partly outside of the plasma incidence region, wherein furthermore the part of the laser incidence region outside of the plasma incidence region has not yet been impinged with powder, an effect results, which can be seen as combination of the effects of the previously described embodiments. On the one hand, a difference in temperature between powder particles and a defined region to be coated is reduced by the effect of the laser beam on the substrate itself. On the other hand the heat drain from these powder particles to the substrate is counteracted by the part of the laser beam impinging on powder particles which have already been applied on the surface of the substrate. [0027] It would be conceivable to use at least two laser beams, of which at least one forms a part of the laser incidence region, which is located fully outside of the plasma incidence region, and of which at least one forms a part of the laser incidence region, which is located fully within the plasma incidence region. Thus, in this case the laser incidence region is not connected. [0028] In one embodiment of the method, a diameter of the laser incidence region is smaller than the diameter of the plasma incidence region. Since laser radiation can be focused to regions of smaller diameter than possible with plasma jets, it is possible with this embodiment of the method, to generate structures with typical size scales, e.g. lines with a width, which are significantly below the size scales or the width, which can be generated by a plasma jet without a mask. With this embodiment of the method, line widths can be generated down to 50 micrometers, whereas line widths below 1 millimeter are hardly possible with a plasma jet alone, without masks. [0029] As mentioned above, a laser beam can be focused on a region of smaller diameter than a plasma jet. Therefore when forming structures with correspondingly small dimensions, for example lines with a width smaller than the diameter of the plasma incidence region, powder is initially applied by the plasma jet also to regions of the substrate, which are located outside of the defined region to be coated. Therefore, the powder is located outside of the structure formed by the cooperation of the laser beam and the plasma jet on the substrate. From the introductory remarks on forming the adhesion of the powder particles on the substrate it follows that the particles deposited outside of the structure adhere to the substrate at best weakly. Such particles can be removed easily from the surface of the substrate, e.g. blown off, so that only the structure constructed on the substrate remains. Sometimes the particles which are applied outside of the defined region to be coated and which solidify quickly are already swept away by the gas stream of the plasma jet itself. [0030] The method is not limited to planar substrates, but can be applied to arbitrarily designed substrates. [0031] The apparatus according to the invention for forming at least one structure on a surface of a substrate has a processing head, which has a nozzle for forming a low-temperature plasma jet. A known plasma generator is used for generating a low-temperature plasma. The apparatus according to the invention further comprises a powder feed, with which the powder out of which the structure is to be formed, can be fed to the plasma jet itself or to the plasma out of which the plasma jet is yet to be formed, or to the gas out of which the plasma should be generated. At least one laser emitter is mounted to the processing head, according to the invention. The mounting is such that a laser beam from the laser emitter can be directed onto the substrate such that a defined relative position between a laser incidence region of the laser beam on the substrate and a plasma incidence region of the low-temperature plasma jet on the substrate can be achieved. For instance, the laser emitter can be attached to the processing head such that the laser beam is emitted under a defined angle to the central axis of the plasma jet, which results in a defined relative position between the laser incidence region and the plasma incidence region. In one embodiment, the laser emitter is a laser mounted on the processing head. The laser can be a semiconductor laser, for example. [0032] Alternatively the laser light of the at least one laser beam can be guided through at least one optical fiber to the processing head. The laser light is coupled out at the processing head from the at least one optical fiber. Herein the laser emitter is an end of the optical fiber, where the end is attached to the processing head. Embodiments of the invention use coupling-out optics for coupling out the laser light from the optical fiber. [0033] These embodiments of the apparatus have the advantage that a fixed geometric relation between the plasma jet and the at least one laser beam is settable by mounting the laser or an end of the optical fiber, respectively, if necessary enclosing a coupling-out optics, on the processing head, so that also a defined relative position between the laser incidence region and the plasma incidence region is settable in an easy manner. [0034] According to a further embodiment, the laser emitter is mounted in an adjustable manner on the processing head. The adjustment is carried out by an operator or by actuators as a result of control signals, which are generated by a user of the apparatus or by a control system; this may be possible during formation of a structure on a substrate, as well. [0035] In another embodiment, at least one movable reflector is provided to guide the laser beam across the substrate. The at least one movable reflector is controllable such that the laser incidence region describes the desired path on the substrate within the defined region to be coated. In such an embodiment, a fixed geometric relation between the plasma jet and the at least one laser beam is not mandatory, this geometric relation is changeable by controlling the at least one reflector. It is also conceivable, that at least one controllable, movable reflector for the laser light is attached to the processing head itself. [0036] Geometric relation between the plasma jet and the at least one laser beam can be understood, for example, as an angle between the at least one laser beam and the plasma jet. More generally, geometric relation between the plasma jet and the at least one laser beam can be understood as a relative path of the plasma jet and the at least one laser beam, which relative path also determines the relative position between the plasma incidence region on the surface of the substrate and the laser incidence region on the surface of the substrate. This relative position can be adapted depending on the embodiment of the method and on, for example, powder and substrate, for instance material or shape of the substrate or further parameters. [0037] The apparatus furthermore comprises a means with which a relative movement between the substrate and the processing head can be generated. Thus a robotic arm can be provided to move the processing head relatively to the substrate, alternatively, for example, a gantry robot can be used. It is possible, as well, to place the substrate on a movable stage or a robot can move the substrate relatively to the plasma jet. [0038] In particular, the apparatus according to the invention is suitable for executing the method according to the invention. [0039] These and other objects, advantages and features of the present invention will be better appreciated by those having ordinary skill in the art in view of the following detailed description of the invention in view of the drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0040] The nature and mode of operation of the present invention will now be more fully described in the following detailed description of the invention taken with the accompanying figures, in which: [0041] FIG. 1 is a first embodiment of the method, where the laser beam is guided before the plasma jet; [0042] FIG. 2 shows a top view onto a surface of the substrate, which is subjected to the embodiment of the method of FIG. 1 ; [0043] FIG. 3 shows a second embodiment of the method, where the laser beam traverses the plasma jet; [0044] FIG. 4 shows a third embodiment of the method, where the laser beam is directed into the plasma jet; [0045] FIG. 5 shows a top view similar to FIG. 2 , wherein the substrate, which is subjected to the embodiment of the method as shown in FIG. 4 ; [0046] FIG. 6 shows an embodiment of the device according to the invention; and, [0047] FIG. 7 shows a further embodiment of the device according to the invention. DETAILED DESCRIPTION OF THE INVENTION [0048] At the outset, it should be appreciated that like reference characters on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred aspects, it is to be understood that the invention as claimed is not limited to the disclosed aspect. Also, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is applicable to other embodiments or of being practiced or carried out in various ways and is intended to include various modifications and equivalent arrangements within the spirit and scope of the appended claims. [0049] Furthermore, it is understood that this invention is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present invention, which is limited only by the appended claims. The invention expressly also covers the combinations of features of the embodiments described. [0050] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described. [0051] FIG. 1 shows a first schematic embodiment of the method and the apparatus according to the invention for forming a structure 2 on a substrate 100 . A powder 20 is supplied to a low-temperature plasma jet 10 and deposited on a surface 1 of the substrate 100 by the plasma jet 10 . The powder 20 is fed to the plasma jet 10 by a powder feed 21 , which here is shown only schematically. The plasma jet 10 exits from a processing head 11 , which is connected to a plasma generator, which is not shown here. A laser beam 30 , generated here by a laser 31 , is directed onto the surface 1 of the substrate and there defines a laser incidence region 35 (see FIG. 2 ) in a region, which has not yet been impinged with powder 20 by the plasma jet 10 . The arrangement of processing head 11 , laser 31 and powder feed 21 is guided and moved respectively in the direction of arrow 50 relatively to the surface 1 of the substrate 100 . Thus also the plasma jet 10 and the laser beam 20 are guided in the direction of arrow 50 relatively to the surface 1 of the substrate 100 . [0052] In this and the following figures the powder 20 is fed to the plasma jet 10 outside of the processing head 11 . However, this is a not limiting factor of the invention. The powder 20 may be fed to the plasma eventually forming the plasma jet 10 in any way known to the person skilled in low-temperature plasma spraying. Likewise, it is not limiting to the invention that the laser beam 30 is directed onto the substrate 100 directly by the laser 31 and that the laser 31 is moved relatively to the surface 1 . It is relevant for the method that the laser beam 30 impinges on the substrate 100 and that the laser beam 30 moves relatively to the surface 1 , irrespectively of where the laser beam 30 is generated and how it is eventually directed onto the substrate 100 . [0053] FIG. 2 shows a top view of a surface 1 of a substrate 100 ; the top view corresponds to an embodiment of the method as shown in FIG. 1 . The laser incidence region 35 is shown, i.e. the region in which the laser beam 30 (see FIG. 1 ) impinges on the substrate 100 ; the shown circular shape of the laser incidence region 35 is not limiting to the invention. A part of a defined region 37 to be coated is also shown. The laser incidence region 35 is guided in the direction of arrow 50 across the defined region 37 and causes a heat input into the substrate 100 there. Therefore the laser incidence region 35 leaves behind a preheated region 36 on the surface 1 of the substrate 100 , when moved in direction of arrow 50 , wherein the preheated region 36 has not yet been impinged with powder 20 (see FIG. 1 ). The plasma jet 10 , shown in FIG. 1 impinges on the surface 1 of the substrate 100 in a plasma incidence region 15 shown here to be of circular shape; however this circular shape is not limiting to the invention. The laser incidence region 35 and the plasma incidence region 15 have a defined relative position R to each other. The preheated region 36 , which has not yet been impinged with powder 20 , is located between the plasma incidence region 15 and the laser incidence region 35 . If the plasma jet 10 , and therefore also the plasma incidence region 15 , is moved in direction of arrow 50 across the surface 1 , a powder 20 is deposited along a trace S of the plasma incidence region 15 on the surface 1 . With this movement the plasma incidence region 15 also sweeps over the respective preheated region 36 , since the plasma jet 10 follows the laser beam 30 . The plasma incidence region 15 follows the laser incidence region 35 . According to the explanations above, a good adhesion can develop between the powder 20 deposited in the preheated region 36 and the surface 1 of the substrate 100 , since, among other things, a difference in temperature between the powder particles in the plasma jet 10 and the preheated region 36 is reduced by preheating the region 36 . Thus the structure 2 , shaped here as a line with a width 3 , is finally formed on the surface 1 of the substrate 100 . [0054] Such a decrease of the difference in temperature between the powder particles in the plasma jet 10 and a corresponding region 16 does not occur in regions 16 outside of the preheated region 36 , so that a good adhesion of the powder particles on the substrate 100 does not develop in the regions 16 . The deposited powder 20 can be easily removed from these regions 16 by known methods. [0055] As mentioned at the beginning, line widths 3 are possible with the method according to the invention which are significantly smaller than the line widths achievable by a low-temperature plasma jet alone, i.e. without using a laser beam. This is so, because focusing the laser beam 30 on corresponding smaller diameters, which correspond approximately to the desired line width 3 , is easier than a corresponding focusing of the plasma jet 10 . Accordingly, in FIG. 2 , a diameter DP of the plasma incidence region 15 is shown larger than a diameter DL of the laser incidence region 35 . [0056] FIG. 3 to a large extent corresponds to FIG. 1 . However, in the embodiment shown in FIG. 3 , the laser beam 30 is directed through the plasma jet 10 onto the surface 1 of the substrate 100 . The laser beam 30 impinges on the surface 1 of the substrate 100 outside of the plasma jet 10 . In a top view an arrangement like in FIG. 2 would result. In the embodiment of the method shown in FIG. 3 , a laser incidence region 35 defined by the laser beam 30 on the substrate 100 is located, relative to the direction of movement 50 , in front of the plasma incidence region 15 , so that the plasma jet 10 follows the laser incidence region 35 in this embodiment, too. In addition to a heat input into a region of the substrate 100 , the laser beam 30 here can also heat powder particles which traverse the laser beam 30 within the plasma jet 10 . This additional heating of the powder particles leads to a delay of the solidification of the powder particles after their impact on the substrate 100 , as already mentioned above. [0057] FIG. 4 shows a further embodiment of the method and apparatus, which are similar to the one shown in FIG. 1 . Most of the elements shown have already been discussed in the context of FIG. 1 . For clarity reasons, plasma jet 10 and laser beam 30 have been shown larger compared with FIG. 1 . Furthermore, a density profile 22 of the powder 20 in the plasma jet 10 , and the plasma incidence region 15 determined by the density profile 22 are shown in FIG. 4 . In this embodiment, the laser beam 30 is directed onto a region of the surface 1 of the substrate 100 , which has already been impinged with powder 20 . More precisely, the laser beam 30 is directed into the plasma jet 10 such that it impinges on a leading slope 22 F of the density profile 22 , if considered in direction 50 of a movement of the plasma jet 10 relative to surface 1 . Therefore a thin powder layer 2 d , which has already been deposited on the substrate 100 in this leading slope 22 F, is impinged with laser radiation. This leads to a heat input into the powder particles in the thin powder layer 2 d . This heat input counteracts the heat drain from these powder particles to the substrate 100 und therefore delays a solidification of the melted material of the powder particles, as mentioned above, so that finally the well adhering structure 2 is built on the surface 1 of the substrate 100 . [0058] FIG. 5 shows a top view of the surface 1 of the substrate 100 , corresponding to an embodiment of the method shown in FIG. 4 . All elements shown have already been discussed in FIG. 2 , which is a corresponding representation for an embodiment of the method shown in FIG. 1 . In contrast to FIG. 2 , the laser incidence region 35 is located within the plasma incidence region 15 in FIG. 5 . A preheated region 36 , like in FIG. 2 , does not exist here, since the heat input in the laser incidence region 35 occurs, as shown in FIG. 4 , into powder which has already been deposited on the surface 1 . A requirement for the embodiment shown in FIGS. 4 and 5 is that the powder 20 is able to absorb the laser light sufficiently. The substrate 100 , on the other hand, may be transparent for laser light in this embodiment. [0059] FIG. 6 shows an embodiment of the apparatus 300 according to the invention. A processing head 11 has a nozzle 12 for forming a plasma jet 10 out of a plasma. A plasma generator known to those skilled in the art may be used for generating the plasma. A laser 31 is attached to the processing head 11 . The laser 31 is adjustable by an actuator 32 , so that in particular the relative position R between the plasma incidence region 15 and the laser incidence region 35 discussed above can be set. The laser may be a semiconductor laser. [0060] FIG. 7 shows a further embodiment of the apparatus 300 according to the invention. Some of the depicted elements have already been discussed in the context of FIG. 6 . An end 33 e of an optical fiber 33 is attached to a holder 33 h on the processing head 11 . The holder 33 h is adjustable by an actuator 32 , so that in particular the relative position R between the plasma incidence region 15 and the laser incidence region 35 discussed above can be set. Moreover, this embodiment provides a coupling-out optics 34 for coupling out the laser light from the optical fiber 33 . In this embodiment the coupling-out optics 34 is mounted on the processing head 11 . The laser light is fed into the optical fiber 33 by a laser 31 in a way known to the skilled person. The laser may be a semiconductor laser. [0061] Thus, it is seen that the objects of the present invention are efficiently obtained, although modifications and changes to the invention should be readily apparent to those having ordinary skill in the art, such modifications are intended to be within the spirit and scope of the invention as claimed. It also is understood that the foregoing description is illustrative of the present invention and should not be considered as limiting. Therefore, other embodiments of the present invention are possible without departing from the spirit and scope of the present invention as claimed.
The invention relates to a method for forming at least one structure on a substrate. By means of a low-temperature plasma jet, powder, of which the structure shall be constructed, is applied to a surface of the substrate. By means of at least one laser beam, heat is input into the substrate and/or the powder within a laser incidence region on the substrate. The heat input delays solidification of the powder particles, which are partly or fully melted in the plasma jet, on the substrate and thereby enables the formation of good adhesion between the applied powder, and thus the structure constructed thereof, and the substrate. The invention further relates to an apparatus for performing the method.
2
STATEMENT OF GOVERNMENT INTEREST The invention described herein may be manufactured and used by or for the Government of the U.S. of America for governmental purposes without the payment of any royalties thereon or therefor. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention generally relates to the field of electroacoustic transducers such as hydrophones and more specifically to an apparatus and technique for coupling magnetically a plurality of electroacoustic transducers or hydrophones to a single conductor trunk cable using seawater as the electrical return path. 2. Statement of the Prior Art One of the common requirements in most of the oceanographic communication studies is to collect at the shore end of a trunk cable acoustic data which is transmitted from a cooperative underwater target in order to determine its position in three dimensions as a function of time. For such applications, metallic connections using either underwater connectors or premolded splices have been used to connect a plurality of hydrophones to the trunk cable. This puts pre-deployment constraints on the location of hydrophones and complicates the deployment process as any discontinuity (e.g., a connector) must be passed through pulleys, drums and other apparatus as required to hold and properly deploy miles of trunk cable. Trunk cables used in the past for such applications have typically employed two conductor-cables usually in a coaxial configuration which puts an additional constraint in deploying long lengths of such cable. It is thus desirable to have an apparatus which can improve deployment of a trunk cable which avoids the use of connector and uses a single conductor cable. SUMMARY OF THE INVENTION This invention teaches the use of magnetic couplers to connect transponder-like devices to a main trunk cable which utilizes a single conductor as seawater is used as the return path. The use of magnetic couplers eliminates the use of connectors which greatly improves its deployment. Furthermore, the use of a single conductor cable further facilitates the deployment of miles of the trunk cable because of its reduced diameter. It is an object of subject invention to use magnetic couplers for deploying transponder-like devices along the length of a long trunk cable. Another object of subject invention is to use magnetic couplers to deploy a plurality of transponder-like devices located at any randomly selected position on the trunk cable and thus increasing flexibility of configuration of the detection system. Still another object of subject invention is to use seawater as the return path which permits the use of a single conductor trunk cable and thus improving its deployment. Another object of subject invention is to reduce the cost of the trunk cable by using a single conductor trunk cable. Other objects, advantages and novel features of the invention will become apparent from the following detailed description thereof when considered in conjunction with the accompanying drawings wherein: BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a schematic arrangement of the teachings of subject invention. FIG. 2 is a perspective view of a magnetic coupler used around a single conductor trunk cable. FIG. 3 is a front-view of the magnetic coupler of FIG. 2. FIG. 4 is a side-view of the magnetic coupler of FIG. 2. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings wherein like reference characters designate identical or corresponding parts throughout various figures, FIG. 1 shows a schematic arrangement 10 using the couplers 20 placed at random points of a trunk cable 26 which is preferably a single conductor trunk cable. Two conductor riser cable 12 is connected to magnetic coupler 20 at one end and to a conventional signal amplifier and processor 14 at the other end. The signal amplifier and processor including power are preferably housed in a waterproof can or unit which is capable of withstanding ambient pressure. Unit 14 and integral hydrophone 16 is connected to a float 18 used for keeping the assembly upright. FIG. 2 shows a perspective view of a magnetic coupler 20 according to the teachings of subject invention. It is preferably in the form of a split toroid magnetic core and includes two halves 22 and 24 encased in encapsulants 32 and 30 respectively. Encapsulated halves 22 and 24 are engagable around any preselected point of a long trunk cable 26 and are held together by fasteners or bolts 34 and 36. These fasteners can be snap fasteners requiring no tools for their use. Toroid half 22 has several turns of wire 28 attached to the riser cable 12 which acts as the primary of a transformer and trunk cable 26 forms the secondary of the transformer with only one turn. The bottom half of the toroid core has no wires and serves only to complete the magnetic path. The split coupler allows it to be easily attachable to the trunk cable particularly if snap fasteners are used. FIG. 3 shows a front view of the magnetic coupler of FIG. 2 whereas FIG. 4 shows an end view of the magnetic coupler of FIG. 2. Acoustic signals generated by a cooperative target are converted to electrical energy by hydrophone 16, then amplified and processed in unit 14 which functions similar to a transponder, except that its response is not acoustic. Instead, the response consists of a burst of electrical energy which is magnetically coupled with the trunk cable. The bursts generated by each transponder-like device are unique, and time delays between the pulses characterize the position of the cooperative target. It should be clearly understood that other modes of signal processing are possible without deviating from the teachings of subject invention. Laboratory experiments have shown that a 30 turn primary for the magnetic coupler gives reasonably good transfer characteristics. The primary side is series tuned to the desired operating frequency and the reactive primary can actually produce a voltage step up at resonance. This almost fully compensates for the 30:1 step down of the transformer. When coupled to the single turn secondary, overall voltage losses are only about 3 dB. Computer analyses and field tests have characterized the performance of a typical single conductor seawater return cable constructed of #14 AWG copper wire with polyurethane jacket. Characteristic impedance is about 74 ohms and the losses per unit length are on the order of 0.8 db/Km at 5 KHz and 1.5 db/Km at 15 KHz. Shallow ranges require many hydrophones to get a moderate tracking area. With so many hydrophones, the use of acoustic transponders is often prohibitive due to the resulting acoustic din. One solution often used is to employ sonobuoys, thus putting the replies in the RF spectrum. However, they must be installed and resurveyed often as sonobuoy ranges cannot be left in place for much longer than a few days, since they are subject to the effects of weather, sea state, tides, traffic and even pilfering. Secondly, they are usually tethered to an anchor, with sufficient slack to allow for tides as they afford limited accuracy due to the watch circle of uncertainty in their position. The seawater return approach with magnetically coupled hydrophones overcomes many of these difficulties. Since all replies are non-acoustic, their responses do not contaminate the medium and up-front costs are low as a result of the simplicity of a single conductor trunk cable and no need for pressurized electronics multiplexers. Also, the installation is simplified as canisters can easily be attached after the last cable pulley. All seaside equipment is located on the ocean bottom, thus supporting either long or short term installations. Deep water ranges typically employ less hydrophones per unit area, but the problems and considerations are similar. The use of acoustic transponders is sometimes employed, but still contributes unnecessary acoustic "noise". Because of this, they are almost never used on noise measurement ranges. When employed, they are liable to battery replacement and resurveying considerations. Due to the greater separation of hydrophones, deep water ranges tend to require more cable than shallow ranges, thus cable costs become a prime consideration, and deep sea electronic multiplexers still suffer from considerable cost and complexity. Thus, for many of the same reasons, deep water ranges can realize several cost and technical benefits by employing magnetically coupled hydrophones to a single conductor trunk cable. Some of the fundamental considerations for such a system are: what is the maximum number of hydrophones which can be coupled to a single trunk cable, and what is the greatest cable length which can be supported? The first parameter is governed by the available spectrum and frequency spacing of the electronics canisters. Experimental data suggests that frequencies extending from near DC to about 15 KHz can be supported, but that it is only a cable consideration. In reality a lower limit of about 5 KHz would be more practical. To go much lower than this puts increasingly greater demands on circuit Q, transformer efficiency and the like. This is not to say that lower reply frequencies are impossible; just increasingly more difficult. Frequency spacing is dictated by processing bandwidth, timing resolution and oscillator accuracy. Spacings of 250 Hz are possible, but 500 Hz is more practical and has been used extensively. Any narrower than this puts serious limitations on timing accuracy and frequency stability. Thus, about 20 electronics canisters, each replying at a unique frequency, could be deployed on a single trunk cable. More sophisticated processing techniques could be used to increase this figure, but it is preferred to base the analysis on conventional methods. Similarly, duplicate reply frequencies could be used on the same trunk cable if their identity could be resolved by spatial separation but this can add considerable complexity to the signal processing task. If more than 20 hydrophones are needed, the straightforward solution is to employ more than one trunk cable. The issue of maximum cable length is determined by signal-to-noise ratio (hereinafter referred to as SNR). Measurements have shown that self noise on a coaxial cable run from deep sea to shore is about -145 dbV/Hz 1/2 the frequency range of interest. This is not affected by cable length, and is the result of electromagnetic interference (EMI) pickup in the shallow waters near shore. The SNR which arrives at the input to the shore processor will determine if the signal is at all detectable. Once detectable, increasing the SNR provides increased timing accuracy up to a given threshold, beyond which no further improvements will be realized. For a typical energy detector type signal processor of unsophisticated design, this SNR threshold is about +45 db when measured in a 1 Hz band. Assuming a +20 dbV source level (10 watts into 10 ohms), 3 db loss in the coupler, 6 db matching loss (cable characteristic impedance to shore load impedance), and a -100 dbV shore signal level requirement (45 db SNR), yields a maximum cable loss of about 110 db. This translates to about 100 Km at 15 KHz and 140 Km at 5 KHz. These great distances are very attractive and offer significant savings in the installed cost per unit length. Clearly, the high frequencies should be placed dearer the shore end of the cable in order to obtain the highest SNR and greatest possible cable lengths. Briefly stated, a magnetic coupler which is used to couple a plurality of electroacoustic transducers at various points of a trunk cable includes a split toroid magnetic core with its two halves encapsulated and easily attachable to the trunk cable at any desired point using snap fasteners or the like. A hydrophone, signal processing electronics and power source are housed in a waterproof canister capable of withstanding the ambient pressure. The signal processing electronics and power source acts like a transponder to transmit information via the single conductor trunk cable to the shore facility many miles away from the hydrophones. From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt to various usages and conditions. As an example, the number of hydrophones used coupled to a single trunk cable can vary. Additionally, the mode of transmitting electric signals may also vary. The method of attaching the magnetic coupler to the trunk cable can also vary depending upon the type of fasteners used for the purpose. It is therefore understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
A magnetic coupler and the use of such couplers to place a plurality of etroacoustic transducers around a lengthy single conductor trunk cable is described. The magnetic couplers are used to place the electroacoustic transducers in any randomly selected configuration. They allow the use of a single conductor trunk cable so as to facilitate the deployment of the system at a relatively low cost.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flocked product having electroconductivity and a molded article on which the flocked product is mounted and fixed. More particularly, the present invention relates to a flocked product to which any dust does not adhere y static electricity, and a molded article on which the flocked product is mounted and fixed and which has the fluffy surface like velvet and corduroy without any adherent dust by static electricity and without any discharge shock of static electricity. 2. Description of the Prior Art In recent years, the so-called flocked products have been widely utilized for clothes, footwear, carpets, furniture, miscellaneous goods and the like, and these flocked products can be prepared by first coating the surfaces of nonwoven, woven or knitted fabric bases with an adhesive, and then planting and fixing, on the surfaces, pieces of short fiber called piles or flocks by the utilization of static electricity. Commercial values of the flocked products reside in a warm and soft appearance like fur as well as a thick and tender feel, with which users are pleased. Further, as interior materials of automobiles and the like, flocked products having warm and soft fluffy surfaces have often been substituted for conventional vinyl chloride leathers and the like. In this case, the flocked products are stuck on molded plastic articles which are base materials. However, with regard to the flocked products and molded articles on which the flocked products have been stuck, dust is very liable to adhere to the surfaces of the flocked products and the molded articles having them by static electricity, and their appearance tends to be impaired, which makes users undelighted. In addition, there is the problem that users often undergo unpleasant shock of electrical discharge of static electricity particularly in winter. SUMMARY OF THE INVENTION According to the present invention, there are provided an electroconductive fabric sheet which is obtained by forming an adhesive layer on either surface of an electroconductive nonwoven, woven and knitted fabric base composed mainly of hot-fusible fiber and electroconductive fiber, and planting and fixing, on the surface having the adhesive layer, flocks of short fiber containing 1% by weight or more of the electroconductive fiber; and a molded article having the above electroconductive fabric sheet on the surface thereof which is obtained by putting the electroconductive fabric sheet in a mold so that the flocks on the fabric sheet may contact with the inner wall of the mold, and injecting melted resin into the mold, or pressing the melted or softened resin against the fabric sheet in the mold. DESCRIPTION OF THE PREFERRED EMBODIMENTS The inventors of the present application have intensively conducted researches with the intention of solving the above-mentioned problems, and as a result, they have found that the generation of static electricity can be inhibited by adding electroconductive fiber to a nonwoven, woven or knitted fabric base, and further adding the electroconductive fiber to short fiber (hereinafter referred to as the flocks) which will be planted on the fabric base, so that dust can be prevented from adhering thereto. The present invention has been completed on the basis of this knowledge. The present invention is directed to an electroconductive fabric sheet which is obtained by forming an adhesive layer on either surface of an electroconductive nonwoven, woven and knitted fabric composed mainly of heat fusible fiber and electroconductive fiber, and planting and fixing, on the surface having the adhesive layer, flocks of short fiber containing 1% by weight or more of the electroconductive fiber; and a molded article having the above electroconductive fabric sheet on the surface thereof which is obtained by putting the electroconductive fabric sheet in a mold so that the flocks on the fabric sheet may contact with the inner wall of the mold, and injecting melted resin into the mold, or pressing the melted or softened resin against the fabric sheet in the mold. In the present invention, there is used, as a base material, a nonwoven fabric (hereinafter referred to as the electroconductive nonwoven fabric) composed mainly of a fiber mixture of heat fusible fiber and electroconductive fiber, or a woven or knitted fabric (hereinafter referred to as the electroconductive woven or knitted fabric) composed mainly of a fiber mixture of heat fusible fiber and electroconductive fiber. Examples of the usable electroconductive fiber include copper-adsorbed fiber, metal-plated fiber, carbon fiber, carbon composite fiber, metal-deposited fiber and metallic fiber. Examples of the usable heat fusible fiber include polyolefin fiber, polyamide fiber, polyester fiber, polyacrylonitrile fiber and composite fibers thereof, and they can be used alone or in a combination thereof. In addition to the electroconductive fiber and the heat fusible fiber mentioned above, the fabric may contain fiber having high melting point or nonmelting fiber. This fiber plays a role of a reinforcing material and other roles at the time of manufacturing nonwoven fabric, at the time of the spinning, knitting or weaving of yarn for the woven or knitted fabric of the present invention, or in the molded articles of the present invention. The electroconductive nonwoven fabric base can be obtained from the above-mentioned fiber mixture composed mainly of the electroconductive fiber and the heat fusible fiber in accordance with a binder method, a needle punching method, a method of utilizing water pressure and spun bonding, a thermal adhesion method or a wet manufacturing method. The unit weight of the electroconductive nonwoven fabric is not particularly limited, but it is preferably within a range of 20 to 200 g/m 2 . In order to facilitate the coating of an adhesive, the nonwoven fabric may be slightly subjected to heat pressing treatment. The amount of the electroconductive fiber used in the electroconductive nonwoven base is within a range of 1 to 90% by weight, preferably 5 to 60% by weight. When the amount of the electroconductive fiber is less than 1% by weight, satisfactory conductivity cannot be obtained, and when it is more than 90% by weight, it is very difficult to manufacture the nonwoven fabric. The electroconductive woven or knitted fabric can be obtained by the following methods: A method of mixing cut fibers of the electroconductive fiber and the heat fusible fiber, spinning yarn from the mixture, and weaving the fabric by the use of the yarn as at least a part of weft and warp; a method of weaving the fabric from filament yarns of the electroconductive fiber and the heat fusible fiber; a method of weaving the fabric from twisted yarn of the electroconductive fiber and the heat fusible fiber; and a method of knitting such a spun yarn as mentioned above, filament yarn and alternately twisted yarn to prepare the knitted fabric or lace. The thickness of the electroconductive woven or knitted fabric is not particularly limited, and any thickness is acceptable. The content of the electroconductive fiber in the electroconductive woven or knitted fabric is within a range of 1 to 90% by weight, preferably 5 to 60% by weight. When the content of the electroconductive fiber is less than 1% by weight, satisfactory conductivity cannot be obtained, and when it is more than 90% by weight, it is difficult to prepare the woven or knitted fabric. The adhesive for the adhesive layer used in the present invention is not particularly limited, but the preferable adhesive is the heat fusible resin which can be readily melted when heated and which can be dissolved or dispersed in water and/or a solvent in order to form a solution or a dispersion. Examples of the heat fusible resin having such characteristics include polyacrylate resin, polyamide resin, polyolefin resin, ethylene-vinyl acetate copolymer and other various hot-melt type resins. These resins may be used alone or in the form of a mixture with known additives suitable for the hot-melt adhesive. Examples of the additives include an elastomeric gum rubber such as a natural or a synthetic rubber latex, an extender such as inorganic fillers, a thickener, a colorant, an agent for imparting thixotropy, and if necessary, an agent for imparting electroconductivity such as carbon black and metallic particles. The flocks which will be planted on the electroconductive nonwoven fabric are short fiber pieces each having a length of about 0.3 to 30 mm and a thickness of about 1 to 20 denier which are prepared from the fiber mixture of the electroconductive fiber and the non-conductive fiber. Examples of the electroconductive fiber used in the flocks include copper-adsorbed fiber, metal-plated fiber, carbon fiber, carbon composite fiber, metal-deposited fiber and metallic fiber, but the copper-adsorbed fiber is most preferable because it has good flexibility and is colorable. Examples of the non-electroconductive fiber include various synthetic fibers such as polyolefin fiber, polyamide fiber, polyester fiber, polyacrylate fiber, polyacrylonitrile fiber, polyvinyl alcohol fiber, polyvinyl chloride fiber; semisynthetic fiber such as cellulose acetate; regenerated fiber such as rayon; natural fibers such as cotton, hemp and wool; and composite fibers thereof. They may be used alone or in the form of a mixed fiber thereof, but it is preferred to use the fiber prepared from material having a higher melting point than that of a resin which is the base material of a molded article. The amount of the electroconductive fiber used for the flocks is required to be 1% by weight or more for the sake of the generation of conductivity. However, when the amount of the electroconductive fiber is in excess, flexibility of the flocked article deteriorates and costs of the article increase unpreferably. The molded article may be prepared by injecting a resin into a mold containing the fabric or pressing the resin against the fabric therein, and examples of this resin include thermoplastic resins such as polypropylene, polyethylene, vinyl chloride resin, ethylene-vinyl acetate copolymer, polyacrylate resin, styrene resin, ABS, polyamide resin, polyester, polycarbonate, polyimide, polyacetal, ethylene-vinyl alcohol copolymer, cellulose resin and polyurethane; and thermosetting resins such as phenol resin, urea resin, melamine resin, guanamine resin, epoxy resin, diallyl phthalate resin and unsaturated polyester resin. In the present invention, the heat fusible fiber used for the electroconductive nonwoven, woven or knitted fabric and the resin for the molded article are preferably the same or homologous, because in such a case, the heat fusible fiber and the resin for the article can be thermally integrated into each other smoothly during molding. The electroconductive fabric of the present invention may be manufactured, for example, by the following procedure: In the first place, the electroconductive nonwoven, woven or knitted fabric which have been prepared in the above-mentioned manner is coated on either surface thereof with a solution or an aqueous emulsion of a hot-melt type adhesive resin by means of knife coating, spray coating, roll coating or the like in order to form an adhesive resin layer, and flocks are then planted on the fabric by a known planting means such as an electrostatic system, a flocking machine by combined use of electrostatic method and vibration method or the like while the adhesive resin layer is still in the wet state. Afterward, drying is carried out to thereby fix the planted flocks on the fabric, and the obtained electroconductive nonwoven, woven or knitted fabric is then subjected to a brushing process. The means for forming the adhesive layer of the heat fusible resin is not limited, and the adhesive to be used may be the hotmelt type adhesive which exhibits adhesive properties at a temperature below softening points of the fibers for the nonwoven, woven or knitted fabric and the flocks thereon. The electroconductive fabric of the present invention may be manufactured by directly forming the adhesive layer on the electroconductive nonwoven, woven or knitted fabric, planting the flocks thereon, drying the adhesive layer to hold and fix the flocks thereon. Therefore, in the thus manufactured fabric of the present invention, flexibility can be retained, and electroconductivity and thus the ability to discharge static electricity can be acquired. The molded article having the electroconductive fabric on the surface thereof which is concerned with the present invention can be manufactured, for example, by the following procedure: The electroconductive nonwoven, woven or knitted fabric is put in a mold so that the flocks on the fabric sheet may contact with the inner wall of the mold, and a base resin is then injected into the mold. Alternatively, the melted or softened base resin is pressed against the electroconductive nonwoven, woven or knitted fabric in the mold by transfer molding, compression molding (drawing or stamping), vacuum molding or pressure forming so as to obtain the molded article on which the fabric is held and fixed. As described above, the electroconductive fabric of the present invention is manufactured by first mixing the nonwoven, woven or knitted fabric material with the electroconductive fiber to impart conductivity to the fabric and directly planting thereon the flocks containing the electroconductive fiber with the interposition of the adhesive layer. Therefore, the obtained fabrics can retain the conductivity throughout. Further, as described above, the heat fusible fiber is used as the main fiber component of the nonwoven, woven or knitted fabric and the base resin of the molded article is molded in the mold containing the nonwoven, woven or knitted fabric sheet by the injection or another means. Therefore, the heat fusible fiber of the nonwoven, woven or knitted fabric is melted into the base resin of the molded article by heat of the latter, so that strong linkage is achieved therebetween and electroconductivity is additionally maintained on the surface thereof. The fabric of the present invention can prevent dust from adhering thereto, probably because electrical charges of static electricity generated on the flocks surfaces are immediately eliminated through the whole fabric. Further, owing to no accumulation of the electrical charges of the static electricity, people can be protected from shock which results from discharge of the static electricity. The electroconductive fabric of the present invention exhibits a beautiful appearance, has a tender feel like fur, prevents the adhesion of dust which is a conventional problem, and possesses flexibility. Therefore, excellent effects are produced, when the fabric is used for interior decoration, furniture, carpets, footwear and miscellaneous goods in addition to clothes. Moreover, the molded article having the electroconductive fabric on the surface thereof gives an elegant appearance of the raised pile tufts, has a tender feel like fur in cooperation with a soft feel of the lined nonwoven, woven or knitted fabric, prevents the adhesion of dust by the static electricity which is one of the conventional problems, and protects people from the shock which results from the discharge of the static electricity. Further, the heat fusible fiber of the nonwoven, woven and knitted fabric is strongly and securely bound with the base resin of the molded article, and therefore the molded article of the present invention is very useful as a material for interior decoration of automobiles and the like. EXAMPLES Now, the present invention will be described in detail in reference to examples and comparative examples, but it should not be limited to these examples. EXAMPLE 1 An electroconductive nonwoven fabric having a unit weight of 100 g/m 2 was prepared from a fiber mixture of 10% by weight of copper-adsorbed polyacrylonitrile fiber having a thickness of 3 denier and a length of 5 cm and 90% by weight of polypropylene fiber having a thickness of 3 denier and a length of 5 cm, and the thus prepared fabric was then coated with an aqueous emulsion comprising heat fusible polyacrylate resin and a thickener and having a solid content of 45% by weight, in a ratio of 100 g/m 2 in terms of wet weight. On the other hand, flocks were prepared from a fiber mixture of 80% by weight of rayon short fiber having a thickness of 2 denier and a length of 0.5 mm and 20% by weight of copper-adsorbed polyacrylonitrile fiber having a thickness of 1.5 denier and a length of 0.5 mm, and these flocks were then planted on the above nonwoven fabric by means of a flocking machine by combined use of electrostatic method and vibration method. After drying at a temperature of about 80° C., brushing was carried out to obtain a flocked electroconductive fabric sheet. The raised flocks on the fabric sheet had a surface resistance of 10 6 Ω□, which meant that it was excellent in electroconductivity, and the planted flocks mainly comprising the rayon fiber exhibited a beautiful appearance. The adhesion of dust onto the surface of the fabric sheet was not observed at all. EXAMPLE 2 An electroconductive nonwoven fabric having a unit weight of 50 g/m 2 was prepared from a fiber mixture of 5% by weight of nickel-plated fiber which was a kind of electroconductive fiber, 65% by weight of nylon fiber and 30% by weight of polyacrylonitrile fiber, and the thus prepared fabric was then coated with the same aqueous emulsion of the polyacrylate resin as in Example 1. On the other hand, flocks were prepared from a fiber mixture of 95% by weight of nylon fiber having a thickness of 3 denier and a length of 2 mm and 5% by weight of copper-adsorbed polyacrylonitrile fiber having a thickness of 1.5 denier and a length of 2 mm, and these flocks were then planted on the above fabric by means of a flocking machine by combined use of electrostatic method and vibration method. The emulsion was dried at a temperature of about 80° C. to fix the flocks on the fabric, and brushing was carried out, thereby obtaining a flocked electroconductive fabric sheet. The standing flocks on the fabric sheet had a surface resistance of 10 8 Ω□. The adhesion of dust onto the surface of the fabric sheet was not observed. EXAMPLE 3 A thin knitted fabric was prepared by knitting a spun yarn made from a fiber mixture comprising 10% by weight of cut copper-adsorbed polyacrylonitrile fiber and 90% by weight of cut polypropylene fiber. This knitted fabric was coated on either surface thereof with an aqueous emulsion comprising heat fusible polyacrylate resin and a thickener and having a solid content of 45% by weight, in a ratio of 100 g/m 2 in terms of wet weight. On the other hand, flocks were prepared from a fiber mixture of 80% by weight of rayon short fiber (2 denier, length 0.5 mm) and 20% by weight of copper-adsorbed polyacrylonitrile fiber (thickness 1.5 denier, length 0.5 mm), and these flocks were then planted on the above knitted fabric by means of a flocking machine by combined use of electrostatic method and vibration method. After drying at a temperature of about 80° C., brushing was carried out to obtain a flocked electroconductive fabric sheet. The raised flocks on the fabric sheet had a surface resistance of 10 6 Ω□, which meant that it was excellent in electroconductivity, and the planted flocks mainly comprising the rayon fiber exhibited a beautiful appearance. EXAMPLE 4 Nylon filament yarn was used as the warp, and two kinds of nylon filament yarn and copper-adsorbed fiber filament yarn were used in a ratio of 3:1 (by weight) as the weft in order to weave a thin woven fabric. Then, the woven fabric was coated on either surface thereof with a polyacrylate adhesive. On the other hand, flocks were prepared from a fiber mixture of 95% of polyacrylonitrile fiber (1.5 denier, length 2 mm) and 5% by weight of copper-adsorbed polyacrylonitrile fiber (1.5 denier, length 2 mm), and these flocks were then planted on the above woven fabric by means of a flocking machine by combined use of electrostatic method and vibration method. After drying at a temperature of about 80° C., brushing was carried out to obtain a flocked electroconductive fabric sheet. The raised flocks on the fabric sheet had a surface resistance of 10 8 Ω□. EXAMPLE 5 An electroconductive nonwoven fabric having a unit weight of 100 g/m 2 was prepared from a fiber mixture of 10% by weight of copper-adsorbed polyacrylonitrile fiber having a thickness of 3 denier and a length of 5 cm and 90% by weight of polypropylene fiber having a thickness of 3 denier and a length of 5 cm, and the thus prepared nonwoven fabric base was then coated with an aqueous emulsion comprising heat fusible polyacrylate resin and a thickener and having a solid content of 45% by weight in a ratio of 100 g/m 2 in terms of wet weight. On the other hand, flocks were prepared from a fiber mixture of 80% by weight of polyester fiber (2 denier, length 0.5 mm) and 20% by weight of copper-adsorbed polyacrylonitrile fiber (1.5 denier, length 0.5 mm), and these flocks were planted on the above nonwoven fabric by means of a flocking machine by combined use of electrostatic method and vibration method. After drying it at a temperature of about 80° C., brushing was carried out to obtain a flocked electroconductive fabric sheet. The flocked fabric sheet was put and fixed in a mold (upper portion) of a compression molding machine, with the raised flock surface of the fabric sheet upward positioned, and polypropylene resin which had been melted at 200° C. was extruded into the mold (lower portion). Compression molding was then performed under conditions that mold clamping pressure was 10 kg/cm 2 G, mold temperature was 30° C. and cooling time was 40 seconds, in order to prepare a moled article. During the above compression molding, the propylene fiber in the electroconductive nonwoven fabric sheet was melted by heat from the polypropylene resin which was the base material of the molded article, so that the fiber and the resin were integrated with each other. On the surface of the molded article, the planted flocks mainly comprising the polyester fiber exhibited a beautiful appearance. The raised flocks on the molded article had a surface resistance of 10 6 Ω□, which meant that it was excellent in electroconductivity, and the adhesion of dust by static electricity was not observed. Further, when measured by a rotary static tester (made by Shishido Electrostatic, Ltd.), triboelectrification voltage was as low as 100 volts or less. EXAMPLE 6 An electroconductive nonwoven fabric having a unit weight of 120 g/m 2 was prepared from a fiber mixture of 5% by weight of nickel-plated polyacrylonitrile fiber having a thickness of 3 denier and a length of 5 cm and 95% by weight of heat fusible type composite fiber comprising crystalline polypropylene and polyethylene and having a thickness of 3 denier and a length of 5 cm, and the thus prepared nonwoven fabric was then coated with a polyacrylate adhesive. On the other hand, flocks were prepared from a fiber mixture of 93% by weight of nylon fiber (1.5 denier, length 2 mm) and 7% by weight of copper-adsorbed polyacrylonitrile fiber (1.5 denier, length 2 mm), and these flocks were then planted on the above nonwoven fabric base by means of a flocking machine by combined use of electrostatic method and vibration method. After drying at a temperature of about 80° C. , brushing was carried out to obtain a flocked electroconductive fabric sheet. Then, the thus obtained flocked fabric sheet was put in a mold of an injection molding machine so that the flocks on the fabric sheet might contact with the inner wall of the mold, and propylene-ethylene block copolymer containing 8.5% by weight of ethylene and having a melt flow rate of 18 g/10 minutes was injected into the mold under conditions of a resin temperature of 200° C., an injection pressure (primary pressure) of 140 kg/cm 2 G, an injection speed of 30 mm/second, an injection time of 20 seconds, a mold cooling temperature 50° C. and a cooling time 25 seconds. As a result, a molded article having a size of 200 mm×200 mm and a depth of 50 mm was obtained. The outer surface of the molded article was covered with the beautiful flocks mainly comprising the nylon fiber and exhibited a tender feel. The raised flocks on the fabric sheet had a surface resistance of 10 8 Ω□, which meant that it was excellent in electroconductivity, and the adhesion of dust onto the flocks by static electricity was not observed. EXAMPLE 7 A nonwoven fabric as used in Example 5 was coated on either surface thereof with a polyacrylate adhesive. On the other hand, flocks were prepared from a fiber mixture of 70% by weight of polyester fiber (2 denier, length 3 mm) and 30% by weight of copper-adsorbed nylon fiber (2 denier, length 3 mm), and these flocks were then planted on the above nonwoven fabric by means of a flocking machine by combined use of electrostatic method and vibration method. After drying it at a temperature of about 80° C., brushing was carried out to obtain a flocked electroconductive fabric sheet. Afterward, the thus prepared flocked fabric sheet was put in a mold of a pressure forming machine so that the flocks on the fabric sheet might contact with the inner wall of the mold, and a polypropylene sheet which had been preheated at 170° C. and softened thereby was put on the fabric sheet in the mold, followed by pressure forming at a pressure of 3 kg/cm 2 G. The outer surface of the resulting rectangular container was covered with the beautiful planted flocks mainly comprising the polyester fiber and exhibited a tender feel. The raised flocks on the fabric sheet had a surface resistance of 10 5 Ω□ and therefore was excellent in electroconductivity. EXAMPLE 8 A thin knitted fabric was prepared by knitting a spun yarn made of a fiber mixture comprising 10% by weight of cut copper-adsorbed polyacrylonitrile fiber and 90% by weight of cut polypropylene fiber. This knitted fabric was then coated on either surface thereof with an aqueous emulsion comprising heat fusible polyacrylate resin and a thickener and having a solid content of 45% by weight, in a ratio of 80 g/m 2 in terms of wet weight. On the other hand, flocks were prepared from a fiber mixture of 80% by weight of polyester fiber (2 denier, length 0.5 mm) and 20% by weight of copper-adsorbed polyacrylonitrile fiber (1.5 denier, length 0.5 mm), and these flocks were then planted on the above knitted fabric base by means of a flocking machine by combined use of electrostatic method and vibration method. After drying it at a temperature of about 80° C., brushing was carried out to obtain a flocked electroconductive fabric sheet. The flocked fabric sheet was put and fixed in a mold (upper portion) of a compression molding machine so that the raised flocks on the fabric sheet might contact with the inner wall of the mold, and polypropylene resin which had been melted at 200° C. was extruded into the mold (lower portion). Compression molding was then performed under conditions that mold clamping pressure was 10 kg/cm 2 G, mold temperature was 30° C. and cooling time was 40 seconds, in order to obtain a molded article. During the above compression molding, the polypropylene fiber in the electroconductive nonwoven fabric sheet was melted by heat from the polypropylene resin of the molded article, so that the fiber and the resin were integrated with each other. On the surface of the molded article, the planted flocks mainly comprising the polyester fiber exhibited a beautiful appearance. Surface resistance of the molded article was 10 6 Ω□, which value was indicative of being excellent in electroconductivity, and the adhesion of dust onto the fabric sheet was not observed. Further, when measured by a rotary static tester (made by Shishido Electrostatic, Ltd.), triboelectrification voltage was as low as 100 volts or less. EXAMPLE 9 For both warp and weft, two kinds of heat fusible type composite fiber filament yarn comprising crystalline polypropylene and polyethylene and copper-adsorbed polyacrylonitrile fiber filament yarn were used in a ratio of 9:1 (by weight) in order to prepare a thick woven fabric base. Then, the thus prepared woven fabric was coated on either surface thereof with a polyacrylate adhesive. On the other hand, flocks were prepared from a fiber mixture of 93% by weight of nylon fiber (1.5 denier, length 2 mm) and 7% by weight of copper-adsorbed polyacrylonitrile fiber (1.5 denier, length 2 mm), and these flocks were then planted on the above woven fabric by means of a flocking machine by combined use of electrostatic method and vibration method. After drying it at temperature of about 80° C., brushing was carried out to obtain a flocked electroconductive fabric sheet. Then, the thus obtained fabric sheet was put in a mold of an injection molding machine so that the flocks on the fabric sheet might contact with the inner wall of the mold, and propylene-ethylene block copolymer containing 8.5% by weight of ethylene and having a melt flow rate of 18 g/10 minutes was injected into the mold under conditions of a resin temperature of 200° C., an injection pressure (primary pressure) of 140 kg/cm 2 G, an injection speed of 30 mm/second, an injection time of 20 seconds, a mold cooling temperature 50° C. and a cooling time 25 seconds. As a result, a molded article having a size of 200 mm×200 mm and a depth of 50 mm was obtained. The outer surface of the molded article was covered with the beautiful planted flocks mainly comprising the nylon fiber and exhibited a tender feel. The raised flocks on the fabric sheet had a surface resistance of 10 8 Ω□, which was indicative that it was excellent in electroconductivity, and the adhesion of dust onto the flocks was not observed. EXAMPLE 10 A knitted fabric as used in Example 8 was coated on either surface thereof with a polyacrylate adhesive. On the other hand, flocks were prepared from a fiber mixture of 70% by weight of polyester fiber (2 denier, length 3 mm) and 30% by weight of copper-adsorbed nylon fiber (2 denier, length 3 mm), and these flocks were then planted on the above knitted fabric by means of a flocking machine by combined use of electrostatic method and vibration method. After drying it at temperature of about 80° C., brushing was carried out to obtain a flocked electroconductive fabric sheet. Afterward, the thus obtained fabric sheet was put in a mold of a pressure forming machine so that the flocks on the fabric sheet might contact with the inner wall of the mold, and a polypropylene sheet which had been preheated at 170° C. and softened was put on the woven fabric sheet in the mold, followed by pressure forming at a pressure of 3 kg/cm 2 G. The outer surface of the resulting rectangular container was covered with the beautiful planted flocks mainly comprising the polyester fiber and exhibited a tender feel. The raised flocks on the fabric sheet had a surface resistance of 10 5 Ω□, which value was indicative that it was excellent in electroconductivity. COMPARATIVE EXAMPLE 1 An electroconductive nonwoven fabric as used in Example 2 was coated with the same aqueous emulsion of the polyacrylate resin as in Example 2. On the other hand, flocks were prepared from a fiber mixture of 99.5% by weight of nylon fiber having a thickness of 3 denier and a length of 2 mm and 0.5% by weight of copper-adsorbed polyacrylonitrile fiber having a thickness of 3 denier and a length of 2 mm, and the thus prepared flocks were then planted on the above nonwoven fabric by means of a flocking machine by combined use of electrostatic method and vibration method. After drying it at a temperature of about 80° C. to fix the flocks thereon, brushing was carried out to prepare a flocked electroconductive fabric sheet. The raised flocks on the fabric sheet had a surface resistance of 10 12 Ω□ or more and therefore was considered to have no electroconductivity, probably because the content of the conductive fiber in the flocks was as small as less than 1% by weight. Therefore, it was observed that some dust adhered to the flocks. COMPARATIVE EXAMPLE 2 A woven fabric as used in Example 4 was coated with the same polyacrylate adhesive as in Example 4. On the other hand, flocks were prepared from a fiber mixture of 99.5% by weight of acrylic fiber (1.5 denier, length 2 mm) and 0.5% by weight of copper-adsorbed polyacrylonitrile fiber (1.5 denier, length 2 mm), and the thus prepared flocks were then planted on the above woven fabric by means of a flocking machine by combined use of electrostatic method and vibration method. After drying it at a temperature of about 80° C., brushing was carried out to prepare a flocked electroconductive fabric sheet. The raised flocks on the fabric sheet had a surface resistance of 10 12 Ω□ or more and therefore was considered to have no electroconductivity. Therefore, it was observed that some dust adhered to the flocks. COMPARATIVE EXAMPLE 3 The same procedure as in Example 5 was repeated with the exception that the fiber mixture was replaced with another fiber mixture of 99.5% by weight of polyester fiber (2 denier, length 0.5 mm) and 0.5% by weight of copper-adsorbed polyacrylonitrile fiber (1.5 denier, length 0.5 mm), in order to obtain a molded article. Although the thus obtained article had a beautiful appearance, surface resistance of the raised flocks thereon was 10 12 Ω□ or more, which was considered to have no electroconductivity. Hence, it was observed that some dust adhered to the flocks. Further, when measured in the same manner as in Example 5, triboelectrification voltage was as high as 7,000 volts. COMPARATIVE EXAMPLE4 The same procedure as in Example 8 was repeated with the exception that the fiber mixture was replaced with another fiber mixture of 99.5% by weight of polyester fiber (2 denier, length 0.5 mm) and 0.5% by weight of copper-adsorbed polyacrylonitrile fiber (1.5 denier, length 0.5 mm), in order to obtain a molded article. Although the thus obtained article had a beautiful appearance, surface resistance of the raised flocks was 10 12 Ω□ or more, which was considered to have no electroconductivity. Hence, it was observed that some dust adhered to the flocks. Further, when measured in the same manner as in Example 8, triboelectrification voltage was as high as 7,000 volts.
There is here provided a flocked product having a warm and soft appearance and a thick and tender feel which is obtained by flocking the surface of a nonwoven, woven or knitted fabric. That is, the present invention intends to provide a flocked electroconductive fabric sheet which is obtained by forming an adhesive layer on either surface of one electroconductive fabric selected from the group consisting of electroconductive nonwoven, woven and knitted fabric each composed mainly of heat fusible fiber and electroconductive fiber, and planting and fixing, on the surface having the adhesive layer, flocks of short fiber containing 1% by weight or more of the electroconductive fiber; and a molded article having the above flocked electroconductive fabric sheet on the surface thereof which is obtained by putting the flocked electroconductive fabric sheet in a mold so that the flocks on the fabric sheet may contact with the inner wall of the mold, and injecting melted resin into the mold, or pressing the melted or softened resin against the fabric sheet in the mold. Since electroconductivity is imparted to the fabric, any dust does not adhere to the flocks on the fabric sheet by static electricity, and therefore people can be protected from shock by discharge of the static electricity. In addition, the fabric sheet can be fixedly and securely bound with the molded article. In consequence, the flocked electroconductive fabric sheet and the molded article having the fabric sheet on the surface thereof can be suitably used as interior decorations in automobiles, furniture, carpets cloths, footwear and miscellaneous goods.
8
FIELD OF THE INVENTION The present invention relates to silencers. More specifically, the present invention is concerned with wide absorption spectrum compact silencers. BACKGROUND OF THE INVENTION A silencer may be described as any section of a duct or pipe adapted to reduce the transmission of sound while allowing the free flow of a gas. Silencers can be broken into two fundamental groups: absorptive silencers and reactive silencers. Absorptive silencers include either fibrous or porous materials and depend on the absorptive properties of these materials to reduce noise. Absorptive silencers are most useful for noise control problems associated with high frequency spectra and their low frequency absorption increases with an increasing thickness of the absorbing material and with an increasing length of the silencer. Reactive silencers contain no absorbing material but depend on the reflection or expansion of sound waves within a chamber to attenuate the sound. Peak attenuation occurs in the lower-frequency ranges, typically below 500 Kz. To provide a wide spectrum of attenuation, several chambers may be assembled in series. Some silencers combine reactive and absorptive elements. However, these silencers typically are large and heavy and have some undesirable properties, such as a large resistance to motion or air within the silencer. Accordingly, difficulties in specifying a silencer for use in a particular situation are generally found when dealing with problems such as size, weight and aerodynamic pressure losses, among others, and not in providing a silencer with adequate acoustical performance. Against this background, there exists a need in the industry to provide a novel and compact silencer. OBJECTS OF THE INVENTION An object of the present invention is therefore to provide an improved compact silencer that is capable of attenuating sound waves in a wide spectrum of frequencies. It is another object of the invention to provide a silencer that through its structural arrangement of parts and dimensions relationship provides efficient attenuation of sound waves while being inexpensive to manufacture and versatile for mounting with any arrangement of fluid circulation. SUMMARY OF THE INVENTION The invention generally relates to a silencer for attenuating sound waves produced in a fluid that circulates through a conveying means. The silencer according to the invention comprises an expansion chamber and means allowing the expansion chamber to be in fluid communication with the conveying means, and to carry the sound waves through the chamber. A sound wave dissipater is provided with the expansion chamber and is arranged to absorb sound waves traveling through the expansion chamber. A resonator is operatively associated with the sound wave dissipater and is constructed and arranged to cause attenuation, and reflection of the sound waves back and forth towards the sound wave dissipater. The expansion chamber has a chamber : conveying means cross-sectional area ratio and chamber length characteristics allowing maximum transmission loss for a given frequency. Finally, means are provided to allow fluid containing attenuated sound waves to exit from the expansion chamber. Advantageously, the silencer should be compact and light. Also, it should preferably attenuate sound waves having a wide spectrum of frequencies and provide only minimal resistance to a flow of gas there through. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be illustrated by means of the annexed drawings which are given by way of limitation and without limitation. In the drawings: FIG. 1 is a perspective view of a silencer according to the invention including a dissipater and a resonator; FIG. 2 is a side cross-sectional view of the dissipater and resonator of FIG. 1 ; FIG. 3 is a perspective view of the resonator of FIG. 2 ; and FIG. 4 is a front view of the resonator of FIG. 2 . DESCRIPTION OF PREFERRED EMBODIMENTS FIG. 1 shows a silencer 10 for attenuating sound waves. The silencer 10 includes an inlet 12 , an outlet 14 , an expansion chamber 16 , a dissipater 18 and a resonator 20 . The expansion chamber 16 is in fluid communication relationship with outlet 14 . Dissipater 18 is provided within the expansion chamber 16 as shown. Resonator 20 is in a fluid communication relationship with inlet 12 and expansion chamber 16 . Resonator 20 is further disposed within expansion chamber 16 and includes three baffles 30 (shown in FIG. 2 ) configured and sized to direct sound waves propagating within the resonator 20 towards dissipater 18 . Silencer 10 provides attenuation of sound waves at frequencies covering a wide spectrum, in a compact and light format. The expansion chamber 16 and the resonator 20 provide attenuation mainly at high frequencies, although they are intended to also attenuate some low frequencies. The silencer 10 shown in FIG. 1 is one that is normally adapted for a Heating, Ventilation and Air Conditioning (HVAC) system. However, the reader skilled in the art will readily appreciate that silencers similar to silencer 10 could be used in many other applications such as, for example, attenuating sound waves in gas turbines, generators, vacuum cleaners and compressors, among others. In fact, silencer 10 can provide sound wave attenuation in any system wherein a fluid passes through a duct or a pipe. The silencer 10 according to the invention is adapted for use in a ventilation system (not shown in the drawings) that is part, for example, of a HVAC system. To that effect, inlet 12 and outlet 14 can be of a diameter that is standard in the HVAC industry. Inlet 12 and outlet 14 can be soldered, or fixed through any other means, to the ventilation system. In a specific example of implementation, the silencer 10 attenuates sound waves in an air duct directing air towards one or more rooms in a building. However, it goes without saying that a silencer according to the invention may be used in conjunction with any fluid circulation system where noise is a problem. Expansion chamber 16 includes a peripheral wall 22 and first and second end walls 24 and 26 . Inlet 12 is provided in the first end wall 24 while outlet 14 is provided in the second end wall 26 . While the expansion chamber 16 shown in FIG. 1 is substantially cylindrical, it could take any other suitable shape. For example, if a HVAC system includes pipes having a square cross-section, a silencer having a substantially square cross-section could be used advantageously. As shown in FIG. 2 , resonator 20 includes a substantially cylindrical perforated inner wall 28 and a plurality of baffles 30 , here three, that are provided within the resonator 20 . Furthennore, the resonator 20 is surrounded at least in part by dissipater 18 , which will be described in further detail herein below. Perforated wall 28 is optionally of a diameter that is substantially equal to the diameter of inlet 12 . Also, perforated wall 28 is in the continuity of inlet 12 . The perforations 29 within wall 28 are sized to provide attenuation of sound waves within the resonator 20 , as will be described herein below, while allowing high frequency sound waves to escape at least in part from resonator 20 towards dissipater 18 . It was found that a perforated wall 28 having perforations 29 covering at least 33% of the area of the perforated wall 28 provides advantageous sound absorption characteristics to the silencer 10 . However, any other suitable type of perforations is within the scope of the invention. In a specific example of implementation, the perforated wall 28 is of a length that is equal to the length required to provide maximal destructive interferences of sound waves present within resonator 20 and expansion chamber 16 . This length is preferably equal to a fourth of a wave length of a sound wave to be attenuated. Accordingly, silencer 10 , through expansion chamber 16 and resonator 20 , operates optimally at a single frequency and at its harmonics. However, although silencer 10 provides an optimal attenuation of sound waves for only a few selected frequencies, other frequencies are also attenuated. This additional attenuation is, in part, caused by perforations 29 within perforated wall 28 and by partially destructive interferences of sound waves propagating substantially longitudinally within silencer 10 . The dimensions of expansion chamber 16 and of resonator 20 can be determined according to the intended use of the silencer using methods that are well known in the art. Baffles 30 are fixed in known manner to perforated wall 28 and are preferably angled at an acute angle with respect to the perforated wall 28 as shown in FIG. 2 . The baffles 30 are configured and sized to reflect sound waves that are propagated within the resonator 20 , towards the dissipater 18 . Resonator 20 , shown in FIG. 2 , includes three baffles 30 . However, any number of baffles could be used in conjunction with the invention, as will be appreciated by one skilled in the art. In the illustrated embodiment, each baffle 30 includes a sector of a substantially frustoconical shell. However, other shapes of baffles are within the scope of the invention. As shown in FIGS. 3 and 4 , the baffles 30 are placed, configured and sized such that when the resonator 20 is seen along a longitudinal axis, the baffles completely block to view an annular region within the resonator 20 . Accordingly, the baffles 30 appear as a cone when seen from this point of view. Optionally, and as better shown in FIG. 3 , baffles 30 adopt a substantially helicoidal configuration when mounted in the resonator. In addition, but non-essentially, the baffles 30 are oriented such that a narrow portion of each baffle 30 is further away from the inlet 12 than a wide portion of each baffle 30 . An efficient way to manufacture baffles 30 includes providing a frustum of a cone in a suitable material and cutting the frustum in a plurality of sectors, thereby forming the baffles 30 . Each baffle 30 includes a steel plate that may include optional perforations (not shown). However, it is within the scope of the invention to have baffles made of a different material, such as aluminum, among others. Also, each baffle 30 can optionally be covered in part or totally with a sound absorbing material of a type described in more details herein below with reference to dissipater 18 . The sound absorbing material can in turn be surrounded by a perforated metal part. Dissipater 18 includes an absorptive material 19 contained within an enclosure 23 . Enclosure 23 is defined by the perforated wall 28 , a surrounding wall 32 spacedly surrounding the perforated wall 28 , an annular wall 34 and part of the first end wall 24 . The surrounding wall 32 and the annular wall 34 can be perforated so as to allow sound waves to escape from the dissipater 18 into expansion chamber 16 . In the embodiment shown in FIG. 1 , a gap 17 is provided between the surrounding wall 32 and peripheral wall 22 . The absorptive material 19 can include felt, rock wool, fiberglass or any other suitable sound absorptive material. In a specific example of implementation, the absorptive material 19 has a density that can vary between two and four pounds per cubic foot. The absorbing material is separated from the peripheral wall 22 by gap 17 . As a result, sound waves exiting the absorptive material 19 can be reflected back into the absorptive material 19 through peripheral wall 22 after traveling in the air contained within the silencer 10 . Accordingly, both the passage of sound waves within the air and multiple journeys through the absorptive material 19 add to an attenuation of high frequencies within the silencer 10 without requiring a large quantity of absorptive material 19 , which lowers manufacturing cost and weight. For example, a gap 17 having a width of substantially 4 inches greatly improves the performance of the absorptive material 19 in the resonator. However, any other suitable width for the gap can be used, as will be appreciated by one skilled in the art. Optionally, a facing (not shown in the drawings) made of nylon, Mylar™, Tedlar™ or felt, for example, may be applied around the absorptive material 19 to provide protection against physical and/or chemical agents. Such facing can also improve the low-frequency absorption characteristics of the dissipater while reducing the possibilities that fragments of the absorptive material 19 become dislodged and are thereafter mixed with the air that circulates within silencer 10 . This characteristic is advantageous in industries wherein dust contamination is undesirable. In the illustrated embodiment, expansion chamber 16 , resonator 20 and dissipater 18 include steel parts. However, the readers skilled in the art will readily appreciate that any other suitable material could be used in manufacturing expansion chamber 16 , resonator 20 and dissipater 18 . In use, an air stream enters silencer 10 through inlet 12 . The air stream in turn strikes baffles 30 . The angle at which the air stream strikes the baffles and the geometry of the baffles create a pressure differential between air upstream of resonator 20 and air downstream of resonator 20 . The disposition of the baffles 30 , which tends to push air circulating within the resonator 20 around the baffles 30 , along with the Bernoulli effect caused by the narrowing of the baffles 30 in a direction substantially identical to the general direction of the air flow within the resonator 20 help to limit the pressure differential. The air flow then exits from the resonator 20 within the expansion chamber 16 . Since the expansion chamber 16 is filled with air, air is continuously expelled from silencer 10 through outlet 14 . With respect to the acoustical properties of silencer 10 , it will be realized that the sound waves incoming at inlet 12 broadly have two different routes to travel through silencer 10 depending on their wavelength. Low frequency sound waves create standing waves within the resonator 20 and the expansion chamber 16 . Since the expansion chamber 16 and the resonator 20 are preferably sized to provide attenuation at low frequencies, the standing waves created destructively interfere and cause attenuation in sound wave intensity at these low frequencies. Low frequency sound waves are also attenuated within the resonator 20 through a transmission loss caused by the frustoconical geometry of the baffles, which provide attenuation similarly to a single-piece frustum of a cone located within a cylindrical tube. The high frequency sound waves are reflected by the baffles 30 toward dissipater 18 . Accordingly, these high frequency sound waves are absorbed by the dissipative material contained within the dissipater 18 . In addition, gap 17 between peripheral wall 22 and surrounding wall 32 , along with the expansion of sound waves within the expansion chamber 16 , further contribute to the attenuation of low and high frequencies within the silencer 10 . It has been found advantageous to provide baffles 30 having a high acoustic impedance at some of the frequencies to be attenuated by the silencer 10 . Thus, a sound wave amplitude of sound waves reflected by the baffles 30 is relatively large and only a minimal portion of high frequency sound waves reaches outlet 14 . In this case, because of the frustoconical geometry of baffles 30 , the sound waves are reflected in many directions within the silencer 10 , which creates many different apparent gap thicknesses in the reflected sound waves. As a result, low frequencies are also absorbed more efficiently than in prior art silencers. It has also been found that sound wave attenuation by the silencer 10 is not a linear function of the length of the resonator 16 as absorption is very large with only a few baffles in the resonator 16 . Accordingly, silencer 10 can be very compact while having good sound attenuation characteristics. However, it was realized that it is essential to provide the expansion chamber with critical dimension characteristics. For example, the ratio between the cross-sectional area of the expansion chamber and the cross-sectional area of the conveying means such as that at the inlet, and the length of the chamber should be such that these parameters allow a maximum transmission loss for a given frequency. More specifically, transmission loss is achieved when TL is at a maximum value. For this purpose, TL is represented by the following formula: TL= 10 log[1+¼(m−1/m) 2 sin 2 kl]db wherein TL represents transmission loss; M=cross-sectional area of chamber/cross-sectional area of fluid conveying means; k=wave number=2π/λ; l=chamber length; λ=wave length of sound at temperature of gas in the expansion chamber. In an alternative embodiment of silencer 10 , the resonator 20 and the dissipater 18 are located outside of and in series with the expansion chamber 16 . Although the present invention has been described hereinabove by way of preferred embodiments thereof, it is obvious that it can be modified, without departing from the spirit and scope of the invention as defined in the appended claims.
There is disclosed a silencer for attenuating sound waves produced in a fluid that circulates through a fluid conveyer. The silencer comprises an expansion chamber that is in fluid communication with the fluid conveyer, and which carries sound waves there through; a sound wave dissipater provided with the expansion chamber and arranged to absorb sound waves traveling there through; a resonator operatively associated with the sound wave dissipater and constructed and arranged to cause attenuation and reflection of the sound waves back and forth towards the sound wave dissipater; the expansion chamber having a chamber: conveyer cross-sectional area ratio and chamber length characteristics allowing maximum transmission loss for a given frequency. The expansion chamber has an exit to allow fluid containing attenuated sound waves to escape therefrom.
5
This application claims benefit of co-pending Provisional patent application Ser. No. 60/194,353 filed on Apr. 3, 2000, and of co-pending Provisional patent application Ser. No. 60/235,013 filed on Sep. 25, 2000; the disclosures of both of which are incorporated herein by reference. FIELD OF THE INVENTION The present invention is directed to the field of fiber and textile dyeing. More specifically, this invention relates to dye fixatives and their use in providing substantially permanent retention of dye color in textiles. BACKGROUND OF THE INVENTION Poor washfastness, that is, the leaching and bleeding of dye stuffs from fabrics, along with poor crockfastness, or the removal of dye from fabric when it is abraded, are two significant problems that to one degree or another must be overcome for any dyed good to be used commercially. Some loss of dye will take place from dyed textiles during washing and/or abrasion with all categories of dyes, including sulfur dyes, direct dyes, and vat dyes, e.g., indigo. A number of coatings or reagents have been developed to improve the fastness properties of dyed textiles. For example, for direct dyes copper aftertreatments and diazotization/coupling have been used to improve fastness. However, the copper (II) ion that is employed in copper aftertreatments is not environmentally friendly, and diazotization requires chemical reactions to be performed on the absorbed dyes in the fibers. For vat dyes, fastness may be improved by soaping (that is, a treatment with a hot aqueous solution of a surfactant), which causes the dye molecules to rearrange and crystallize. Soaping may, however, substantially change the shade of the dyed good and the process can be time-consuming. SUMMARY OF THE INVENTION This invention is directed to treatments for dyed textile goods that will improve their fastness properties. More particularly, the invention is directed to certain fixatives that, when placed on the dyed textile, allow the dye to be permanently or substantially permanently affixed to the fabric. The dye-reactive fixative comprises a water-soluble or water-dispersible polymer or oligomer having reactive groups that react with a dye on a dyed web to affix the dye to the web. The dye-reactive fixative, in one embodiment, comprises a polyethylene glycol (PEG) polymer or oligomer that is terminally capped with glycidyl groups or with oxirane rings in other forms, such as epoxycyclohexyl groups. In another embodiment, the dye fixative comprises a mixture of functionalized or unfunctionalized PEG and poly(butadiene), preferably maleinized polybutadiene. In a further embodiment, the dye-reactive fixative comprises a silicone that is terminally capped with epoxide groups or with groups that form anhydrides. The invention is further directed to the process for treating dyed textiles and other webs with a dye-reactive fixative preparation, wherein the fixative compound or mixture is applied to the fiber, yarn, textile, or other web. In a presently preferred embodiment, the dyed web is placed into the fixative preparation (dipped), then padded and dried in a single continuous process. This invention is further directed to the dyed fibers, yarns, fabrics, textiles, finished goods, or nonwovens (encompassed herein under the terms “textiles” and “webs”) treated with the dye-reactive fixative preparation. Such textiles and webs exhibit a greatly improved colorfastness and resistance to fading, even after multiple launderings. DETAILED DESCRIPTION OF THE INVENTION The dye-reactive fixative preparation of the invention comprises, in one embodiment, a glycidyl- or other oxirane-containing polyethylene glycol (PEG) polymer or oligomer. Without being bound by theory, it is believed that the PEG fixative preparation covalently binds to the dye. These dye-reactive PEG preparations provide improved colorfastness and retention of the dye on the textile or web fiber structure. In one presently preferred embodiment, the dye-reactive PEG fixative comprises a coating or finish composed of a polyethylene glycol (PEG) polymer or oligomer that is terminally capped with glycidyl groups. Other PEG derivatives that contain 1, 3, or more glycidyl groups are also possible, as are PEG oligomers and polymers that contain oxirane rings in other forms, such as epoxycyclohexyl groups. The PEG oligomers and polymers may contain from one ethylene glycol unit up to many thousands. Copolymers of ethylene glycol and propylene glycol that contain one or more oxirane moieties may also be employed. This invention is not limited to oxirane groups as reactive groups on PEG, or copolymers thereof. Reactive groups derived from cyanuric chloride or based on vinyl sulfones or anhydrides may also be used, as well as silicones with epoxide groups or with groups that form anhydrides. Additionally, N-methylol compounds including dimethylol dihydroxyethylene urea (DMDHEU), dimethylol urea (DMU), dimethylol ethylene urea (DMEU), formaldehyde, and the like can be used. Without being bound by theory, it is believed that glycidyl groups on PEG react with sulfhydryl groups (—SH) (reactions 1a and 1b, below) in sulfur dyes, or with amines (reactions 2a and 2b, below) in other dyes, e.g., direct, vat, sulfur, acid, and disperse dyes. The PEG preparation will crosslink the dye molecules together. Sulfhydryl groups should be present on sulfur-dyed goods because of incomplete coupling to produce disulfides during dye application. The amine group, which is usually attached to an aromatic ring structure but may be aliphatic, is widely found in dye structures. Any crosslinking between dye molecules should increase the substantivity of the dyes in the textile, and a greater degree of crosslinking is to be expected if more than one nucleophilic group is present on the dye. Reactions with hydroxyl, carboxyl, or other nucleophilic groups on dyes may occur. It should also be possible for some oxirane groups to react with nucleophiles that are part of the fiber, such as hydroxyls, amines, carboxyls, sulfhydryls, etc. If such reactions do occur, they would also be expected to increase the substantivity of the dyes. PEG and the reactive groups taught herein have a number of advantages. PEG is readily available, inexpensive, water-soluble or water-dispersible, and of low toxicity. It also has a low T g , which may help soften the hand of textiles to which it is applied. PEG that is endcapped with glycidyl groups is commercially available in a variety of molecular weights (from, for example, Aldrich) and is reasonably priced. PEG can also be derivatized with cyanuric chloride; the resultant compound can react with dyes and reactive textiles (e.g. cellulosics). Another approach to improving colorfastness is to add polymeric “nets” to the dyed textile. These nets may react with the textiles and provide physical barriers preventing dye loss during washing. The nets may also chemically react with the dye, thus affixing the dyes to the fabric through chemical bonds. A preferred embodiment of this approach uses a combination of hyperbranched polyethylenimine (PEI) and solubilized chlorotriazines to form textile- and dye-reactive nets. It should be recognized that seemingly small chemical changes on a dye structure can shift its absorption spectrum and, therefore, the shade on a fabric. For aromatic systems, the electron-donating capability of pendant groups increases in the following order: —OR, —OH, —NH 2 , —NHR, —NR 2 , where R is an alkyl group. Therefore, reactivity of an amine that is pendant on an aromatic system with a glycidyl group is expected to red-shift the absorption maximum of the dye, and similar reactivity of a hydroxyl group should blue-shift its absorption maximum. Some possible reactions of diglycidyl-PEG with sulfhydryls and amines are illustrated below: The present invention is further directed to the dyed fibers, yarns, fabrics, finished goods, or other textiles (encompassed herein under the terms “textiles” and “webs”) treated with the dye-reactive PEG fixative. These textiles or webs will display improved colorfastness and retention of the dye on the textile or web fiber structure, even after multiple launderings. The colorfast webs of the present invention are intended to include fabrics and textiles, and may be a sheet-like structure (woven, knitted, tufted, stitch-bonded, or non-woven) comprised of fibers or structural elements. Included with the fibers can be non-fibrous elements, such as particulate fillers, binders, sizes and the like. The textiles or webs include fibers, woven and non-woven fabrics derived from natural or synthetic fibers or blends of such fibers, as well as cellulose-based papers, and the like. They can comprise fibers in the form of continuous or discontinuous monofilaments, multifilaments, staple fibers, and yarns containing such filaments and/or fibers, which fibers can be of any desired composition. The fibers can be of natural, man-made, or synthetic origin. Mixtures of natural fibers, man-made fibers, and synthetic fibers can also be used. Examples of natural fibers include cotton, wool, silk, jute, linen, and the like. Examples of man-made fibers include regenerated cellulose rayon, cellulose acetate, and regenerated proteins. Examples of synthetic fibers include polyesters (including polyethyleneterephthalate), polyamides (including nylon), acrylics, olefins, aramids, azlons, modacrylics, novoloids, nytrils, aramids, spandex, vinyl polymers and copolymers, vinal, vinyon, Kevlare, and the like. To prepare the webs, the fiber, the yarn, the fabric, or the finished good is dyed in the normal manner and is then exposed (by methods known in the art such as by soaking, spraying, dipping, fluid-flow, padding, and the like) to an aqueous solution or dispersion of the dye-reactive PEG fixative. The treated web is then removed from the solution and dried. The dye-reactive functional groups on the PEG fixative compound react, by covalent bonding, with the dye on the textile or web to permanently or substantially permanently affix the dye to the textile. Additional additives may be included in the dye-reactive PEG fixative bath. For example, a hydroxyl-containing polymer, such as poly(vinyl alcohol) or starch, may be added to help improve colorfastness. Softeners, such as maleinized polybutadiene for example, or surfactants may also be added. A variety of other chemicals, including but not limited to wetting agents, antioxidants, salts such as sodium sulfate or sodium chloride and acids, bases, or salts that buffer the solution may also be present. In order to further illustrate the present invention and advantages thereof, the following specific examples are given, it being understood that the same are intended only as illustrative and in nowise limitative. EXAMPLES Example 1 An aqueous solution containing 5 wt % diglycidyi-PEG (poly(ethylene glycol) diglycidyl ether, Aldrich, Mn˜526) and 0.2% WetAid NRW (a commercially available wetting agent from B. F. Goodrich) were applied to fabric obtained from a pair of black jeans that were purchased from an Old Navy store (it is almost a certainty that the jeans were dyed with a sulfur dye). The wash liquors from a series of accelerated home launderings (“HLs”) were collected, centrifuged, and their absorbances were measured by UV-VIS. The absorbances at 450 nm of the wash liquors from a control Oeans fabric not treated with the diglycidyl-PEG solution) and the PEG-treated fabric are given in Table 1 below. The results show what the diglycidyl-PEG fixative prevents dye leakage. TABLE 1 Black Dye Removed by Washing 1 HL 2 HL 3 HL 4 HL 5 HL Treated 0.125 0.04 0.02 0.025 0.025 Control 0.45 0.195 0.13 0.075 0.06 Example 2 1 Weight % Direct Black 19 (used as received from Dintex Dyechem Ltd., India) and 0.2 wt. % WetAid NRW (B. F. Goodrich) were padded onto cotton twill and then dried for 10 min. at 180° C. The fabric was then dipped in an aqueous solution of 2 wt. % diglycidyl PEG (1000 MW), 0.2 wt. % WetAid NRW (B. F. Goodrich), and 1 wt. % NaCl, padded, and dried for 15 min. at 180° C. Even after multiple home launderings, the color of this fabric remained black and dark while that of the control (only the dye application in the first step) lost its color rapidly. Example 3 1 Weight % Direct Black 19 (used as received from Dintex Dyechem Ltd., India) and 0.2 wt. % WetAid NRW (B. F. Goodrich) were padded onto cotton twill and then dried for 10 min. at 180° C. The fabric was then dipped in an aqueous solution of 5 wt. % diglycidyl PEG (1000 MW), 0.2 wt. % WetAid NRW (B. F. Goodrich), and 1 wt. % NaCl, padded, and dried for 15 min. at 180° C. Even after multiple home launderings, the color of this fabric remained black and dark while that of the control (only the dye application in the first step) lost its color rapidly. Example 4 1 Weight % Direct Black 19 (used as received from Dintex Dyechem Ltd., India) and 0.2 wt. % WetAid NRW (B. F. Goodrich) were padded onto cotton twill and then dried for 10 min. at 180° C. The fabric was then dipped in an aqueous solution of 5 wt. % diglycidyl PEG (1000 MW), 0.2 wt. % WetAid NRW (B. F. Goodrich), and 3 wt. % NaCl, padded, and dried for 15 min. at 180° C. Even after multiple home launderings, the color of this fabric remained black and dark while that of the control (only the dye application of the first step) lost its color rapidly. Example 5 Preparation of Fixative Agent A 1-L flask was charged with 500 mL of acetone, 38.3 g of PEG (poly(ethylene glycol), Aldrich, 200 MW) and 80 g of sodium carbonate (Fisher). 76.6 Grams of cyanuric chloride (Aldrich) were added portion-wise while stirring. The resulting slurry was stirred under a nitrogen atmosphere for 36 hours. A white solid was filtered off, and the resultant liquid phase was concentrated on a rotary evaporator. This concentration afforded a white solid (unreacted cyanuric chloride) and a liquid phase. The white solid was filtered off. The liquid phase was composed of oligomers of PEG (MW 200) and cyanuric chloride and will hereafter be referred to as “PEG(200)-cyan”. Example 6 A 2 wt % solution of PEG(200)-cyan in water was padded onto a 2″×6″ swatch of black denim cloth (supplied by Burlington Industries). The fabric was dried and cured at 350° C. for three minutes. The fabric was washed in a roto-washer for 45 minutes (equivalent to 5 home launderings), and the wash liquor was removed and allowed to settle. The coloration of the wash liquor was compared to that of two control swatches of black denim, one untreated and the other padded in water and cured at 350° C. for three minutes. The treated fabric wash liquor was transparent and colorless, whereas both controls were dark and translucent. Example 7 A 10% solution of commercially available dimethylol dihydroxyethylene urea (DMDHEU) was prepared with a wetting agent (1 wt %) and a softener (3 wt %). A swatch of overdyed black denim fabric was dipped in the solution and padded to a wet pick-up of 65%. The fabric was then dried at 220° F. and cured at 350° F. for 60 seconds. Treated and untreated fabric swatches were then laundered 30 times in a conventional home laundering machine. Treated swatches showed substantially less color loss than the untreated control. Samples of the laundered treated and untreated fabrics as well as unlaundered untreated fabric were digitally scanned to produce a black and white image. The average grayscale reading from 0 (white) to 255 (black) for each sample was determined using a computer software package. The results are shown in Table 2 below. TABLE 2 Sample Description Grayscale % Color Loss Untreated, unlaundered 234 0% Treated, 30 launderings 232 1% Untreated, 30 launderings 210 10% Example 8 A 5% PEI solution was padded onto a swatch of overdyed black denim supplied by Burlington Industries (style 4271). The swatch was then dried at 265° F. and padded with a 5% dichlorotriazinylanilinesulfonate solution at pH 11.5 and dried/cured at 265° F. for three minutes. The swatch was then subjected to 30 HLs (home launderings) along with control swatches of untreated fabric, water-dipped (dry, cure) fabric, and fabric treated with DMDHEU as described in example 7. The resultant swatch was darker than both the untreated and water dipped swatches, and similar to the DMDHEU-treated swatch.
This invention is directed to treatments for dyed textile goods that will improve their fastness properties. More particularly, the invention is directed to certain fixatives that, when placed on the dyed textile, allow the dye to be permanently or substantially permanently affixed to the fabric. The dye-reactive fixative comprises a water-soluble or water-dispersible polymer or oligomer having reactive groups that react with a dye on a dyed web to affix the dye to the web.
3
BACKGROUND OF THE INVENTION The present invention relates to a mixer for use in agitating fluid in a pressure vessel. In particular, it relates to a magnetically driven mixer that eliminates the need for a seal around a mechanical drive shaft as is required for a mechanical mixer. The use of magnetically driven mixers is known in the art. Magnetically driven mixers generally employ a rotating magnetic field located external to a mixing vessel, and a rotating agitator within the vessel that is coupled to the magnetic driver by one or more magnets located on, or embedded within the body of the agitator. Because such an agitator is magnetically coupled to its driver rather than being mechanically coupled, a sanitary environment can be maintained within the vessel without the need for packed or mechanical seals, such as would be required around a drive shaft that would penetrate the vessel if a mechanically coupled agitator were used. By eliminating such seals, leakage into or out of the vessel due to the agitator linkage can be eliminated. Furthermore, with growing environmental concerns and stricter environmental regulations, magnetic mixers are gaining importance in the chemical industry in general. By eliminating the packed or mechanical seals associated with the mixer of an agitated vessel, fugitive emissions are eliminated as well as the possibility of releasing harmful or noxious fumes due to a seal failure. Generally, in the prior art magnetically driven mixers, the agitator is held against a bearing surface by the same magnetic force that is used to drive the agitator. By its nature, such a system generates a thrust force against the bearing surface which can lead to increased friction as well as the generation of particles within the fluid being mixed due to the friction between the bearing surfaces. In many, if not most applications, the generation of particles is undesirable. Therefore, any reduction in the frictional forces between the associated bearing surfaces or other parts that contact one another is highly desirable. SUMMARY OF THE INVENTION A novel magnetically driven agitator is provided in which the agitator is magnetically levitated within the mixing vessel. By levitating the agitator within the vessel, the need for thrust bearings is eliminated. By eliminating such bearings and the friction associated with them, the generation of undesirable particles is greatly reduced. Moreover the reduction of friction provides reduced wear on the bearing surfaces, lower power consumption for the driver, and reduced maintenance for the entire mixing system. The novel system is also easy to assemble and disassemble, further reducing maintenance costs. Furthermore, due to its novel design, the mixer can be cleaned without disassembling the various parts. Moreover, the use of the magnetically levitated, magnetically driven mixer of the present invention promotes flow of the fluid to be mixed around the bearing surfaces, virtually eliminating any dead spots within the mixing vessel. These improvements are achieved by the use of mixing vessel that includes a vessel fitting which is a cup-shaped hollow cylinder, either fabricated integral to the mixing vessel itself or welded to an existing mixing vessel. The vessel fitting protrudes into the vessel typically at the bottom, and defines an aperture into which the driver can be placed. Preferably, the driver consists of a plurality of permanent magnets mounted about a motor driven drive shaft. The drive magnets are arranged in an alternating orientation such that a given drive magnet having a particular north or south outwardly facing orientation is adjacent to drive magnets having the opposite polar orientation. An agitator fits over the vessel fitting and includes a hollow cylindrical hub on which agitator magnets are arranged circumferentially. The magnets allow the agitator to be both driven and levitated by the drive magnets. The agitator magnets are oriented such that the agitator magnets adjacent to any given agitator magnet are oriented with opposing poles facing inward towards the rotational axis of the drive shaft. A plurality of agitator blades are fixed about the hub for providing the agitation of the fluid within the vessel once the driver engages the hub. The magnetic forces between the driver and the agitator tend to cause the agitator to levitate and center itself along the length of the vessel fitting. While any thrust generated by the agitator and/or the weight of the agitator may cause the agitator to slightly de-center itself along the longitudinal axis of the vessel fitting, the magnetic levitation of the agitator eliminates any thrust forces and, therefore, eliminates the need for thrust bearings. Moreover, since the magnets of both the driver and the agitator hub are balanced radially, there is very little radial force generated by the rotating agitator. Theoretically, the radial forces cancel one another completely. However, due to minor variations in the magnetic attractions between the drive and agitator magnets due to manufacturing tolerances and due to the unstable equilibrium caused by the concentric magnetic fields of the driver and hub, the agitator may tend to favor one side of the vessel fitting when rotating. Therefore, bearings are useful for maintaining the agitator in a centered position and reducing friction resulting from these secondary effects. The bearings include a pair of bearing surfaces located on the top and bottom of the agitator on either end of the agitator magnets. Preferably, the bearing surfaces are on removable bearing rings. A mating pair of bearing rings are located on the vessel fitting to cooperate with the agitator bearing surfaces and are mounted to the vessel fitting such that they can slide up and down along the vessel fitting and thereby allow the agitator to magnetically levitate along the length of the vessel fitting. The mixer assembly described above provides an extremely low friction mixer which results in low particle generation, low power consumption and a reduced maintenance schedule compared to conventional magnetic mixers. In the preferred embodiment, the agitator also includes a plurality of radial holes extending through the hub which help to promote circulation of fluid around the bearing surfaces and into the area between the hub and the vessel fitting. By including these radial holes, any dead spots which might otherwise develop between the hub and the vessel fitting, are eliminated. Moreover, by promoting flow of fluid around the bearings, the bearings are continuously flushed, further reducing friction and providing cooling of the bearing surfaces. The design further provides a mixer that is simple to clean. By promoting the flow of fluid around the bearing surfaces and between the hub and vessel fitting, the mixer can be effectively cleaned without the need for disassembling the agitator from the vessel fitting. When there is a need to clean the vessel, the vessel is merely drained of the fluid that has been mixed and then filled with water or some other solvent for cleaning the interior walls of the vessel and the various components of the agitator. The agitator can be driven by the driver during cleaning. Moreover, the agitator can also be steamed or autoclaved for sterilization. Because the mixing assembly is so easy to clean, a single vessel and mixer can be used for multiple applications without extensive downtime between mixing different batches of product as is generally encountered with conventional mixers. Additional features of the invention will be described by the following description and by the accompanying figures. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 illustrates in partial cutaway, an elevation view of a mixing vessel with a vessel fitting of the present invention welded in place and a driver for driving an agitator of the present invention; FIG. 2 is an exploded perspective view of the mixing assembly; FIG. 3 is an elevation view of the mixing assembly shown partly in section; FIG. 4 is a plan view illustrating the features of the agitator; FIG. 5 is a plan view illustrating the features of the drive magnet housing; and FIG. 6 is a schematic diagram illustrating the placement of and interaction between the magnets. DETAILED DESCRIPTION OF THE INVENTION Referring to FIG. 1 a vessel fitting 12 is shown attached to a mixing vessel 13. Preferably, the vessel fitting is made of a non-magnetic alloy such as stainless steel, so that it will not interfere with the magnetic field which is used to drive the agitator. The vessel fitting includes a weld flange 14 that can be used to weld the vessel fitting to an existing mixing vessel. The vessel fitting is generally a cylindrical fitting that extends into the mixing vessel and which is closed on the end innermost to the mixing vessel. The outer surface of the vessel fitting which is located inside the mixing tank, provides a surface about which the agitator can rotate as will be discussed in further detail later. The interior of the vessel fitting provides an aperture area into which a magnetic drive assembly 16 can be inserted at least partially. The drive assembly comprises a motor 17, which is preferably a variable speed electric motor. Gear box 18 is used to reduce the speed of the motor output and redirect the motor's driving force to drive shaft 19, which is used to rotate a drive magnet housing 21. The drive magnet housing includes a plurality of drive magnets 22 that are used to supply the magnetic force for driving an agitator located within the vessel. The drive magnet housing defines a bearing aperture 23 with inner bearing surface 24. Upper and lower magnet positioning rings 25 and 26 hold the drive magnets in place. The inner bearing surface mates with a similar outer bearing surface 27 external to a steady bearing 28 that is mounted in the uppermost inner portion of the vessel fitting by bolt 29. Once the drive magnet housing has been inserted into the vessel fitting and the motor is started, the steady bearing maintains the drive magnet housing in a central location and prevents it from wobbling within the vessel fitting. Preferably, the drive assembly is mounted to the vessel fitting by a quick-release mechanism. This permits easy access to the drive assembly for maintenance purposes. Moreover, if for some reason the magnetic field needs to be disengaged such as for maintenance, a quick-release fitting is useful. The preferred quick release mechanism comprises a driver mount 31 with a pair of opposing bayonet pins 32 which cooperate with a pair of opposing L-shaped bayonet slots 33 on a lower flange 34 of the vessel fitting. As illustrated by the drawing figures, the drive magnetic housing can be inserted into the vessel fitting and locked in place by a slight twist of the driver mount so as to engage the bayonet pins in the bayonet slots. A spring pin 35 is useful for locking the driver mount in place once the bayonet pins have been engaged. Referring now to FIGS. 2 and 3, the agitator is illustrated in further detail. The agitator 36 comprises a hollow cylindrical agitator hub 37 and a plurality of agitator blades 38 mounted to the agitator hub by blade mounting pins 39. The agitator hub is a hollow cylinder which can be mounted over and rotated about the vessel fitting. In order to reduce friction between the agitator and the vessel fitting, a system of bearings is used. A pair of hub mounted bearing rings 41, each having an inner bearing surface 42, are mounted at the top and bottom of the agitator hub and fixed with respect to the agitator hub. In order to prevent the hub mounted bearing rings from rotating with respect to the agitator hub a pair of opposing outer flats 43 cooperate with similar internal flats 44 on the inner surface of the agitator hub. For simplicity, only the upper bearing assembly is illustrated in FIG. 2. FIG. 3 illustrates both the upper and lower bearing assemblies. A pair of vessel fitting bearing rings 46, each with an outer bearing surface 47, mate with the inner bearing surface of the hub mounted bearing rings. An inner flat 48 on each of the vessel fitting bearing rings cooperates with an outer flat 49 on the vessel fitting so as to prevent the vessel fitting bearing rings from rotating with respect to the vessel fitting. While the vessel fitting bearing rings are fixed against rotation with respect to the vessel fitting, they may slide up or down along the outer surface of the vessel fitting such that an agitator, as described below, can be magnetically levitated along the length of the vessel fitting by the same magnetic force generated by the drive magnets for driving the agitator. In the preferred embodiment, tungsten carbide bearing surfaces are used. A pair of C-shaped spring clips 51 engage with an inner slot 52 of the agitator hub in order to hold the bearing assemblies in place. The agitator hub also includes a plurality of fluid circulation apertures 54 spaced radially about the circumference of the agitator hub. These apertures promote the flow of fluid outwardly from the interior of the agitator hub between the vessel fitting and the agitator so as to both help cool the bearing surfaces and prevent any build-up of materials or dead spots within the space between the vessel fitting and agitator. It should also be recognized that the bearings are assembled with enough play so that the fluid to be mixed can flow between the bearing surfaces to reduce metal-on-metal contact and provide lubrication. The placement of the magnets and the structure for retaining the magnets in the agitator is best illustrated in FIGS. 3 and 4. Six pairs of agitator magnets 61 are spaced equidistantly around the circumference of the agitator hub. One magnet from each pair is placed above the center line of the agitator while the other magnet from each pair is placed below the center line forming an upper and a lower set of six magnets for each set. Six pairs of magnet spacers 62 hold adjacent magnets apart. A pair of split backing rings 63 hold the magnets and magnet spacers against the agitator hub and a pair of outer housing rings 64 hold the magnet assembly in place. One split backing ring and one outer housing ring hold the upper set of magnets in place while the other split backing ring and outer housing ring held the lower set of magnets in place. Preferably, the outer housing rings are welded in place to keep the magnets sealed from contact with the fluid to be mixed. The placement of the magnets in the drive magnet housing is best illustrated in FIG. 5. The six drive magnets are spaced from one another by magnet spacers 71 and held in place in the drive magnet housing by six drive magnet retaining plates 72. The specific orientation of each of the magnets is illustrated schematically in FIG. 6. Adjacent agitator magnets 61 alternate such that their north and south poles face inwardly towards the axis of rotation of the agitator. The drive magnets 22 are similarly oriented facing outwardly away from the axis of rotation with adjacent drive magnets having alternating north and south poles facing outwardly. As illustrated, the magnetic forces created by the drive magnets engage opposing poles of the agitator magnets such that the agitator is magnetically coupled to the drive magnetic housing so that when the drive magnetic housing spins, the agitator rotates within the mixing vessel. The same magnetic force that is used to rotate the agitator is also used to levitate the agitator along the length of the vessel fitting. Because the vessel fitting bearing rings are permitted to slide up or down the vessel fitting, the agitator can also slide up and down the vessel fitting until it finds an equilibrium position. The equilibrium position is determined by the precise placement of the drive magnet housing within the vessel fitting, the weight of the agitator, and the thrust generated by the agitator when in operation. The strength of the magnetic field also prevents the agitator from flying off the top of the vessel fitting when in operation. By such a sliding bearing arrangement, any thrust generated by the agitator, either due to its weight or due to its rotation in the fluid to be mixed, is transferred through the magnetic field to the magnetic drive assembly. This eliminates the need for thrust bearings within the mixing vessel, thus reducing friction and the associated wear and power demands associated with such friction. While the embodiment described illustrates the use of six pairs of agitator magnets and six drive magnets, different numbers of magnets can be used depending on the strength of the magnetic attraction needed. For large mixers or for mixing viscous fluids, more magnets may be needed. Preferably, the magnets are provided in even sets so that an alternating pole arrangement can be maintained. In the preferred embodiment, rare earth magnets are used as they provide very strong attractive forces. One example of such a rare earth magnet, is a magnet made from neodymium-iron-boron. In the preferred embodiment, all wetted portions of the agitator assembly, that is those surfaces coming in contact with the fluid to be mixed, preferably are made of stainless steel or some other non-magnetic, corrosion resistant alloy. In certain applications, the wetted surfaces may be plastic rather than metal. While the preferred embodiment described above employs a variable speed electric motor as the motive force for driving the agitator, any number of different motive forces can be used. For example, either pneumatic or hydraulic driven motors can be used for rotating the drive magnet housing. Similarly, if steam is available, then a steam turbine or other steam driver can be used as the motive force. Furthermore, while the preferred embodiment describes the use of a plurality of permanent magnets which are rotated in order to form a magnetic coupling to the agitator magnets, and thereby rotate the agitator within the mixing vessel, a fixed stator may also be used to drive the agitator magnets. In such an embodiment, a number of electromagnets located within the vessel fitting can be controlled so as to create a rotating magnetic field which can be used to drive the agitator magnets. If a starter is used, the agitator acts as a rotor. Having described the preferred embodiment of the present invention, it is apparent that several modifications may be made while keeping within the scope of the following claims.
An improved magnetic mixer includes an agitator that includes a plurality of agitator magnets. A bearing arrangement allows the agitator to be magnetically levitated along the outer surface of a cylindrical vessel fitting located within a mixing vessel. The same magnetic force that is used to levitate the mixer drives the agitator. The magnetic force is preferably generated by a plurality of magnets which rotate within an aperture extending into the vessel fitting. By magnetically levitating the agitator, there is no thrust generated by the agitator against the vessel fitting which eliminates the need for thrust bearings and reduces the overall frictional forces. The low friction results in reduced particle generation, reduced power consumption and reduced maintenance compared to conventional magnetic mixers.
5
FIELD OF THE INVENTION The present invention provides for an elevator sill system, consisting of both a cab sill and a hoistway sill that are comprised of a novel sill foundation and a corresponding and novel sill foundation covering, that when implemented together, provides for an elevator sill system of superior application, performance, durability and appearance at a comparatively low cost to standard and customized elevator sills. The elevator sill system of the present invention may be comprised of: (a) an existing elevator sill foundation and a sill foundation covering adapted to fit said existing sill foundation; or (b) a newly fabricated paired sill foundation and sill foundation covering; or (c) a sill foundation specially adapted to receive a sill foundation covering that, when united together, provides such superior application, performance, durability and appearance at a comparatively low cost to standard and customized elevator sills. Importantly, the final product, when installed, must maintain the functionality of the existing elevator door system. With this invention, the sometimes arduous and costly task of replacing existing elevator sills is simplified and enhanced with a more durable and/or attractive sill. In some cases, what might be too expensive (and not get done), actually now gets done, which enhances safety. Notably, the existing elevator sill system does not have to be removed to accept the new sill foundation covering, as it can be implemented by adding as little as approximately ⅛″ of added thickness, which variance is generally within elevator door system's adjustment capabilities. Alternatively, and significantly easier than replacing an elevator sill system, the existing sill foundation can be adjusted in place to accept the sill foundation covering of the present invention and resultantly come within the elevator door system's adjustment capabilities. The combined sill foundation (whether it is an existing sill foundation or a newly fabricated sill foundation) and sill foundation covering will provide for ease of installation, superior performance, durability, safety and appearance at a comparatively low cost when compared to standard or customized elevator sills or the replacement of an existing elevator sill system. BACKGROUND In operation, when an elevator cab stops at a certain floor, the interior door of the elevator cab (“cab door”) and exterior door of the floor (“hoistway door”) must meet and slide open and closed uniformly. To accomplish this, the doors slide along a bottom sill that has horizontal grooves to guide the door movement. There is a portion of the sill that is constructed in the cab (“cab sill”) and a portion of the sill that is constructed on the floor where the cab stops (“hoistway sill.”) Jointly, the cab sill and hoistway sill are known as an “elevator sill system.” When the cab stops at a given floor, the cab sill and the hoistway sill align allowing for uniformity in the opening and closing of the cab and hoistway doors. Cab and hoistway sills are utilized in elevator systems that have sliding doors. Both sills are comprised of a sill foundation material with a sill surface material. Cab and hoistway sills have horizontal grooves. A set of door gibs (guides) attach to the bottom of a cab door and/or hoistway door and travels in the horizontal grooves of a cab and/or hoistway sill. This configuration allows the corresponding cab door and hoistway door to open and close uniformly. The cab and hoistway sill materials typically undergo significant wear and tear, as well as stress from the continual opening and closing of the cab and/or hoistway doors and foot traffic. In addition, cab and hoistway sills must be fireproof, fire resistant and/or fire rated to ensure that during a fire emergency, smoke and fire stay contained to the affected floor of a multistory building. Sill materials must be able to withstand fire and smoke stresses and create an acceptable barrier over an acceptable time frame. Typically, existing elevator sill systems comprise a unified sill foundation material and a sill surface material, i.e., they are one continuous material fabricated as one piece. As such, cab and hoistway sills are constructed from durable and fireproof materials, typically, cast or extruded aluminum, bronze, iron, stainless steel or nickel silver. Softer materials, such as aluminum, or plastics and other manufactured materials such as PVC, acrylic, polycarbonate, ABS, polystyrene, epoxy, resin, epoxy resin and the like are easier, faster and less expensive to manufacture, but wear much faster. These softer materials can also provide for fireproofing. On the other hand, harder and more durable materials, such as cast or extruded bronze, iron, stainless steel, or nickel silver and other architecturally desirable metals, are difficult and more expensive to manufacture, but when made and installed properly, last longer and remain cosmetically more attractive. Extruded stainless steel and other materials have the additional limitation in that the extrusion process does not provide for sharp edges and angles, i.e., what is required to produce cosmetically and/or architecturally desirable visible surfaces and/or treads. This limitation is present in other extruded metals, thus making extruded elevator sill systems aesthetically and architecturally disfavored. Due to this limitation, aesthetically desirable cab and hoistway sills are fabricated from several different non-extruded sections that must be welded together—an expensive and time consuming process. In many circumstances and for a variety of reasons, including but not limited to brand competition and varying architectural limitations, there are no standard unified dimensions of a cab and/or hoistway sill. This substantially raises the costs and time necessary for construction of cab and hoistway sills. Recently, there have been attempts at improving currently available elevator sills and hoistway sills. For example, American Safety Tread Co., Inc. has developed a cast anti slip protection sill. They manufacture an “‘alumacast’—corrosion resistant, maintenance free aluminum alloy all-purpose usage; ‘feracast’—cast iron all-purpose usage. Will withstand heavy industrial punishment. Ships with one coat of shop applied black paint; “bronzacast/nickelcast’—natural bronze finish makes this an ideal choice for an upscale, classic effect.” See www.americansafetytread.com/cast/elevator-door-sills/. In another example, U.S. Pat. No. 5,609,224 titled, “ELEVATOR DOOR SILL” issued Mar. 11, 1997 discloses, “an elevator cab (10) with a door sill (28) adjacent to the landing sill (40) with a gap (44) there between and door sill and/or landing sill configured to produce a visual effect of enlarging the visual appearance of the gap.” In another example, U.S. Pat. No. 5,715,913 titled, “DOOR SILL FOR AN ELEVATOR CAR” issued Feb. 10, 1998 discloses a “sill system for an elevator car, comprising a sill profile (5), a lower door guide (7) movable in a slot (12) in the sill profile (5) and a guide holding bracket (9) for connecting the lower door guide (7) to the door. The guide holding bracket (9) is passed to the lower door guide (7) from below the surface level of the car floor (3).” In another example, U.S. Pat. No. 6,684,573 titled, “ELEVATOR DOOR SILL ASSEMBLY” issued Feb. 3, 2004 discloses an “elevator door sill assembly for use in elevator systems that have sliding doors. The door sill assembly comprises a sill plate, a support sill located below the sill plate having a rail that presents an inboard sliding surface and an outboard sliding surface. The assembly also comprises a first guiding surface that engages that inboard sliding surface and a second guiding surface that engages the outboard sliding surface. The assembly prevents that bottom of the elevator door from swinging while the door slides opened and closed. The sill assembly and guide system may be used with either hoistway doors or elevator car doors.” In another example, U.S. Pat. No. 6,938,380 titled, “ELEVATOR ENTRANCE SILL STRUCTURE AND INSTALLATION METHOD” issued Sep. 6, 2005 discloses an invention that “related to a cost saving way of solving a difficult problem in the structure and installation and leveling of an elevator sill. This invention provides ease of installing from the hallway without the use of a moving elevator platform. The structure consists of a sill, a cradle for the sill and a pair of end brackets for supporting the cradle. The pair of spaced L-shaped end brackets are provided for attachment to the hall floor. A vertically adjustable sill is mounted on the sill cradle. The elevator door sill cradle is adjustable vertically by means of fasteners that are moveable in vertical slots in the end brackets and is horizontally adjustable on the cradle by means of fasteners that are moveable in horizontal slots provided in the cradle.” In another example, Application No. PCT/US2009/068633 discloses, “an exemplary sill for use in an elevator system includes a sill plate that is a single piece of metal. The sill plate has a first portion in a first plane and a second portion adjacent to the first portion. The second portion is bent into a second plane that intersects the first plane. A third portion is adjacent to the second portion. The third portion is bent at least partially into a third plane that intersects the second plane. A fourth portion is adjacent to the third portion. The fourth portion is bent into a fourth plane that intersects the third plane and intersects the first plane. A fifth portion is adjacent to the fourth portion. The fifth portion is bent into the first plane. The second, third and fourth portions collectively establish a groove that is configured to receive a portion of an elevator system door. A base portion is provided in a plane parallel to the first plane. Connector portions near opposite ends of the base portion protrude from the base portion in a direction toward the first plane of the sill plate. At least one of the connector portions is connected to a selected portion of the sill plate near an end of the sill plate.” There is no currently disclosed cab and/or hoistway sill or elevator sill system that combines the low cost and ease of manufacturing of sills comprised of inexpensive materials and the high durability, fire rating and attractive finish of expensive custom fabricated architecturally desirable nonferrous materials such as bronze, stainless steel, nickel silver or other architecturally desirable ferrous materials. Objectives of the present invention include providing a low cost, easy to manufacture, durable, fire rated, attractive and fully customizable cab and/or hoistway sill that includes sharp, architecturally and aesthetically desirable angled, non-rounded edges. All known elevator cab and hoistway sills sacrifice one or more of the foregoing attributes. The present invention provides a solution to the unmet need by providing cab and hoistway sills that are economical to manufacture that are also highly durable, fire rated, possesses an architecturally attractive and safety conscious finish consisting of architecturally and aesthetically desirable materials and custom designed surface finishes, as well as sharp, angled non-rounded edges. The present invention also allows for existing elevator sill systems to be upgraded by cladding with sill foundation coverings consisting of architecturally and aesthetically desirable materials, thus eliminating the costly and destructive exercise of removing and replacing preexisting cab and hoistway sills when a new sill is needed or desired. None of the foregoing references, alone or in combination, teach the salient and essential features of the instant invention. There remains, therefore an unmet need for a device that provides all of the attributes of a low cost, economical to manufacture, durable, fire rated, attractive and fully customizable cab sill and hoistway sill. SUMMARY In one embodiment, the device of the present invention comprises a sill foundation and a corresponding sill foundation covering, that when implemented together, provides for an elevator sill of superior performance, durability, fire rating, and appearance at a comparatively low cost to standard and customized elevator sills. The sill foundation covering provides an economical to manufacture cladding to cover the sill foundation in a custom configuration wherein the sill foundation covering is comprised of durable and aesthetically pleasing materials such as architectural metals or other aesthetically desirable materials. In one embodiment, the device of the present invention comprises a sill foundation covering made of a durable and aesthetically pleasing material such as an architectural metal, that matches existing and currently installed cab and/or hoistway sills dimensionally such that when covering the existing sill, the now covered sill is a functional reproduction, within variable tolerances of the original sill in orientation and configuration of grooves and is therefore capable of implementation into the existing elevator cab and hoistway door assemblies. In one embodiment, the sill foundation covering could be fashioned from any suitable material desirable for an elevator sill system. For example, any architecturally desirable nonferrous material can be used such as bronze, stainless steel, nickel silver and the like. In addition, other architecturally desirable ferrous materials or other as yet undeveloped materials can also be utilized. In one embodiment, the surface of the sill foundation covering may be brushed or finished with anti-slip coatings and/or metallic finishes for functional and/or cosmetic purposes. In one embodiment, the sill foundation covering is fashioned by bending a sheet of bronze, nickel, nickel-steel, nickel-silver, iron, stainless steel and the like, into the proper configuration via a proprietary process of “v-grooving” wherein a groove is first cut in the sheet via a custom v-groove machine to create “v-channels” where the bends in the sheet will occur to create sharp, angled, non-rounded edges. In one embodiment, the sharp, angled, non-rounded edges are approximately ninety degree angles. In one embodiment, the sharp, angled, non-rounded edges are any architecturally desired angle based on the configuration of the grooves required in the sill system to impart functionality and/or pleasing aesthetics and/or safety features. In one embodiment, any suitable sturdy underlying material can be used to create a cab and/or hoistway sill foundation upon which the sill foundation covering can be added. For example, PVC, acrylic, polycarbonate, ABS, polystyrene, epoxy, resin, epoxy resin, plastic and the like could be used to create a cab and/or hoistway sill foundation to accept the sill foundation covering so long as the material can support the required weight load, endure the daily stresses and embody the appropriate fire rating. In one embodiment, any fireproof sturdy underlying material that can support the required weight load could be used to create a cab and/or hoistway sill foundation upon which the sill covering can be added. For example, a fireproof and/or fire resistant resin or epoxy resin such as VIPEL™ K010-TB, FIREPEL™ K130 or FIREPEL™ K133 could be utilized to create a cab and/or hoistway sill foundation to accept the sill foundation covering. In one embodiment, the sill foundation covering may be adhered to any sill foundation through the use of bonding adhesives, cement, glue or permanent tape. In one embodiment, the sill foundation covering may be adhered to a new sill foundation through the use of bonding adhesives, cement, glue or permanent tape. In one embodiment, the sill foundation covering may be adhered to an existing elevator sill system, that in this situation becomes the sill foundation, through the use of bonding adhesives, cement, glue or permanent tape. In one embodiment, the sill foundation covering may be adhered to any sill foundation through the use of any known metal fastening mechanism, such as screws, rivets, welds, solder and the like. In one embodiment, the sill foundation covering may be adhered to a new sill foundation through the use of any known metal fastening mechanism, such as screws, rivets, welds, solder and the like. In one embodiment, the sill foundation covering may be adhered to an existing elevator sill system, that in this case becomes the sill foundation, through the use of any known metal fastening mechanism, such as screws, rivets, welds, solder and the like. In one embodiment, the sill foundation covering may be adhered to any sill foundation through the use of any known metal fastening mechanism, such as screws, rivets, welds, solder and the like and/or in combination with bonding adhesives, cement, glue or permanent tape. In one embodiment, the sill foundation covering may be adhered to a new sill foundation through the use of any known metal fastening mechanism, such as screws, rivets, welds, solder and the like and/or in combination with bonding adhesives, cement, glue or permanent tape. In one embodiment, the sill foundation covering may be adhered to an existing elevator sill system, that in this case becomes the sill foundation, through the use of any known metal fastening mechanism, such as screws, rivets, welds, solder and the like and/or in combination with bonding adhesives, cement, glue or permanent tape. In one embodiment, a typical permanent tape bonding may be implemented to bond the sill foundation covering with an existing or new cab and/or hoistway sill or sill foundation such as disclosed by 3M™ VHB™ permanent assembly tapes. Because the underlying new cab and/or hoistway sill foundation or existing elevator sill system is typically made of metal or other flat surface, it provides a sturdy surface with an appropriate fire rating to adhere the sill foundation covering to provide an outer surface resistant to normal wear and tear. Although, the underlying cab and hoistway sill or sill foundation may be made of PVC, acrylic, polycarbonate, ABS, polystyrene, epoxy, resin, epoxy resin, plastic or most metals, they all provide sturdy surface for bonding with an acrylic foam tape to provide the attachment of an outer surface, such as the sill foundation covering, resistant to normal wear and tear. In one embodiment, a cab and/or hoistway sill foundation made from PVC, acrylic, polycarbonate, ABS, polystyrene, epoxy, resin, epoxy resin, plastic and the like may be reinforced for added strength or contain a fire retardant layer for added fire rating. In this manner, it becomes economical to manufacture and form any shape, dimension and configuration of cab and/or hoistway sill foundation in a rapid manner. Once the sill foundation of the present invention is adhered with the sill foundation covering of the present invention, strength and stability will be enhanced and the wear and durability properties of the outer surface will maintain the same inherent properties as if the entire cab and hoistway sills were comprised exclusively of architecturally and/or aesthetically desirable materials such as architectural metals. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 depicts a view of one embodiment of the sill foundation covering ( 1 ) of the elevator sill system of the present invention comprising sharp, angled non-rounded edges ( 2 ) and tread grooves ( 3 ). FIG. 2 depicts an alternate view of one embodiment of the sill foundation covering ( 1 ) of the elevator sill system of the present invention comprising sharp, angled non-rounded edges ( 2 ) and tread grooves ( 3 ). FIG. 3 depicts a view of one embodiment of the present invention showing the sill foundation covering ( 1 ) with custom designed outer finish ( 4 ) showing tread grooves ( 3 ) and horizontal grooves in which a cab door and/or hoistway door gib will travel ( 5 ) and adhered to a sill foundation ( 6 ) via a permanent bonding tape ( 7 ). FIG. 4 depicts an alternate view of one embodiment of the present invention showing the sill foundation covering ( 1 ) with custom designed outer surface finish ( 4 ) showing tread grooves ( 3 ) and horizontal grooves in which a cab door and/or hoistway door gib will travel ( 5 ) and adhered to a sill foundation ( 6 ) via a permanent bonding tape ( 7 ). FIG. 5 depicts a view of one embodiment of the elevator sill system of the present invention ( 8 ) showing an alternate configuration of a sill foundation ( 6 ) and a corresponding sill foundation covering ( 1 ). FIG. 6 depicts a view of an alternate view of the elevator sill system of the present invention ( 8 ) showing an alternate configuration of a sill foundation ( 6 ) and a corresponding sill foundation covering ( 1 ). FIG. 7 depicts a view of one embodiment of the present invention showing an alternate configuration of the sill foundation covering ( 1 ) of the elevator sill system of the present invention comprising sharp, angled non-rounded edges ( 2 ) and tread grooves ( 3 ) and dual horizontal grooves in which a cab door and/or hoistway door gib will travel ( 5 ). FIG. 8 depicts an alternate view of one embodiment of the present invention showing an alternate configuration of the sill foundation covering ( 1 ) of the elevator sill system of the present invention comprising sharp, angled non-rounded edges ( 2 ) and tread grooves ( 3 ) and dual horizontal grooves in which a cab door and/or hoistway door gib will travel ( 5 ). FIG. 9 depicts a view of one embodiment of the present invention showing an alternate configuration of the sill foundation covering ( 1 ) with custom designed outer surface finish ( 4 ) showing tread grooves ( 3 ) and horizontal grooves in which a cab door and/or hoistway door gib will travel ( 5 ) and adhered to a sill foundation ( 6 ) via a permanent bonding tape ( 7 ). FIG. 10 depicts an alternate view of one embodiment of the present invention showing an alternate configuration of the sill foundation covering ( 1 ) with custom designed outer surface finish ( 4 ) showing tread grooves ( 3 ) and horizontal grooves in which a cab door and/or hoistway door gib will travel ( 5 ) and adhered to a sill foundation ( 6 ) via a permanent bonding tape ( 7 ). FIG. 11 depicts a view of one embodiment of the elevator sill system of the present invention ( 8 ) showing an alternate configuration of a sill foundation ( 6 ) and a corresponding sill foundation covering ( 1 ). FIG. 12 depicts an alternate view of one embodiment of the elevator sill system of the present invention ( 8 ) showing an alternate configuration of a sill foundation ( 6 ) and a corresponding sill foundation covering ( 1 ). FIG. 13 is an exploded, diagrammatic view illustrating the adhesion of an adhered elevator sill foundation covering to a receiving elevator sill system. DETAILED DESCRIPTION For clarity of disclosure, and not by way of limitation, the detailed description of the invention is divided into the following subsections that describe or illustrate certain features, embodiments or applications of the present invention Definitions “Cab sill” as used herein refers to the bottom horizontal member of an elevator cab assembly across which the elevator cab door is guided through opening and closing. A corresponding hoistway sill exists at every floor where the elevator stops. “Hoistway sill” as used herein refers to the bottom horizontal member of an elevator floor entry assembly across which the outer elevator door or hoistway door is guided through opening and closing. A corresponding cab sill exists within the elevator cab assembly that stops at the floor. “Sill surface” as used herein refers to the upward horizontal facing surface of a cab and/or hoistway sill as defined herein. “Sill foundation covering” as used herein refers to a component of a cab and/or hoistway sill that is capable of affixing atop a sill foundation and comprises the sill surface. “Silt foundation” as used herein refers to a component of a cab sill and/or hoistway sill that is below the sill surface of the cab sill and/or hoistway sill and forms a suitable base material for supporting a sill foundation covering comprising the sill surface. At times, the sill foundation and sill foundation covering may be constructed of one continuous material and at times may be constructed separately and adhered together. At times, an existing cab sill, hoistway sill or elevator sill system may form a sill foundation in an alternative sill construction. “Elevator sill system” as used herein refers to both the cab sill and hoistway sill as they are defined herein and function together within an elevator door system. “Elevator door system” as used herein refers to the entire mechanism by which the operation of both an elevator's cab and hoistway doors is achieved. The Device of the Present Invention In one embodiment, the device of the present invention comprises low cost high durability cab and hoistway sills comprised of individual sill foundations, constructed of a low-cost foundation such as PVC, acrylic, polycarbonate, ABS, polystyrene, epoxy, resin, epoxy resin, plastic or most metals, that are clad in and/or otherwise attached to a sill foundation covering comprised of a more expensive, durable and aesthetically pleasing and desirable materials such as architectural metals. In one embodiment, the sill foundation covering may be adhered to an existing elevator sill system serving as the sill foundation or a new cab and/or hoistway sill foundation through the use of bonding adhesives, cement, glue or permanent tape. In one embodiment, the sill foundation covering may be adhered to an existing elevator sill system or a new cab and/or hoistway sill foundation through the use of any known metal fastening mechanism, such as screws, rivets, solder, welds or the like. In one embodiment, the sill foundation covering may be adhered to an existing elevator sill system or a new cab and/or hoistway sill foundation through the use of any known metal fastening mechanism, such as screws, rivets, welds, solder and the like and/or in combination with bonding adhesives, cement, glue or permanent tape. In one embodiment, the device of the present invention comprises a sill foundation covering made of durable and aesthetically pleasing architecturally desirable metals such as bronze, nickel, nickel-steel, nickel-silver, iron, stainless steel and the like that conforms to an existing and currently installed elevator sill system dimensionally such that when covering the existing elevator sill system, the now covered elevator sill system maintains the functionality of the existing elevator door system. In one embodiment, the sill foundation covering is fashioned from architectural metals such as bronze, nickel, stainless steel, steel and/or nickel silver. In one embodiment, the sill foundation covering is fashioned by bending sheets of bronze, nickel, nickel-steel, nickel-silver, iron, stainless steel and the like, into the proper configuration by a proprietary process of “v-grooving” wherein a groove is first cut in the sheet via a custom v-groove type router to create “v-channels” where the bends in the sheet will occur, to create the sharp, angled, non-rounded edges which may be ninety-degree angles or some other angle that is architecturally required or desired in a given application. In one embodiment, any suitable sturdy underlying material for a cab and/or hoistway sill foundation would work. For example PVC, acrylic, polycarbonate, ABS, polystyrene, epoxy, resin, epoxy resin, plastic and the like could be used to create the cab and/or hoistway sill foundation that will accept the sill foundation covering so long as the material can support the required weight load, endure the daily stresses and is appropriately fire rated when implemented as taught herein. The PVC, acrylic, polycarbonate, ABS, polystyrene, epoxy, resin, epoxy resin, plastic and the like may be reinforced fir added strength. In this manner, it becomes economical to firm any shape, dimension and configuration of cab and/or hoistway sill foundation and otherwise provide for rapid manufacturing. Once the sill foundation of the present invention is adhered to the sill foundation covering of the present invention, the strength and stability of the elevator sill system will be enhanced and the wear and durability properties of the outer surfaces of the elevator sill system will maintain the same inherent properties as if the elevator sill system was comprised exclusively of architectural metals or other more expensive materials. In one embodiment, if the cab and/or hoistway sill is required to be fireproof and/or fire resistant, fireproof and/or fire resistant resins and/or epoxy resins such as VIPEL™ K010-TB, FIREPEL™ K130 or FIREPEL™ K133 or the like could be utilized to create a cab and/or hoistway sill foundation to accept the sill foundation covering. In one embodiment, if cab and/or hoistway sill is required to be fireproof and/or fire resistant, any available fire proof and/or fire resistant material could be utilized to create a cab and/or hoistway sill foundation to accept the sill foundation covering. In one embodiment, the sill foundation covering could be fashioned from any suitable material desirable for the outer surface of an elevator sill system. For example, nonferrous metals such as bronze, nickel-silver, stainless steel as well as ferrous materials such cold rolled steel, galvanized steel and the like may be used. In one embodiment, the cab and/or hoistway sill foundations could be fashioned out of any suitable material that can withstand the load requirements of an elevator sill system. In one embodiment, any of the foregoing surfaces of the sill foundation covering may be brushed or finished with anti-slip coatings, metallic finishes or the like for functional and/or cosmetic purposes. EXAMPLES The present invention is further illustrated, but not limited by, the following examples. In one embodiment, someone desires to replace an existing elevator sill system. Typically, to replace an elevator sill system, that person must purchase a costly new elevator sill system. In addition, they must undertake the labor intensive, destructive and expensive process of removing the existing elevator sill system. The removal of an existing elevator sill system is especially difficult and costly if the existing elevator sill system is installed in custom flooring or flooring that is no longer commercially available. The present invention solves the aforesaid inherent problems associated with the replacement of existing elevator sill systems. Through the use of the present invention, the person desirous of replacing the existing elevator sill system no longer must remove it to replace it. Instead, the existing elevator sill system is field measured and a custom made sill foundation covering constructed from architecturally and/or aesthetically desirable materials specified is manufactured. An installer would then apply the custom made sill foundation covering on top of the existing elevator sill system. The sill foundation covering would be attached to the existing elevator sill system through the use of adhesive tape or other bonding chemicals or methods. The cladding of the existing elevator sill system, which in this case functions as a sill foundation, with the sill foundation covering does not interfere with the existing elevator door system, thus providing seamless integration between the sill foundation covering and the pre-existing elevator sill system. In another example, the existing elevator sill system requires routing so that the custom sill foundation covering can be integrated into the existing elevator door system. Once the required routing is completed, the sill foundation covering can be attached to the existing elevator sill system now functioning as the sill foundation in the same manner as above. In yet another example, the sill foundation covering is manufactured by bending metal sheet, such as nickel, nickel-steel, nickel-silver, iron, stainless steel and the like into the proper configuration by a proprietary process of “v-grooving” wherein a groove is first cut in the metal sheet via a custom v-groove machine to create “v-channels” where the bends in the sheet will occur to create sharp, angled, non-rounded edges. In other example, someone may wish to purchase a new elevator sill system. In this instance, the sill foundation device of the present invention is comprised of extruded aluminum, plastics or other manufactured materials such as PVC, acrylic, polycarbonate, ABS, polystyrene, epoxy, resin or epoxy resin that is formed into the necessary shape to fit the associated elevator and to accommodate the sill foundation covering. The combined sill foundation and sill foundation covering are of the proper dimensions and possess the proper grooves and tracks such that it can be integrated into the desired elevator door system. In this example, the integrated sill foundation covering and sill foundation of the present invention create an elevator sill system with identical external properties as more expensive currently existing elevator sills systems at a fraction of the cost. One of skill in the art will appreciate that the above examples do not limit the manner in which the device of the instant invention may be constructed and/or implemented but are just examples of the flexibility and low-cost of using the device of the present invention over known alternatives. Publications cited throughout this document are hereby incorporated by reference in their entirety. Although the various aspects of the invention have been illustrated above by reference to examples and preferred embodiments, it will be appreciated that the scope of the invention is defined not by the foregoing description but by the following claims properly construed under principles of patent law. Each and every feature described herein, and each and every combination of two or more of such features, is included within the scope of the present invention provided that the features included in such a combination are not mutually exclusive.
The present invention provides for an elevator sill system, consisting of both a cab sill and a hoistway sill that are comprised of a novel sill foundation and a corresponding and novel sill foundation covering, that when implemented together, provides for an elevator sill system of superior application, performance, durability and appearance at a comparatively low cost to standard and customized elevator sills.
1
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and apparatus for moistening or humidifying and cleaning or purifying the air of a room. The apparatus includes a housing that has at least one air inlet and one air outlet, with a lower part of the housing being embodied as a trough for a liquid. The apparatus also includes fan wheel means for generating an air flow through the housing, and a pump for producing a liquid flow within the housing. 2. Description of the Prior Art Known apparatus of this general type serves exclusively, or at least essentially, for humidifying the air in closed rooms, such as is necessary especially in winter in artificially heated rooms to produce a natural air moisture content in conformity with the temperature. The heretofore known apparatus operates pursuant to various methods, with the air being supplied with water droplets, water vapor, or water from evaporation. One generally differentiates between two systems, namely vaporizers, where the water is artificially evaporated by supplying heat thereto, and evaporators that essentially evaporate the water at room temperature by enlarging the surface area. Water vaporizers have the drawback that although they can supply water to the air, it is not possible to purify the air, because the water/air exchange takes place within the room. In addition, if poorly placed and/or overdosed, water vaporizers have the drawback that water droplets condense on objects in the room, especially on metal objects and windows. These particular drawbacks do not occur with evaporators. In the latter, an airstream, generated for example by a motor-driven fan, is conveyed through a very porous mat that is continually sprayed with water. The air that flows through the moistening mat is divided into a plurality of small airstreams that take up water as they flow through the mat. Apparatus operating pursuant to this system has the drawback that the moistening mats, depending upon the lime content of the water that is used, often become unusable already after a very short period of time due to a buildup of lime. Furthermore, such moistening mats are a constant breeding ground for bacteria, so that considerable maintenance is required in order to avoid undesirable odors. In order also to avoid these drawbacks, apparatus having no moistening mats were designed where the airstream was conveyed through a liquid stream that was preferably preliminarily swirled. One such apparatus is known from German patent No. 14 54 601--Katzman et al dated Dec. 2, 1971, corresponding to U.S. Pat. No. 3,283,478--Katzman et al dated Nov. 8, 1966, for a Humidifier. In this known apparatus, an airstream generated by a fan wheel, and a liquid stream produced by a rotary pump, were each conveyed to one side of a guide plate in the direction of a stationary impingement grate where the two streams were at least partially mixed together, and the air was enriched with water. The drawback with this heretofore known apparatus is that a portion of the air flowing through the apparatus can escape without coming into contact with the liquid. At the impingement grate, on which a main portion of the liquid evaporation takes place, deposits easily form that greatly reduce the effectiveness of this grate. In addition, there is a danger of bacteria formation. Unfortunately, it is nearly impossible to clean the grate since it is accessible only from one side unless the pump is disassembled. A further drawback of this apparatus is that the air is not purified to any great extent; furthermore, the volume of the air that passes through is relatively low. Proceeding from the last-mentioned state of the art, an object of the present invention is to provide an apparatus for purifying and humidifying the air of a room that avoids the aforementioned drawbacks and provides for a good purifying and humidifying effect of the air that passes through. BRIEF DESCRIPTION OF THE DRAWINGS This object, and other objects and advantages of the present invention, will appear more clearly from the following specification in conjunction with the accompanying schematic drawings, in which: FIG. 1 is a very simplified vertical cross-sectional view through one exemplary embodiment of the inventive apparatus, taken along the rotor axis; FIG. 2 is a partially broken away and sectioned side view of the apparatus of FIG. 1,; FIG. 3 is a detailed view of the rotor tube portion of the apparatus of FIG. 1; and FIG. 4 is an enlarged cross-sectional view taken along the line IV--IV in FIG. 3. SUMMARY OF THE INVENTION The apparatus of the present invention is characterized primarily in that a freely forming sheet-like stream of liquid is provided in a free space above the liquid level, with the air flow passing completely through this stream of liquid. The inventive construction of the humidifying and purifying apparatus avoids the aforementioned drawbacks. At the same time, an intensive purifying and humidifying of the air that flows through the apparatus is achieved. The inventive construction makes it possible to have a high rate of flow while the overall size of the apparatus is relatively small. During operation, the liquid, preferably water, is conveyed upwardly by the driven rotor of the rotary pump, where the liquid flows out of the outlet channels that are disposed radially about the axis of the rotor, and then flows into the free space between the surface of the liquid and the inside of the housing. An umbrella-like swirl of water results due to the essentially horizontal discharge of the water streams, accompanied by simultaneous rotation. At the same time, the fan wheel conveys a strong air flow through this rotating swirl of water. When the air flow meets the swirl of water the air flow is spun into a plurality of partial flows, so that an intensive, mutual swirling through of water and air takes place. In so doing, the air that is flowing through the swirl of water takes up a large amount of water; at the same time, dirt particles contained in the air flow are washed out. The washed-out dirt remains in the liquid cycle and settles to the bottom of the supply tank. Since the entire air flow, in order to leave the housing, must flow through the swirl of liquid, a high degree of humidification and a good purifying effect are achieved. To protect the liquid cycle from larger particles of dirt, it is advantageous to dispose an air filter after the air inlet opening means in the direction of flow of air. This air filter is preferably a replaceable filter unit that is mounted in the cover of the housing. A particularly advantageous construction results if the housing is essentially in two parts, including a trough-like lower housing part having a liquid supply and collection tank, and a cover for closing off the tank. The units for producing the air and liquid flows are then provided in the cover. With such an arrangement where only a single drive motor is provided for the pump and fan wheel, with a fan wheel for generating the air flow and therebelow the pump rotor for generating the liquid stream both being seated on the motor shaft, it is particularly advantageous if the air outlet opening is disposed in the cover concentric to the drive motor, because with such an arrangement the cross-sectional area of the outlet opening can be relatively large, as a result of which the resistance to flow of the air through the apparatus is reduced and a greater through put of air can be achieved. In this connection, the air inlet opening means is advantageously disposed next to the air outlet opening in the cover of the housing, so that in operation air flows through practically the entire surface of the cover, as a result of which it is even possible with smaller apparatus to have a great through put of air. To prevent drops of liquid (mist) from being carried outwardly by the air flow, it is proposed pursuant to a further specific embodiment of the present invention to dispose a drop separator ahead of the air outlet opening in the direction of flow of the air, preferably even ahead of the fan wheel. To facilitate handling of the apparatus, an opening is advantageously provided in the apparatus for filling the tank up with liquid; especially with large apparatus, an outlet is advantageously provided for draining and replacing the liquid. An appropriate indicator can be provided in the cover or in the wall of the housing to indicate the level of filling. This indicator can operate, for example, pursuant to the float principle. In order to assure sufficient cooling of the motor even when the apparatus is in constant operation, it is advantageous to provide a cooling air vein above the pump rotor, on the drive shaft of the motor, for cooling the latter. In order to achieve as rapid a mixture of the humidified air with the remaining air in the room, it is advantageous to provide appropriate guide surfaces within the air outlet opening. These guide surfaces cause the air to flow out in a laminar fashion. In this way, not only is the mixture of the air in the room enhanced, but the noise level of the apparatus is also reduced. To achieve a constant air humidity, the apparatus is advantageously provided with a control and adjustment device that automatically turns the apparatus off, for example when a specific air moisture content has been achieved, and that again turns the apparatus on when the humidity drops below a certain value. The operating state and/or the desired and actual parameters can be indicated by an appropriate indicator disposed on the apparatus. To facilitate cleaning of the apparatus, the inner surfaces of the apparatus are advantageously smooth. To positively guide the entire air flow through the swirl of liquid, it is proposed pursuant to a further embodiment of the present invention to provide a circumferential rib on the underside of the cover. During operation, this rib provides a lateral boundary for the stream range from all of the outlet channels, so that the air outlet opening, which is preferably disposed inwardly of this circumferential rib, is completely blocked-off from the swirl of liquid. Pursuant to one particularly advantageous embodiment of the pump rotor, the upper end of the rotor tube is seated in, at a distance from, a member that is rigidly connected with the tube and surrounds the upper end thereof. This member, together with the tube, forms an annular channel that runs downwardly from the top and then outwardly, opening into the discharge channels. The latter are formed by a horizontal gap that is interrupted by ribs and that is provided between the underside of the member rigidly connected with the tube and an annular disk disposed on the outer side of the tube. The fan wheel for generating the air flow, and the fan wheel for generating the cooling air flow, can both be integrally formed with the rotor tube, with both fans wheels being coaxial to one another and being connected to the tube via the member that surrounds the upper end thereof. With this inventive embodiment, the air is advantageously guided into the air outlet opening, and the drive motor is reliably protected from spraying water by the upper part of the rotor. Further specific features of the present invention will be described in detail subsequently. DESCRIPTION OF PREFERRED EMBODIMENTS Referring now to the drawings in detail, the illustrated apparatus includes an essentially two-part housing that has a smooth inner surface. The housing comprises a lower housing part 1, which is the water supply tank, and a cover 3. The lower housing part 1 is in the shape of a trough and serves as supply and collection tank that is filled with water 2 during operation. At the top, the supply tank 1 has a circumferential rim 1' that has an approximately L-shaped cross-sectional shape and projects laterally beyond the side walls of the tank 1. The rim 1' forms the support surface for the housing cover 3, the outer edge of which, during operation, rests upon the horizontal surface of the rim 1' and is secured by the vertical portion of the rim 1' from shifting to the side. A motor housing 4, in which is disposed a drive motor 5, projects beyond a portion of the top of the cover 3. The drive motor 5 has a motor shaft 6 that is directed vertically downwardly. Disposed on the motor shaft 6 are an outer fan wheel 7, an inner fan wheel 8, and the rotor 9 of a rotary pump. In the illustrated embodiment, the outer fan wheel 7 and the inner fan wheel 8 are advantageously integrally formed with the rotor 9. The rotor 9 of the rotary pump comprises a tube that tapers conically downwardly and that has an axial inlet opening 10 at its lower end. The length of the rotor tube 9 is such that the opening 10 is spaced slightly from the base 11 of the supply tank 1 when the cover 3 is placed on the latter. The tube 9 extends upwardly to within the inner fan wheel 8, where it ends at a distance from an annular disk 12. Near its inner side, the annular disk 12 has a downwardly directed, hollow cylindrical part 13 with which the annular disk 12, as well as the parts 7, 8, and 9 that are fixedly connected thereto, are nonrotatably connected to the drive shaft 6 of the motor 5. An approximately hollow cylindrical, downwardly directed part 14 is connected near the outer periphery of the annular disk 12. This part 14 surrounds the upper part of the tube 9, with spacing, with the inner periphery of the part 14 widening conically from the top toward the bottom. In the upper region of the tube 9, where it is surrounded with spacing by the part 14, the outer surface of the tube 9 has a diameter that increases from the top toward the bottom, so that an annular channel 15 is formed between the part 14 and the upper part of the tube 9. The distance of the annular channel 15 from the axis of rotation of 16 of the rotor increases from the top toward the bottom. The annular channel 15 is delimited by an annular disk 17 that extends perpendicular to the axis of rotation 16 and is disposed on the outer periphery of the tube 9. The disk 17 is spaced from a similarly annular disk 18 that is connected to the bottom of the approximately hollow cylindrical part 14 on the outside thereof. The annular disks 17 and 18 are interconnected by radially extending ribs 19 so that outlet channels 20 are formed between the disks 17 and 18. These outlet channels 20 are disposed in a star-shaped and radial manner relative to the axis of rotation 16 (see FIGS. 1, 3, and 4). Via the ribs 19, the rotor 9 is connected to the motor shaft 6 via the parts 18, 14, 12, and 13. Connected to the outer periphery of the annular disk 18 is a hollow cylindrical part 21 that first extends upwardly and outwardly, is then directed cylindrically upwardly, and ends approximately at the level of the annular disk 12. Disposed between the inner hollow cylindrical part 14, the annular disk 18, and the outer hollow cylindrical part 21 are a plurality of fan blades that are disposed radially relative to the axis of rotation 16 and that form the inner fan wheel 8. Disposed on the straight outer surface of the hollow cylindrical part 21 are a plurality of fan blades that are similarly radially disposed relative to the axis of rotation 16 and that form the outer fan wheel 7. In the illustrated embodiment, the fan blades of the outer fan wheel 7 are provided on the outer periphery with a stabilizing ring 22 that extends over the entire height of the fan blades. The inner fan wheel 8 serves for cooling the motor 5, and conveys cooling air into the motor housing 4. The air can exit at the top of the housing 4 via appropriate ventilation openings 23. The motor housing 4 is approximately cylindrical and is connected to a hollow cylindrical cover part 24 of greater diameter by not-illustrated connecting ribs. In the illustrated embodiment, the cover part 24 is securely seated in an appropriate recessed portion in the cover 3. The annular space between the motor housing 4 and the hollow cylindrical cover part 24 forms an air outlet opening 25 for the air flow 34 that can be produced by the outer fan wheel 7. Air inlet means 26 for this air flow 34 is provided in the cover 3 next to the hollow cylindrical cover part 24. In the illustrated embodiment, the air inlet means 26 is completed by a cover grating 27 that is disposed flush in the upper side of the cover 3. Disposed below the cover grating 27 is an air filter 28 that is completed on the underside by a further cover grating 27. For this purpose, as can be seen in FIG. 1, the cover 3 has appropriate rims in which are held the cover gratings 27 and 29 and the air filter 28 that is disposed therebetween. The air inlet means 26 can extend over nearly the entire surface of the cover 3 externally of the cover part 24. In this way, despite the provision of an air filter 28, little resistance to the flow-through of air results. Provided on the underside of the cover 3, concentric to the axis of rotation 16, is a downwardly directed, circumferential rib 30 that extends to a level that is in the region between the outlet channels 20 and the surface 31 of the water 2. In the illustrated embodiment, on the outer side of the cover 3 (the left side in FIG. 1), the rib 30 merges into the rim of the cover. The rib 30 is embodied and disposed in such a way that the streams of water 32, which during operation exit the outlet channels 20 and form sheet-like swirls of water due to the rotation of the rotary pump rotor 9, extend to the inner side of the rib 30, so that the air flow 34 that flows through housing can reach the air outlet opening 25 only by passing through the swirl of water. A drop separator 35, which in this embodiment is ring-shaped, is disposed within the rib 30 below and at a slight distance from the outer fan wheel 7. The outer periphery of the separator 35 is secured to a downwardly directed rib of the cover 3. The drop separator 35 extends nearly to the hollow cylindrical part 21 that is disposed between the inner and outer fan wheels 8 and 7. During operation, the water droplets that are carried along by the air flow 34 are separated by the drop separator 35 and are returned to the supply tank 1. During operation of the inventive apparatus the motor 5 is driven, thereby turning the parts 7, 8, and 9 that are securely connected to the motor shaft 6. In so doing, due to the inner fan wheel 8, a cooling airstream is provided through the motor housing 4. This airstream exits through the ventilation openings 23 at the top of the housing 4. By rotating the rotor tube 9, which operates as a pump tube pursuant to the rotary pump principle, a stream of water 33 is provided within the tube 9. During rotation, the lower part of the pump tube 9 that extends into the supply of liquid 2 in the tank 1, due to the adhesive capacity on the inner surface of the tube and the centrifugal forces that result during rotation, conveys the stream of water 33, which first rises from the inlet opening 10 of the pump tube 9 due to the communicating effect and then rises upwardly to the end of the tube due to the described pump affect, where, due to the centrifugal force, it is pressed outwardly and then changes direction by 180°. After this change of direction, the stream of water 33, due to centrifugal force flows through the annular channel 15 where, due to the high centrifugal forces that are produced at this location due to the great circumferential speed, the water is again accelerated and finally obtains its greatest acceleration in the approximately horizontal outlet channels 20. The acceleration within the annular channel 15 is at that location advantageously enhanced by the force of gravity. The stream of water 33, which is divided into numerous streams of water 32 by the outlet channels 20, due to the rotation of the rotor 9, is formed into a vigorously pulsating, umbrella-like swirl of water. This swirl of water fills the region between the outlet channels 20 and the circumferential rib 30. The air flow 34 produced by the rotation of the outer fan wheel 7 must pass through the swirl of water 32. In so doing, the air flow 34 that passes through the swirl of water 32 is divided into a number of swirling airstreams that experience an intensive mixing as they pass through the swirl of water 32, so that the air takes up a lot of water while at the same time dirt particles are washed out of the air. The air flow 34 that flows through the apparatus is drawn in through the air inlet means 26, whereafter larger particles of dirt are retained in the air filter 28. The thus preliminarily purified air flow 34 flows between the underside of the cover and the surface 31 of the water to below the umbrella-like swirl of water 32, through which the air passes. After passing through the drop separator 35, the air exits through the air outlet opening 25 and again passes into the atmosphere. During this process, the rib 30 prevents any of the air flow 34 from exiting without passing through the swirl of water 32. In the illustrated embodiment, guide vanes 36 are disposed in the upper region of the annular air outlet opening 25. These guide vanes 36 insure a good distribution of the humidified and purified air with the ambient air, since they deliver a laminar discharge. As can be seen in FIG. 2, the inventive apparatus also has a condition of filling indicator 43 with a float ball 44 that indicates the water level within the supply tank 1. A closeable filling opening 40 is provided on the apparatus to refill the tank with water. The apparatus is also provided with a lower outlet 41 that can be closed off by screwing a cap 42 thereon. The desired operating condition can be maintained with a control and adjustment device 45 and indicator lights 46; the setting can thereby be read from the outside. The one-piece construction of the rotor with the fan wheels 7 and 8 is particularly advantageous; however, the aforementioned parts can also be individually mounted on the drive shaft 6. In such a case, the rotor 9 should be embodied in such a way that the previously described guidance of the stream of water 33 via the pump tube 9 is still retained through the annular channel 15 to the outlet channels 20 after the direction is changed by 180°. This construction is particularly advantageous, since in this way a high acceleration of the stream of water 32 up to discharge from the outlet channels 20 results, as a result of which a freer, flatter swirl of water is produced within the supply tank, through which swirl of water the air flow 34 is conveyed for purifying and humidifying the latter. The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
An apparatus for humidifying and purifying the air of a room. The apparatus has a water supply tank with a cover in which is mounted a motor. Disposed on the motor shaft is a fan wheel for generating a flow of air through the housing, a fan wheel for cooling the motor, and a pump tube. When the pump tube is rotated, it delivers a stream of liquid that leaves the pump tube as a free, sheet-like swirl of water through which the air flow is positively guided. Consequently, the air flowing through the swirl of water is purified and humidified.
5
BACKGROUND AND SUMMARY OF THE INVENTION In the construction of artificial Christmas trees, one of the convention techniques is to provide a central pole supported vertically by a suitable mounting stand. A series of sleeves is received over the central pole to provide for the mounting of artificial branches, and spacing between levels of branches. The branch structure for many of the artificial tree designs includes a wire element having a short, generally vertical mounting section and which is bent at an angle to provide a radially outwardly and slightly upwardly extending branch arm or limb portion that mounts the artificial needles, and in some cases, subsidiary branching. Branch elements for the lower portion of the tree are, of course, of a relatively substantial length, with the length of branches at successively higher levels becoming progressively shorter to provide the traditional conical Christmas tree configuration. Typically, the mounting sleeves for the branch structure are provided with a series of radially spaced vertical bores, to receive the vertical mounting portions of the branch wires. In addition, the inner limb portions of the branch wires may be received in radially spaced, upwardly inclined grooves or channels, which serve both to radially orient the branches and to provide additional support to the inner portions thereof. Because artificial trees are intended to be reused, year after year, provision is usually made for removal of the individual branches from their mounting sockets, to enable the components of the tree to be packed away in a conveniently small space. In the most common forms of artificial Christmas trees, the disassembly/reassembly operation can involve considerable time, not only because of the time required to assemble a relatively large number of branches into their respective mounting sleeve elements, but also because the branches are of different sizes and must be assembled at the proper level on the tree. Efforts have been made, of course, to construct artificial Christmas trees to have a folding branch structure so that, ideally, putting away of the artificial tree for the next season can be accomplished by simply folding the branches upwardly, close in to the central pole. Examples of prior attempts to construct such folding trees are represented by the Abramson U.S. Pat. No. 3,115,435, the Hermanson U.S. Pat. No. 3,829,349 and the Wang U.S. Pat. No. 4,468,421. The structures of these representative patents, while presumably serving the basic purpose of providing a foldable structure, all require the use of special, non-standard branch constructions, so that special branch-making machinery is required to carry out these designs. That requirement impacts very negatively on the economics of the production and marketing of trees of this type. In accordance with the present invention, a novel and improved structural arrangement is provided for artificial Christmas trees and the like, which provides for permanently or semipermanently assembled branches which fold upwardly for storage, yet which accommodates the use of conventionally manufactured bent wire branch elements, produced by conventional, existing machinery. The construction of the invention thus enables, full utilization to be made of the significant installed base of branch-making machinery. In accordance with a more specific aspect of the present invention, a foldable branch mounting arrangement is provided which includes a branch-mounting sleeve formed with -5 a plurality of radially oriented branch receiving slots and further includes special branch-receiving adapter elements arranged to be pivotably mounted by the sleeve. The adapters and sleeve are of molded plastic construction, and the adapters are specially constructed to receive the base portions of conventionally configured bent wire branches. In accordance with the invention, the branch-holding adapter is arranged to be assembled with a branch element while separate and independent from the mounting sleeve. After joining the branch to the adapter, the adapter is inserted in one of the branch-receiving slots of a mounting sleeve and secured therein for pivoting movement. The geometry of the adapter is such as to provide substantial support for the branch in its normal position, while allowing upward pivoting of the branch for storage of the tree between seasons. To particular advantage, each of the branch-receiving radial slots of the branch mounting sleeve is provided with a horizontal pivot bar. The adapters are provided with open-sided bores for the reception of such pivot bars, to provide for the support and pivoted mounting of the branches and their adapters. A snap-in assembly is accommodated by this design, so that the parts may be easily assembled in the first instance but will remain permanently assembled unless there is a special reason for disassembly. For a better understanding of the above and other features and advantages of the invention, reference should be made to the following detailed description of a preferred embodiment, and to the accompanying drawing. DESCRIPTION OF THE DRAWINGS FIGS. 1 and 2 are simplified, schematic representations of an artificial Christmas tree of the type contemplated by the present invention, illustrating the tree in its normal display position (FIG. 1) and in a folded position (FIG. 1). FIG. 3 is an enlarged top plan view of a branch-mounting sleeve constructed according to the invention and mounting a branch and adapter. FIG. 4 is a cross sectional view as taken generally on line 4--4 of FIG. 3. FIG. 5 is a perspective view illustrating a branch-mounting adapter constructed according to the invention. FIGS. 6 and 7 are sequential top views illustrating the manner in which a conventional branch is assembled together with the adapter of FIG. 5. FIG. 8 is an illustration of the procedure for assembly of a branch and its adapter to the branch-mounting sleeve of FIG. 3. FIG. 9 is a fragmentary cross sectional illustration, showing the branch and adapter mounted in the sleeve, and illustrating the normal and folded positions of the branch. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawing, the reference numeral 10 designates generally the trunk assembly of an artificial tree, which is supported by a suitable base 11. The trunk assembly typically includes a central support pole 12, a plurality of branch support sleeves 13, and intervening spacer sleeves 14. In some cases, the spacer sleeves 14 may be eliminated, with other means being provided to locate the branch-mounting sleeves 13 at various appropriate locations along the vertical height of the central pole 12. Individual branches 15 are supported in a radially spaced array by each of the branch-mounting sleeves 13, in a known configuration. With the structure of the invention, the individual branches 15 may be, and advantageously are, of a well-known, conventional construction. To this end, the branches are wire construction, possibly of solid wire, as shown in the drawings, or perhaps, more typically, of a twisted wire construction, such as shown in the Chase U.S. Pat. No. 4,343,842, for example. In either case, the branch 15 includes a short, generally vertically oriented mounting portion 16 joined at an arcuate bend 17 with an outwardly and upwardly extending limb portion 18, to which is mounted an arrangement of needles 19. For particularly high quality constructions, the outer portions of each branch may include subsidiary branching, as illustrated in FIG. 1, but that is independent of the subject matter of the present invention. With reference now to FIGS. 3 and 4, the branch-mounting sleeve preferably utilized in the practice of the invention is formed of injection molded plastic material, such as rigid PVC, and includes a central, cylindrical portion 20 from which project a plurality of pairs of recess forming walls 21, each pair forming between them a radially oriented vertical recess 22. The inside walls of the recesses 22 are formed by H) the outer surface of the cylindrical sleeve portion 20. At least the upper and outer portions of the recesses are open, and for the purpose of simplicity also preferably the bottoms as well. In the illustrated device, there are six pairs of recess forming walls 21, arranged at angles of 60 degrees. The particular geometry, however, will be a function of the size of the tree and other factors. Extending between each of the walls 21 of a recess-forming pair is an integral cylindrical pivot bar 23, which is arranged to form a pivot support for the tree branch structure, to be further described. Between each adjacent, angularly disposed pair of recess forming walls 21 is a strengthening web 24. To facilitate molding of the product, the walls of the cylindrical portion 20 may taper slightly from top to bottom, in which case the sleeve may be provided internally with a series of tapered ribs 25 to provide snug support with the outer wall of the central tubular post 12. In accordance with the invention, a novel and improved branch-holding adapter element 30 is provided, which is arranged to receive and retain a branch of conventional, bent wire construction and to enable such conventional branch to be pivotally mounted within each recess 22 of the branch-mounting sleeve 13. The adapter element 30, shown in detail in FIGS. 5-9 of the drawing, is ideally of injection molded construction, typically of the same material used in the molding of the sleeve 13. The adapter is formed with a horizontal, cylindrical bore 31, extending from side to side and partially open along its bottom side 32, below the diameter of the circular section, so that the opening 32 is somewhat smaller than the diameter of the bore. As reflected in the drawing, the adapter 30 is somewhat in the form of an inverted "J", including a downwardly extending support leg 33 of considerable length and a short, downwardly projecting front leg 34. The front surface 35 of the support leg 33 and the rearwardly facing surface 36 of the short front leg 34 desirably define a convergent guide leading to the restricted opening 32 into the bore 31. This arrangement facilitates assembly of the adapter to the mounting sleeve 13, as will be further described. The side-to-side thickness of the adapter 30 is substantially the same as the width of the recesses 22, such that, when the adapter is inserted in one of the recesses 22, it is closely confined therein. In accordance with the invention, the support leg 33 is provided with a vertical recess 37. Desirably, the recess is in the form of a bore of a size to closely and snugly receive the vertically-extending mounting portion 16 of the branch wire. Further, the adapter is provided with an open-sided recess 38 of a size and shape to conform generally to the arcuate portion 17 and inner limb portions of the branch wire. The recess is defined on the top by an integral plastic abutment tab 39, which extends generally horizontally from one side of the adapter and is arranged to overlie inner limb portions of the branch wire 18 in the assembled device. As reflected particularly in FIG. 8, the rearward edge extremity 40 of the abutment tab is generally aligned with the front extremity of the vertical bore 37. This provides vertical clearance which enables the branch 15 to be assembled with the adapter. This is done by first orienting the adapter and branch at right angles to each other (see FIG. 6) and then inserting the mounting portion 16 of the wire vertically downward into the adapter recess 37. Once the branch wire is properly positioned in the recess 37, the adapter and wire may be rotated into alignment (see FIG. 7). In this aligned position, the wire is restricted against vertical removal from the adapter bore 37 by the presence of the overlying abutment tab 39. To advantage, the adapter 30 is shaped with an upwardly facing arcuate support surface 41 adapted to conform to the inside radius of the curved portion 17 of the branch wire, such that, after the wire is properly assembled with the adapter, the wire is retained snugly between the abutment tab 39 and the arcuate surface 41. At the forward extremity of the adapter, the lower surface 42 may advantageously diverge slightly from the confining surface of the abutment tab 39 to accommodate slightly varying bend angles of the branch 15. Pursuant to the invention, after mounting of the adapter 30 at the base end of the branch wire, the adapter is assembled to the branch-mounting sleeve 13 by aligning the parts substantially in the manner shown in FIG. 8 and pressing the assembled branch and adapter downwardly with sufficient force to cause the pivot bar 23 to snap into the bore 31. In this respect, there is sufficient resilience in the plastic material of which the adapter is formed to allow the front portion to deflect outwardly enough to accommodate the snap-in assembly operation. As reflected in FIG. 9, the spacing between the pivot bar 23 and the back wall 45 of the recess 22 equals the distance between the adapter bore 31 and the adapter back wall 46 such that, when the adapter is properly seated on the pivot bar 23, the support leg 33 and the wire mounting portion 16 inserted therein are supported in a substantially vertical orientation. In this respect, it will be understood that the downward weight upon the outer portion of the branch will tend to pivot the outer portion downward which will, in turn, press the support leg 33 of the adapter firmly against the back wall 45 of the recess 22. As reflected in FIG. 9, for example, the recess-forming walls 22 extend outward a sufficient distance to completely enclose the adapter 30 so as to provide firm side-to-side support thereof. In addition, the side opening recess 38 of the adapter is confronted by the adjacent recess-forming wall 21 so that, after assembly of the adapter onto the pivot bar 23, the branch wire 18 can no longer be swung at right angles to the adapter. Accordingly, it is no longer possible to remove the branch wire independently of the complete assembly of branch wire and adapter. In order to separate the branch wire from the adapter, it is first necessary to detach the assembly from the pivot bar 23, remove it from the recess 22 and then effect disassembly of wire and adapter. In normal usage, this will not take place, as it is intended that the adapters 30 will remain permanently attached to their respective pivot bars 23 in normal usage. For dismantling and/or storing of the tree after usage, the branches 15 may be pivoted upward, to a position such as shown in dotted lines in FIG. 9. To this end, the upper arcuate contours of the adapter, as indicated at 47 (FIG. 8) forms a radius about a point preferably located below the axis of the pivot bar 23, so as to provide assured clearance along the recess inner wall 45, when the branch and adapter are pivoted upwardly. Of particular significance in the apparatus of the present invention is the ability to utilize branch structures of wholly conventional and widely utilized configuration. In this respect, the need for utilizing special branch configurations in order to accommodated pivoting action of the branches for stow-away purposes constitutes a major economic impediment to commercial adoption of such designs. The arrangement according to the invention, by providing a unique and advantageous adapter element, enables the fold-away construction to be incorporated in an artificial Christmas tree while at the same time allowing conventional branching to be utilized. The mounting sleeve and adapter element may be economically produced by high volume, injection molding procedures and the necessary assembly operations to join the adapter to the conventional branching may be easily and quickly accomplished. One of the very desirable features of the new adapter element resides in the provision of an open-sided recess for receiving the arcuate portion of the branch wire while allowing the branch wire to be confined at the top against separation from the adapter. The initial assembly is enabled by rotationally orienting parts at an angle to each other to accommodate insertion of the wire to the adapter. Thereafter, after the assembled adapter and wire have been joined with the mounting sleeve, the open sided recess is effectively closed by a confronting surface of the recess-forming wall in the mounting sleeve. It should be understood, of course, that the specific form of the invention herein illustrated and described is intended to be representative only and certain changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention.
An artificial Christmas tree with folding branches is disclosed. A special form of branch-mounting sleeve and adapter element allow pivoting action to be achieved while enabling the use of conventional, readily-available bent wire branch elements. The adapter element is initially assembled with the bent wire branch, after which the adapter is snapped onto a pivot bar formed by the branch mounting sleeve. The branch wire and adapter are inseparably assembled once the adapter is pivotally attached to the sleeve. Considerable savings are realized by the ability to use conventional bent wire branches.
0
BACKGROUND OF THE INVENTION The present invention relates to a method and an apparatus for special reproduction of coded data stored via communication media or the like or coded video or audio data read out from recording media such as disks. And more particularly, the invention is adapted for reverse reproduction of coded data. In recording media such as digital video disks (hereinafter referred to as DVD), communication media such as LAN (Local Area Network) or broadcasting media such as satellites which are used for processing video and audio signals converted into digital data, it is usual that the data are digitally compressed and coded so that the video and audio signals can be processed efficiently. One of the data compression and coding systems proposed for that purpose is the MPEG (Motion Picture coding Experts Group) system. Now an exemplary MPEG coder will be described below with reference to FIG. 32. The MPEG coder is so designed as to perform data compression of a video input signal by executing any one of the following three predictive coding modes, wherein the digitized video input signal is supplied first to a motion detector 101 which detects a motion vector for motion compensative prediction per minimum unit of the motion compensative prediction. Thereafter predictive coding of the signal is performed in a next predictive coding circuit, wherein one of the following three predictive coding modes is executed to obtain: (1) an intra-frame coded picture (I-picture) by coding the video input signal within a frame; (2) an inter-frame forward predictive coded picture (P-picture) by coding the video input signal only in a forward direction; or (3) a bidirectionally predictive coded picture (B-picture) by coding the video input signal in both forward and backward directions. More specifically, in a DCT 103 of the predictive coding circuit, the video input signal supplied thereto via a subtracter 102 is processed through discrete cosine transform (DCT) which is a kind of Fourier transform, and a DCT coefficient obtained as a result of such transform is quantized in a quantizer (Q) 104. Subsequently to the quantization, the signal is variable-length coded in a variable-length coder (VLC) 109 where a code of a length different depending on the incidence probability is allocated. The coded signal thus quantized is dequantized in a dequantizer (IQ) 105, and then is supplied to an inverse DCT (IDCT) 106 where the signal is processed through inverse discrete cosine transform. Subsequently an output of a frame memory predictor 108 is added thereto to consequently reproduce the original video signal. The reproduced video signal is supplied as a prediction signal to the subtracter 102 so as to be subtracted from the input video signal, whereby a difference signal between the input video signal and the prediction signal is outputted from the subtracter 102. Accordingly the coded signal outputted from the quantizer 104 is a difference signal, and since this difference signal is processed through discrete cosine transform to be thereby quantized, the coded signal is compressed. The coded signal thus compressed is then supplied to the variable-length coder 109, where entropy coding is executed on the basis of the occurrence frequency deflection, so that the code is further compressed. Thereafter in a multiplexer 110, the compressed coded signal is multiplexed with the prediction mode data indicative of the I-picture, P-picture or B-picture and the motion vector data. However, since the multiplexed data are generated at an irregular rate, such data are once stored in a buffer 111 and then are outputted therefrom at a fixed code rate. In order to fix the average code rate, the code quantity may be controlled by changing the quantization scale factor q of the quantizer 104 in accordance with the code quantity stored in the buffer 111. FIG. 33A shows an exemplary structure of inter-frame prediction obtained among the predictive-coded frames. A data unit termed a GOP (Group of Pictures) may be composed of, e.g., 15 frames as illustrated in this diagram. In this case, since a random access is necessary in one GOP, at least one frame of an I-picture is required within the GOP, so that there are 1 frame of an I-picture, 4 frames of P-pictures predicted from the temporally preceding I-pictures or P-pictures, and remaining 10 frames of B-pictures predicted from the temporally preceding and succeeding I-pictures or P-pictures. A GOP is a coding unit corresponding to each segment of one sequence of motion pictures. More specifically, as indicated by arrows in FIG. 33A, an I-picture 1I is coded by intra-frame prediction within that frame alone, a P-picture 4P is coded by inter-frame prediction with reference to the I-picture 1I, a P-picture 7P is coded by inter-frame prediction with reference to the P-picture 4P, a P-picture 10P is coded by inter-frame prediction with reference to the P-picture 7P, and a P-picture 13P is coded by inter-frame prediction with reference to the P-picture 10P. Further, B-pictures 2B and 3B are coded by inter-frame prediction with reference to both of the I-picture 1P and the P-picture 4P, and B-pictures 5B and 6B are coded by inter-frame prediction with reference to both of the P-picture 4P and the P-picture 7P. Similarly, subsequent pictures are coded by such prediction in the manner indicated by arrows. The numbers of I, P and B represent the ordinal numbers of original pictures. In decoding the predictive-coded pictures mentioned, the I-picture can be decoded alone since it is predictive-coded within the frame. However, as any P-picture is coded with reference to the temporally preceding I-picture or P-picture, such preceding I-picture or P-picture is required at the decoding time. Similarly, in decoding any B-picture coded with reference to the temporally preceding and succeeding I-pictures or P-pictures, such preceding and succeeding I-pictures or P-pictures are required. For this reason, the pictures are positionally changed as illustrated in FIG. 33B so that the pictures required at the decoding time can be decoded in advance. As illustrated in FIG. 34A, such positional changes are so made that the I-picture 1I precedes the B-pictures -B and 0B since the B-pictures -1B and 0B require the I-picture 1I at the decoding time, and also that the P-picture 4P precedes the B-pictures 2B and 3B since the B-pictures 2B and 3B require the I-picture 1I and the P-picture 4P. Similarly, the pictures are positionally so changed that the P-picture 7P precedes the B-pictures 5B and 6B since the B-pictures 5B and 6B requires the P-pictures 4P and 7P at the decoding time, and also that the P-picture 10P precedes the B-pictures 8B and 9B since the B-pictures 8B and 9B require the P-pictures 7P and 10P at the decoding time. In the same manner, such positional changes are so made that the P-picture 13P precedes the B-pictures 11B and 12B. The I-, P- and B-pictures thus arranged in the order shown in FIG. 34B are converted into on-medium coded video data in FIG. 34C so as to be recordable on a recording medium such as a DVD. Then the on-medium coded video data are read out therefrom to become decoded video data in the order shown in FIG. 34D. Subsequently, in displaying normal reproduced pictures, the decoded video data are rearranged in the order which is indicated by suffixes in FIG. 34C and corresponds to the original picture order, whereby normal pictures are displayed on a display device. When displaying special reproduced pictures which are in a reverse direction of reproduction, it is necessary to display the pictures in the reverse order of the original pictures shown in FIG. 34A, as 12B, 11B, 10P, 9B . . . and so on. Therefore, in the case of decoding the B-picture 12B for example, since this B-picture 12B is a coded picture predicted from the P-pictures 10P and 13P, these P-pictures 10P and 13P need to be decoded in advance. Further the P-picture 7P is required for obtaining the decoded P-picture 10P, and the P-picture 4P is required for obtaining the P-picture 7P, and the I-picture 1I is required for obtaining the P-picture 4P. Consequently, even in such reverse reproduction, it is necessary to perform successive operations of first reading out and decoding the I-picture 1I, then decoding the P-picture 4P, subsequently decoding the P-picture 7P and next decoding the P-picture 10P. It is further necessary to decode the P-picture 13P from the P-picture 10P to finally achieve desired decoding of the B-picture 12B from the P-pictures 10P and 13P. In succession, the B-picture 11B can be decoded from the P-pictures 10P and 13P, and further the P-picture 10P can be immediately outputted since it has already been decoded. However, as the P-picture 7P is required for decoding the B-pictures 9B and 8B, it is necessary to decode the P-picture 7P by reading out the I-picture 1I again and then decoding the P-pictures sequentially. For reversely reproducing the video data of the MPEG standard in the reverse order of the original pictures, a greater number of decoding steps are needed in comparison with ordinary reproduction and a longer time is required until display of the pictures, so that it is necessary to increase the data transfer rate and so forth to the decoder for shortening the delay time. Furthermore, due to the limited storage capacity of a frame memory, I- and P-pictures need to be decoded so many times. Therefore, it has been customary in the prior art to solve the above problems by decoding and displaying merely the I-picture in a reverse reproduction mode. However, when only the I-picture alone is displayed, merely one picture is obtained per 15 frames for example as shown in FIG. 33, and it follows that an extremely reduced number of the pictures are displayed to consequently become unnatural. SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide improvements in a method and an apparatus for special reproduction of coded data, wherein special reproduction in a reverse direction and so forth can be achieved to realize natural reproduced pictures on a display device without the necessity of raising a coded-data transfer rate to a decoder or increasing the storage capacity of a frame memory either. According to one aspect of the present invention, there is provided a coded-data special reproduction method which reads out and decodes a unit group of intra-frame coded data, inter-frame forward predictive coded data and bidirectionally predictive coded data, then writes the decoded data into a frame buffer means and, after reading out the data from the frame buffer means, displays such data. The method comprises the steps of: continuously decoding portions of the intra-frame coded data and the inter-frame forward predictive coded data constituting the unit group read out, while intermittently decoding the remaining coded data; subsequently writing the decoded data in the frame buffer means; then reading out the data from the frame buffer means in the reverse order of the original pictures; and displaying the pictures thus read out. In the coded-data special reproduction method mentioned above, some portion of the bidirectionally predictive coded data also is decoded intermittently. In decoding the unit group of data by the above method, priority is granted to the intra-frame coded data and the inter-frame forward predictive coded data anterior to the intra-frame coded data appearing first in the unit data. Further, the unit group of data is composed of a block consisting of two or more unit data. And when a picture to be displayed next has not yet been written in the frame buffer, the picture being displayed now is continuously displayed. According to another aspect of the present invention, there is provided an apparatus capable of carrying out the above coded-data special reproduction method. This apparatus comprises: a buffer for storing read unit data composed of intra-frame coded data, inter-frame forward predictive data and bidirectionally predictive coded data; a decoder for decoding the coded data obtained from the buffer; and a frame buffer for storing the respective coded data decoded by the decoder; wherein some portions of the intra-frame coded data, the inter-frame forward predictive coded data and the bidirectionally predictive coded data constituting the unit group are read out continuously from the buffer and are decoded, while the remaining portions of the data are read out intermittently therefrom and are decoded, and after the decoded data are written in the frame buffer, the data are read out from the frame buffer in the reverse order of the original pictures and then are displayed. In the coded-data special reproduction apparatus mentioned above, some portion of the bidirectionally predictive coded data also is decoded intermittently. In decoding the unit group of data in the above apparatus, priority is granted to the intra-frame coded data and the inter-frame forward predictive coded data anterior to the intra-frame coded data appearing first in the unit data. Further, the unit group of data is composed of a block consisting of two or more unit data. And when a picture to be displayed next has not yet been written in the frame buffer, the picture being displayed now is continuously displayed. Thus, according to the present invention, some portions of I-picture and P-picture data constituting the unit group are continuously decoded at the time of special reproduction, while the remaining picture data are intermittently decoded and transferred to a display means, thereby reducing the number of required decoding steps. Consequently it becomes unnecessary to raise the data transfer rate to the decoder, hence eliminating failure in the data flow. Furthermore, the reproduced pictures can be displayed with reduction of the display delay time without the necessity of increasing the storage capacity of the frame buffer required for special reproduction. The above and other features and advantages of the present invention will become apparent from the following description which will be given with reference to the illustrative accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing the constitution of an exemplary embodiment which represents the coded-data special reproduction apparatus of the present invention; FIGS. 2A and 2B show frame structures of group data; FIGS. 3A to 3E are timing charts of signals produced in an example of special reproduction; FIG. 4 is a flow chart showing the operation performed in special reproduction; FIG. 5 is a schematic table of an example in performing the special reproduction of FIG. 4; FIG. 6 is a schematic table of an example in performing reverse reproduction with I- and P-pictures; FIG. 7 is a schematic table of another example in performing reverse reproduction with I- and P-pictures; FIG. 8 is a schematic table of an example in performing reverse reproduction with I-, P- and B-pictures; FIG. 9 is a schematic table of another example in performing reverse reproduction with I- and P-pictures; FIG. 10 is a schematic table of an example in performing reverse reproduction with entire I- and P-pictures; FIG. 11 is a schematic table of another example in performing reverse reproduction with entire I- and P-pictures; FIG. 12 is a schematic table of an example in performing reverse reproduction with approximately alternate I- and P-pictures; FIG. 13 is a schematic table of another example in performing reverse reproduction with I- and P-pictures; FIG. 14 is a schematic table of an example in performing reverse reproduction with I- and P-pictures while not displaying any same pictures in succession; FIGS. 15 to 19 are schematic tables of other examples in performing reverse reproduction with I- and P-pictures; FIG. 20 is a schematic table of an example in performing reverse reproduction with entire I- and P-pictures and alternate B-pictures; FIG. 21 is a schematic table of an example in performing reverse reproduction with entire I- and P-pictures and some B-pictures while not displaying any same pictures in succession; FIG. 22 is a schematic table of an example in performing partial reverse reproduction with entire I-, P- and B-pictures; FIGS. 23 to 25 are schematic tables of an example in performing reverse reproduction with entire I-, P- and B-pictures; FIGS. 26 to 28 are schematic tables of an example in performing reverse reproduction with approximately entire I-, P- and B-pictures; FIGS. 29 to 31 are schematic tables of another example in performing reverse reproduction with approximately entire I-, P- and B-pictures; FIG. 32 is a block diagram showing the construction of an MPEG coder; FIGS. 33A and 33B show an inter-frame prediction structure and a medium frame structure, respectively; and FIGS. 34A to 34E show the relationship among original pictures, coded pictures, on-medium pictures, decoded pictures and normal reproduced pictures. DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows the constitution of an exemplary embodiment which represents a data special reproduction apparatus contrived for carrying out the coded-data special reproduction method of the present invention, wherein a recording medium employed is a disk. In this diagram, reference numeral 1 denotes a disk drive for reading out from the disk the coded data recorded through compression according to the MPEG standard. There are also shown a decoder 2 which consists of a code buffer 2-1, a decode processor 2--2 and a frame buffer 2-3 for decoding the data read out from the disk drive 1; a display device 3 for displaying the data decoded by the decoder 2; a controller 4 for controlling the decoder, by supplying control data to a specific data access means 5, in a manner to read out the specific data from the disk drive 1 and to obtain normal reproduced signal or special reproduced signal; and the specific data access means 5 for driving the disk drive 1 in a manner to read out the specific data from the disk under control of the controller 4. Now an explanation will be given on the operation performed in a normal reproduction mode in the data special reproduction apparatus of the above constitution. On the disk, there are recorded I-, P- and B-pictures which are coded according to the MPEG standard in the format of FIG. 34C. In order to decode such recorded picture data in the order of FIG. 34D, specific picture data included in the video data is read out by the specific data access means 5 and then is supplied to and stored temporarily in the decode buffer 2-1 of the decoder 2. Subsequently the data thus stored in the code buffer 2-1 is read out therefrom and is decoded by the decode processor 2--2, so that the picture data are decoded in the order of FIG. 34D. And the decoded pictures are supplied to the frame buffer 2-3. The frame buffer 2-3 has a memory capacity sufficient for storing three frames which are composed usually of an area 1, an area 2 and an area 3. And the decoded pictures supplied to the frame buffer 2-3 are stored in predetermined areas respectively. Thereafter the pictures are read out from the frame buffer 2-3 in the order of FIG. 34E and then are visually represented on the display device 3, whereby the reproduced pictures are displayed in the order of the original ones. Next the operation performed in a special reproduction mode will be described below with regard to an example of reverse reproduction. Since the MPEG2 standard includes both cases with and without the aforementioned GOP structure, a description will be given on an assumption that a plurality of MPEG-coded pictures constitute a unit of group data (GD). FIGS. 2A and 2B show an exemplary GD structure where one group data is composed of 15 pictures, in which n denotes a distance between an I-picture and a P-picture or a distance between P-pictures, and m denotes a distance between I-pictures. More specifically, FIG. 2A shows an example of pictures arranged in four GD, and FIG. 2B shows actual bit streams rearranged on a recording medium in the decoding order in a normal reproduction mode. Referring now to FIGS. 3A to 3E, an explanation will be given on an exemplary data supply pattern supplied to the decoder and an exemplary data output pattern read out from the decoder and displayed when the MPEG-coded pictures thus arranged on the recording medium are reproduced in a reverse direction. In this case, it is supposed that the frame buffer 2-3 has areas sufficient for storing four pictures. First in FIG. 3A, Dsync is a timing signal according to which the pictures read out from the disk drive 1 are written in the code buffer 2-1. This signal Dsync has a period of 2 V corresponding to a double of a vertical synchronizing signal Vsync, i.e., a period of 1 frame. Therefore the code buffer 2-1 is triggered by the signal Dsync in such a manner that the pictures read out from the disk drive 1 are written in the period of 2 V as shown in FIG. 3B. More specifically, under control of the specific data access means 5, pictures are read out from the disk drive 1 in the order of 16I, 19P, 22P, 25P, 28P, 27B, 16I, 19P, 24B, . . . and so forth, as shown in FIG. 3B. The pictures stored in the code buffer 2-1 are decoded by the decode process means 2--2 in such a manner that the decoding of each picture is completed within the period of 2 V from the start thereof, and the decoded pictures are stored successively in the frame buffer 2-3, as shown in FIG. 3C. More specifically, the I-picture 16I started to be decoded synchronously with timing td1 is decodable alone without reference to any other picture since it is an intra-frame coded picture, and in synchronism with td2 of Dsync after a lapse of 2 V therefrom, the data of the decoded I-picture 16I starts to be stored in the area 1 of the frame buffer 2-3. Then in synchronism with timing td3 after a lapse of 2 V therefrom, the P-picture 19P decoded with reference to the I-picture 16I starts to be stored in the area 2. Subsequently in synchronism with timing td3 after a lapse of 2 V, the P-picture 22P decoded with reference to the P-picture 19P starts to be stored in the area 3; and next in synchronism with timing td5 after a lapse of 2 V, the P-picture 25P decoded with reference to the P-picture 22P starts to be stored in the area 4. And further in synchronism with timing td6 after a lapse of 2 V therefrom, the P-picture 28P decoded with reference to the P-picture 25P starts to be stored in the area 1 by overwriting. Similarly, the B-picture 27B is decoded with reference to the P-picture 25P stored in the area 4 and also to the P-picture 28P stored in the area 1, and then starts to be stored in the area 2 synchronously with timing td7. Subsequently the respective areas of the frame buffer 2-3 are overwritten successively as shown in FIG. 3C, whereby the decoded pictures are stored therein. The decoded pictures thus stored in the frame buffer 2-3 are supplied to the display device 3 in a manner to be in the reverse order of the original pictures and are displayed thereon, but the timing to read out such decoded pictures from the frame buffer 2-3 conforms to the timing of the vertical synchronizing signal Vsync which is shown in FIG. 3D and has, as compared with the aforementioned signal Dsync, a deviation of 1 field corresponding to the period V of the vertical synchronizing signal. For example, regarding the P-picture 28P started to be stored in the area 1 synchronously with timing td6 of Dsync, the data thereof starts to be transferred to the display device 3 synchronously with timing tv1 of Vsync after a lapse of V from the timing td6 . In this case, storage of the P-pictre 28P in the area 1 is completed latest synchronously with timing td7 after a lapse of 2 V. However, since one field of the P-picture 28P can be transferred to the display device 3 at the time point td7 , the data to be displayed can be transferred properly to the display device 3 without any failure. As the data are read out from the disk driver 1 in the picture order of FIG. 3B and then are decoded, the data of the decoded pictures can be transferred to and displayed on the display device 3 in the order of FIG. 3C. More specifically, the P-picture 28P starts to be transferred from the area 1 to the display device 3 synchronously with timing tv1 of Vsync; the B-picture 27B starts to be transferred from the area 2 to the display device 3 synchronously with timing tv2; the P-picture 25P starts to be transferred from the area 4 to the display device 3 synchronously with timing tv4 ; the B-picture 24B starts to be transferred from the area 2 to the display device 3 synchronously with timing tv5 ; and the P-picture 22P starts to be transferred from the area 3 to the display device 3 synchronously with timing tv7 . Thereafter the B-picture 21B, P-picture 19P, B-picture 18B, I-picture 16I . . . and so forth are transferred from the respective areas to the display device 3 in this order. Consequently the video signals of the above P-picture 28P, B-picture 27B, P-picture 25P, B-picture 24B, P-picture 22P, B-picture 21B, P-picture 19P, B-picture 18B, I-picture 16I . . . and so forth are displayed on the display device 3 in this order, whereby the pictures reproduced in the reverse direction can be visually represented on the display device 3. FIG. 4 is a flow chart showing the operation of the controller 4 performed in this case. When the operation is switched to a reverse reproduction mode, the routine of this flow chart is started. First at step S10, the data of pictures 16I, 19I, 22P and 25P are supplied to the decoder successively to be decoded therein, and the resultant decoded data are written respectively in the corresponding area 1, area 2, area 3 and area 4 of the frame buffer in the decoder. Next at step S20, the data of P-picture 28P is transferred to the decoder to be decoded therein, and the decoded data is written in the non-displayed area of the frame buffer. In selection of such write area, the controller previously stores divisions where pictures are not displayed, being displayed and already displayed respectively, then determines the picture reproducible by the least number of times of decoding operations when the data is once decoded, and overwrites that area. In this exemplary case, the area 1 with the I-picture 16I written therein is determined, and the decoded P-picture 28P is overwritten in the area 1. Subsequently at step S30, the controller 4 controls the decoder 2 in such a manner as to start display of the P-picture 28P by triggering the same synchronously with Vsync after a lapse of 1 V from the Vsync (Dsync) used to start decoding the P-picture 28P. Next at step S40, the controller 4 executes its control action for reading out the data from the disk drive 1 so that the B-picture 27B can be decoded in synchronism with Vsync (Dsync) as a trigger after a lapse of 1 V from the start of displaying the P-picture 28P, and also that the P-pictures 25P and 28P can be read out from the frame buffer 2-3 and be decoded. Thereafter at step S50, the controller 4 controls the decoder 2 in a manner to start display of the B-picture 27B by triggering the same synchronously with Vsync after a lapse of 1 V from the Dsync used to start decoding the B-picture 27B. Further at step S60, the controller 4 executes its control action for enabling the decoder 2 to read out the data from the disk drive 1 and to decode the data so that the I-picture 16I can be decoded again in synchronism with Dsync as a trigger after a lapse of 1 V from the start of displaying the B-picture 27B. And finally at step S70, the controller 4 controls the decoder 2 to decode the data synchronously with the timing shown in FIG. 3. Thus, in the coded-data reproduction apparatus of the present invention, there exist data portions where, in a special reproduction mode, I- and P-pictures are decoded continuously, and data portions where such pictures are decoded intermittently. And B-pictures are decoded intermittently. The reason is based on that the controller 4 controls both the decoder 2 and the specific data access means 5 in such a manner as not to cause failure in the data flow without the necessity of raising the data transfer rate to the decoder 2. In this case, decoding is performed with priority granted to the I-picture decodable alone and the P-picture decodable with reference merely to the immediately preceding I-picture or P-picture in the forward direction. And in case the next picture data to be supplied to the display device 3 is not stored in the frame buffer 2-3, the picture being displayed now is supplied continuously to the display device. It is to be understood here that the data supply patterns of FIGS. 3A to 3E in supplying the data to the decoder and the data output patterns thereof in reading out the data from the decoder and displaying such data are merely illustrative examples, and a variety of patterns are applicable in a special reproduction mode. Hereinafter various patterns adapted for special reproduction will be described, wherein the patterns shown in FIGS. 3A to 3E are represented as FIG. 5. In each of FIGS. 5 through 31, a column "Code buffer read Dsync" includes the pictures read out from the code buffer 2-1 synchronously with the signal Dsync shown in FIG. 3A. A column "Frame buffer" is divided into fractional columns of numerals indicating the individual areas of the frame buffer 2-3, wherein there are included the pictures written in such areas synchronously with the signal Dsync as shown in FIG. 3C. Meanwhile, a column "Display Vsync" includes the pictures read out from the frame buffer 2-3 synchronously with the signal Vsync shown in FIG. 3D and displayed on the display device 3. Now each of FIGS. 6 through 31 will be schematically described below. FIG. 6 shows an example in performing reverse reproduction with I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 7 shows another example in performing reverse reproduction with I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 8 shows an example in performing reverse reproduction with I-, P- and B-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 9 shows another example in performing reverse reproduction with I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 10 shows an example in performing reverse reproduction with entire I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 11 shows another example in performing reverse reproduction with entire I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to four. FIG. 12 shows an example in performing reverse reproduction with approximately alternate I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 13 shows another example in performing reverse reproduction with I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 14 shows an example in performing reverse reproduction with I- and P-pictures while not displaying any same pictures in succession, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to five. FIG. 15 shows another example in performing reverse reproduction with I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 16 shows another example in performing reverse reproduction with I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 17 shows another example in performing reverse reproduction with I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 18 shows another example in performing reverse reproduction with I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to two. FIG. 19 shows a further example in performing reverse reproduction with I- and P-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to two. FIG. 20 shows an example in performing reverse reproduction with entire I- and P-pictures and alternate B-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIG. 21 shows an example in performing reverse reproduction with entire I- and P-pictures and some B-pictures while not displaying any same pictures in succession, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to six. FIG. 22 shows an example in performing partial reverse reproduction with successive I-, P- and B-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. FIGS. 23 to 25 show an example in performing reverse reproduction with entire I-, P- and B-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to four. FIGS. 26 to 28 show an example in performing reverse reproduction with approximately entire I-, P- and B-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. And FIGS. 29 to 31 show another example in performing reverse reproduction with approximately entire I-, P- and B-pictures, wherein the number of storable frames (number of areas) in the frame buffer 2-3 is set to three. Although the explanation given above is concerned with an exemplary case of coded data read out from recording media, the present invention is not limited thereto alone, and the coded data may be those stored via communication media or broadcasting media as well. Thus, according to the present invention, some portions of I-picture and P-picture data constituting unit data are continuously decoded in a special reproduction mode, while the remaining picture data are intermittently decoded and transferred to a display means, thereby reducing the number of required decoding steps. Consequently it becomes unnecessary to raise the data transfer rate to the decoder, hence eliminating failure in the data flow. Furthermore, the reproduced pictures can be displayed with reduction of the display delay time without the necessity of increasing the storage capacity of the frame buffer required for special reproduction. Although the present invention has been described hereinabove with reference to some preferred embodiments thereof, it is to be understood that the invention is not limited to such embodiments alone, and a variety of other modifications and variations will be apparent to those skilled in the art without departing from the spirit of the invention. The scope of the invention, therefore, is to be determined solely by the appended claims.
A coded-data special reproduction method which reads out and decodes unit group data composed of intra-frame coded data, inter-frame forward predictive coded data and bidirectionally predictive coded data, then writes the decoded data into a frame buffer means and, after reading out the data therefrom, displays such data. The method comprises the steps of continuously decoding portions of the intra-frame coded data and the inter-frame forward predictive coded data constituting the unit group data read out, while intermittently decoding the remaining coded data; writing the decoded data in the frame buffer means; reading out the data therefrom in a reverse order of the original pictures; and displaying the pictures thus read out. An apparatus contrived to carry out the above method comprises a buffer for storing the group data; a decoder for decoding the coded data obtained from the buffer; and a frame buffer for storing the respective coded data decoded by the decoder. Special reverse reproduction of the coded data can be achieved to realize natural reproduced pictures on a display device without the necessity of raising the coded-data transfer rate to the decoder or increasing the storage capacity of the frame buffer.
6
CROSS-REFERENCE TO RELATED APPLICATIONS This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2011-243735 filed Nov. 7, 2011. BACKGROUND Technical Field The present invention relates to a booklet storage and an electronic apparatus. SUMMARY According to an aspect of the invention, there is provided a booklet storage including: a first storage member that includes a first receiver portion and a second receiver portion connecting with the first receiver portion; and a second storage member that includes a third receiver portion and a fourth receiver portion connecting with the third receiver portion, wherein the first storage member and the second storage member together receive a booklet in combination, and wherein a first width between the first receiver portion or the second receiver portion and the third receiver portion and a second width between the first receiver portion or the second receiver portion and the fourth receiver portion are different from each other. BRIEF DESCRIPTION OF THE DRAWINGS Exemplary embodiments of the present invention will be described in detail based on the following figures, wherein: FIG. 1 is an enlarged perspective view illustrating the arrangement when a booklet is placed longitudinally in a booklet storage according to an exemplary embodiment of the invention; FIG. 2 is an enlarged perspective view illustrating the arrangement when a booklet is placed transversely in the booklet storage according to the exemplary embodiment of the invention; FIG. 3 is a perspective view illustrating the booklet storage and an image forming apparatus when a booklet is placed longitudinally according to the exemplary embodiment of the invention; FIG. 4 is a perspective view illustrating the booklet storage and the image forming apparatus when a booklet is placed transversely according to the exemplary embodiment of the invention; FIG. 5 is an enlarged perspective view illustrating the booklet storage according to the exemplary embodiment of the invention when it is carried; FIG. 6 is an enlarged perspective view illustrating a state where the width for storing the booklet is changed using the booklet storage according to the exemplary embodiment of the invention; FIG. 7 is an enlarged perspective view illustrating another state where the width for storing the booklet is changed using the booklet storage according to the exemplary embodiment of the invention; FIG. 8 is a diagram illustrating the configuration of the image forming apparatus according to the exemplary embodiment of the invention; FIG. 9 is a diagram schematically illustrating the configuration of the image forming apparatus according to the exemplary embodiment of the invention; FIGS. 10A and 10B are perspective views illustrating a state where a booklet is stored using one member of the booklet storage according to the exemplary embodiment of the invention; and FIG. 11 is a perspective view illustrating examples of sizes of members of the booklet storage according to the exemplary embodiment of the invention. DETAILED DESCRIPTION A booklet storage and an electronic apparatus according to an exemplary embodiment of the invention will be described with reference to FIGS. 1 to 11 . The arrow UP in the drawings represents the upward direction in the vertical direction. As shown in FIG. 9 , a cover member 12 that can be opened and closed, a glass platen 16 on which a sheet of original document is loaded, and a document reader 14 that reads the original document R loaded onto the glass platen 16 are disposed in the upper part of an apparatus body 10 A of an image forming apparatus 10 as an example of the electronic apparatus according to this exemplary embodiment. A light source 18 irradiating the original document R loaded onto the glass platen 16 with light is disposed in the document reader 14 . The document reader 14 is provided with an optical system including a full-rate mirror 20 reflecting the light emitted by the light source 18 and reflected from the original document R in a direction parallel to the glass platen 16 , a half-rate mirror 22 reflecting the light reflected by the full-rate mirror 20 downward, a half-rate mirror 24 reflecting and returning the light reflected by the half-rate mirror 22 in the direction parallel to the glass platen 16 , and an imaging lens 26 on which the light returned by the half-rate mirror 24 is incident. The document reader 14 is also provided with a photoelectric conversion device 28 converting the reflected light imaged by the imaging lens 26 into an electrical signal and is also provided with an image processor 29 processing the electrical signal converted by the photoelectric conversion device 28 as an image. The light source 18 , the full-rate mirror 20 , the half-rate mirror 22 , and the half-rate mirror 24 can move along the glass platen 16 . According to this configuration, when reading the original document R loaded onto the glass platen 16 , the light source 18 applies light to the original document R loaded onto the glass platen 16 while causing the light source 18 , the full-rate mirror 20 , the half-rate mirror 22 , and the half-rate mirror 24 to move, and the reflected light reflected by the original document R is imaged on the photoelectric conversion device 28 . On the other hand, plural image forming units 30 forming toner images of different colors and being arranged to be inclined about the horizontal direction is disposed at the center of the vertical direction of the apparatus body 10 A. An endless intermediate transfer belt 32 wound on a rotating driving roll 48 , a tension supplying roll 54 supplying a tension, a support roll 50 rotating with the rotation of the driving roll, a first idler roll 56 , and a second idler roll 58 is disposed above the image forming units 30 . The toner images formed by the image forming units 30 of different colors are transferred to the intermediate transfer belt 32 while the intermediate transfer belt 32 circulates in the direction of arrow A in the drawing. Specifically, as shown in FIG. 8 , four image forming units 30 Y, 30 M, 30 C, and 30 K of yellow (Y), magenta (M), cyan (C), and black (K) are arranged in this order. The image forming unit 301 in which the toner image of yellow (Y) to be first transferred to the intermediate transfer belt 32 is formed is located at the highest position, the image forming unit 30 K in which the toner image of black (K) to be finally transferred to the intermediate transfer belt 32 is formed is located at the lowest position, and the image forming units 30 Y, 30 M, 30 C, and 30 K are arranged at a constant interval in the state where they are inclined about the horizontal direction. The four image forming units 30 Y, 30 M, 30 C, and 30 K have the same basic configuration. In the below description, characters (Y, M, C, and K) corresponding to the colors are attached to the reference signs when the colors are distinguished from each other and the characters corresponding to the colors are not attached when the colors are not particularly distinguished from each other. The image forming unit 30 of each color includes an image supporting member 34 rotating in the direction of arrow D by the use of a driving unit not shown and a charging member 36 uniformly charging the surface of the image supporting member 34 . An optical scanner 40 irradiating the surface of the image supporting member 34 of which the surface is uniformly charged by the charging member 36 with a laser beam corresponding to a predetermined color to form an electrostatic latent image is disposed below the image forming units 30 so as to be inclined along the plural image forming units 30 . A developing device 42 developing the electrostatic latent image formed on the surface of the image supporting member 34 with a toner of a predetermined color to visualize the electrostatic latent image is disposed downstream in the rotation direction of the image supporting member 34 about the charging member 36 . A power source unit 43 being arranged in the direction parallel to the optical scanner 40 and supplying power to the image forming units 30 and the like is disposed. A first air inlet and output port 112 and a second air inlet and outlet port 114 penetrating the surface of the side plate 11 of the apparatus body 10 A are vertically arranged on the side of the power source unit 43 . On the other hand, a primary transfer member 46 transferring the toner image formed on the surface of the image supporting member 34 to the intermediate transfer belt 32 is disposed on the opposite side of the image supporting member with the intermediate transfer belt 32 interposed therebetween. A cleaning device 44 cleaning the residual toner or the like remaining on the surface of the image supporting member 34 without being transferred to the intermediate transfer belt 32 from the image supporting member 34 is disposed downstream in the rotation direction of the image supporting member 34 about the primary transfer member 46 so as to come in contact with the surface of the image supporting member 34 . That is, each image forming unit 30 includes the image supporting member 34 , the charging member 36 , the developing device 42 , and the cleaning device 44 . Toner cartridges 38 Y, 38 M, 38 C, and 38 K supplying the toners of predetermined colors to the developing devices 42 of yellow (Y), magenta (M), cyan (C), and black (K), respectively are disposed above the intermediate transfer belt 32 . The toner cartridge 38 K containing the toner of black (K) has a high use frequency and thus has a size larger than those of the other toner cartridges. According to this configuration, color image data of yellow (Y), magenta (M), cyan (C), and black (K) are sequentially output to the optical scanner 40 from the image processor 29 (see FIG. 9 ) or the outside. The laser beam emitted from the optical scanner 40 on the basis of the image data exposes the surface of the corresponding image supporting member 34 to form an electrostatic latent image on the surface of the image supporting member 34 . The electrostatic latent images formed on the surfaces of the image supporting members 34 are developed as the color toner images of yellow (Y), magenta (M), cyan (C), and black (K) by the developing devices 42 Y, 42 M, 42 C, and 42 K. The toner images of yellow (Y), magenta (M), cyan (C), and black (K) sequentially formed on the surfaces of the image supporting members 34 are multiply-transferred to the intermediate transfer belt 32 disposed inclined above the image forming units 30 Y, 30 M, 30 C, and 30 K of the colors by the primary transfer member 46 . On the other hand, the cleaning device 52 cleaning the surface of the intermediate transfer belt 32 is disposed on the opposite side of the driving roll 48 with the intermediate transfer belt 32 interposed therebetween. The cleaning device 52 may be detached from and attached to the apparatus body 10 A by opening the front cover (not shown) disposed on the front surface (the front side where a user stands) of the apparatus body 10 A. A secondary transfer member 60 secondarily transferring the toner images primarily transferred to the intermediate transfer belt 32 to a sheet member P as a recording medium is disposed on the opposite side of the support roll 50 with the intermediate transfer belt 32 interposed therebetween. That is, a position between the secondary transfer member 60 and the support roll 50 serves as a secondary transfer position where the toner images are transferred to the sheet member P. A fixing device 64 fixing the toner images to the sheet member P to which the toner images are transferred by the secondary transfer member 60 and which is transported along a transport path 62 is disposed above the secondary transfer member 60 . As shown in FIG. 9 , a transport roll 66 transporting a sheet member P to which the toner image is fixed is disposed downstream in the transport direction of the sheet member P about the fixing device 64 (hereinafter, simply referred to as “downstream in the transport direction”) and a switching gate 68 switching the transport direction of the sheet member P is disposed downstream in the transport direction about the transport roll 66 . A first discharge roll 70 discharging the sheet member P, which is guided by the switching gate 68 switched to one direction, to the first discharge section 69 is disposed downstream in the transport direction about the switching gate 68 . A second discharge roll 78 discharging the sheet member P, which is guided by the switching gate 68 switched to the other direction and transported by the transport roll 73 , to the second discharge section 76 is disposed downstream in the transport direction about the switching gate 68 . On the other hand, sheet feeding sections 80 , 82 , 84 , and 86 storing sheet members P are disposed in the lower part of the apparatus body 10 A and upstream in the transport direction of the sheet member P (hereinafter, simply referred to as “upstream in the transport direction”) about the secondary transfer member 60 . Sheet members P having different sizes are stored in the sheet feeding sections 80 , 82 , 84 , and 86 . Each of the sheet feeding sections 80 , 82 , 84 , and 86 is provided with a feed roll 88 sending the sheet member P from each of the sheet feeding sections 80 , 82 , 84 , and 86 to a transport path 62 . A transport roll 90 and a transport roll 92 transporting the sheet members P sheet by sheet are disposed downstream in the transport direction about the feed roll 88 . A registration roll 94 temporarily stopping the sheet member P and sending the sheet member P to the secondary transfer position at a predetermined time is disposed downstream in the transport direction about the transport roll 92 . On the other hand, a double-side transport unit 98 inverting and transporting the sheet member P to form images on both sides of the sheet member P is disposed aside the secondary transfer position. The double-side transport unit 98 is provided with an inversion path 100 through which the sheet member P transported by inversely rotating the transport roll 73 passes. Plural transport rolls 102 are disposed along the inversion path 100 and the sheet member P transported by the transport rolls 102 is transported again to the registration roll 94 in the state where it is upside down. A foldable manual bypass feed unit 106 is disposed around the double-side transport unit 98 . A feed roll 108 and transport rolls 110 and 111 transporting a sheet member P fed from the opened foldable manual bypass unit 106 are provided and the sheet member P transported by the transport rolls 110 and 111 are transported to the registration roll 94 . A booklet storage 120 which is attached to a side plate 116 as an example of an attachment member disposed below the side plate 11 having the first air inlet and outlet port 112 and the second air inlet and outlet port 114 formed therein and which stores a booklet S in which the operation sequences of the image forming apparatus 10 and the like are described will be described below. As shown in FIG. 1 , the booklet storage 120 includes a first storage member 122 and a second storage member 124 having substantially a symmetric shape and can store a booklet S by arranging the first storage member 122 and the second storage member 124 in a horizontal direction. FIG. 1 shows the booklet storage 120 when a booklet S of an A4 size is placed longitudinally (hereinafter, referred to as “in the longitudinal arrangement of a booklet”) and FIG. 2 shows the booklet storage 120 when a booklet S of an A4 size is placed transversely (hereinafter, referred to as “in the transversal arrangement of a booklet”). Specifically, as shown in FIG. 1 , the first storage member 122 in the longitudinal arrangement of a booklet is disposed on the left side in the drawing surface and the second storage member 124 is disposed on the right side of the drawing surface. On the other hand, as shown in FIG. 2 , the first storage member 122 in the transversal arrangement of a booklet is disposed on the right side of the drawing surface in a state where the attachment direction is rotated counterclockwise by substantially 90 degrees about the posture in the longitudinal arrangement of a booklet and the second storage member 124 is disposed on the left side of the drawing surface in a state where the attachment direction clockwise by substantially 90 degrees about the posture in the longitudinal arrangement of a booklet. As shown in FIGS. 1 and 2 , the first storage member 122 includes a first receiver portion 122 A (see FIG. 1 ) having a rectangular panel shape and receiving an end face of a booklet S in the longitudinal arrangement of the booklet and a second receiver portion 122 B (see FIG. 2 ) having a rectangular panel shape and receiving an end face of a booklet S in the transversal arrangement of the booklet. The first receiver portion 122 A and the second receiver portion 122 B are connected to each other at the ends in the length direction and the angle formed by the first receiver portion 122 A and the second receiver portion 122 B is substantially 90 degrees. The booklet support width (the size G shown in the drawing) of the first receiver portion 122 A receiving the end face of a booklet S in the longitudinal arrangement of the booklet is smaller than the booklet support width (the size H shown in the drawing) of the second receiver portion 122 B receiving the end face of a booklet S in the transversal arrangement of the booklet. In the first storage member 122 , a pair of plate-like wall portions 122 C and 122 D supporting the cover surfaces (including the rear cover surface) of the booklet S stored in the first storage member 122 , having substantially the same shape, and facing each other are connected to edge portions in which the width directions of the first receiver portion 122 A and the second receiver portion 122 B are different from each other. A cutout 128 reducing the storage depth of the booklet S and having an L-shaped edge is formed in the wall portion 122 C and the wall portion 122 D. Similarly, the second storage member 124 includes a third receiver portion 124 A (see FIG. 1 ) having a rectangular panel shape and receiving the end face of a booklet S in the longitudinal arrangement of the booklet and a fourth receiver portion 124 B (see FIG. 2 ) having a rectangular panel shape and receiving the end face of a booklet S in the transversal arrangement of the booklet. The third receiver portion 124 A has substantially the same shape as the first receiver portion 122 A and the fourth receiver portion 124 B has substantially the same shape as the second receiver portion 122 B. Similarly to the first receiver portion 122 A and the second receiver portion 122 B, the third receiver portion 124 A and the fourth receiver portion 124 B are connected to each other at the ends in the length direction and the angle formed by the third receiver portion 124 A and the fourth receiver portion 124 B is substantially 90 degrees. In the second storage member 124 , a pair of plate-like wall portions 124 C and 124 D supporting the cover surfaces (including the rear cover surface) of the booklet S stored in the second storage member 124 , having the same shape, and facing each other are connected to edge portions in which the width directions of the third receiver portion 124 A and the fourth receiver portion 124 B are different from each other. The wall portion 124 C and the wall portion 124 D have substantially the same shapes as the wall portion 122 C and the wall portion 122 D, respectively, and a cutout 130 having the same shape as the cutout 128 is formed in the wall portion 124 C and the wall portion 124 D. Specifically, the shape of the cutout 128 and the cutout 130 is determined so that even when a CD (Compact Disk) case K having a CD storing software such as a printer driver as data is stored in the booklet storage 120 in the longitudinal arrangement of a booklet and in the transversal arrangement of a booklet, a user can take out the CD case K. That is, at least a part of the CD case K stored in the booklet storage 120 is exposed from the cutout 128 or the cutout 130 to outside (see FIGS. 3 and 4 ). According to this configuration, by causing the opening edge 164 of the first receiver portion 122 A and the opening edge 166 of the third receiver portion 124 A to face each other so that the plate surface of the first receiver portion 122 A and the third receiver portion 124 A faces the longitudinal direction in the longitudinal arrangement of a booklet as shown in FIG. 1 , the postures of the first storage member 122 and the second storage member 124 may be determined. Accordingly, a first width (the size J shown in FIG. 1 ) may be achieved which may be set when a booklet S of an A4 size is arranged longitudinally. The end face of the booklet S stored from a first storage direction (the direction of arrow E shown in FIG. 1 ) is received by the first receiver portion 122 A and the third receiver portion 124 A. In this state, the booklet S may not be arranged transversely. The wall portion 122 C of the first storage member 122 and the wall portion 124 C of the second storage member 124 come in contact with the side plate 116 . On the other hand, as shown in FIG. 2 , the postures of the first storage member 122 and the second storage member 124 may be determined in the transversal arrangement of a booklet by causing the opening edge 168 of the second receiver portion 122 B and the opening edge 170 of the fourth receiver portion 124 B to come in contact with each other so that the plate surface of the second receiver portion 122 B and the fourth receiver portion 124 B faces the vertical direction. Accordingly, a second width (the size N shown in FIG. 2 ) may be achieved which is different from the first width and which may be applied when a booklet S of an A4 size is arranged transversely. The end face of the booklet S stored from a second storage direction (in the direction of arrow F in FIG. 2 ) is received by the second receiver portion 122 B and the fourth receiver portion 124 B. In this state, similarly to the longitudinal arrangement of a booklet, the wall portion 122 C of the first storage member 122 and the wall portion 124 C of the second storage member 124 come in contact with the side plate 116 . As shown in FIG. 1 , in the first storage member 122 , first attachment holes 134 as an example of plural (two in this exemplary embodiment) first attachment portions used in the longitudinal arrangement of a booklet are formed in the wall portion 122 C attached to the side plate 116 of the apparatus body 10 A. Specifically, two first attachment holes 134 are arranged in the horizontal direction in the posture in the longitudinal arrangement of a booklet and the pitch therebetween is defined as a distance L. Similarly, as shown in FIG. 2 , in the first storage member 122 , second attachment holes 136 as an example of plural (two in this exemplary embodiment) second attachment portions used in the transversal arrangement of a booklet are formed in the wall portion 122 C attached to the side plate 116 of the apparatus body 10 A. Specifically, two second attachment holes 136 are arranged in the vertical direction in the posture in the transversal arrangement of a booklet and the pitch therebetween is defined as a distance L, similarly to the first attachment holes 134 . The first attachment hole 134 (see FIG. 1 ) disposed on the side of the first storage member 122 in the longitudinal arrangement of a booklet and the second attachment hole 136 (see FIG. 2 ) disposed on the side of the first storage member 122 in the transversal arrangement of a booklet are used in common (are the same hole). On the other hand, as shown in FIG. 1 , in the second storage member 124 , third attachment holes 140 as an example of plural (two in this exemplary embodiment) third attachment portions used in the longitudinal arrangement of a booklet are formed in the wall portion 124 C attached to the side plate 116 of the apparatus body 10 A. Specifically, two third attachment holes 140 are arranged in the horizontal direction in the posture in the longitudinal arrangement of a booklet and the pitch therebetween is defined as a distance L. Similarly, as shown in FIG. 2 , in the second storage member 124 , fourth attachment holes 142 as an example of plural (two in this exemplary embodiment) fourth attachment portions used in the transversal arrangement of a booklet are formed in the wall portion 124 C attached to the side plate 116 of the apparatus body 10 A. Specifically, two fourth attachment holes 142 are arranged in the vertical direction in the posture in the transversal arrangement of a booklet and the pitch therebetween is defined as a distance L, similarly to the third attachment holes 140 . That is, the first attachment holes 134 , the second attachment holes 136 , the third attachment holes 140 , and the fourth attachment holes 142 are arranged to be substantially symmetric about a virtual center line extending in the vertical direction and being drawn between the first storage member 122 and the second storage member 124 . The third attachment hole 140 (see FIG. 1 ) disposed on the side of the second storage member 124 in the longitudinal arrangement of a booklet and the fourth attachment hole 142 (see FIG. 2 ) disposed on the side of the second storage member 124 in the transversal arrangement of a booklet are used in common (are the same hole). The positions of the attachment holes are determined so that the relative positional relationship between the plural first attachment holes 134 and the plural third attachment holes 140 when the first storage member 122 and the second storage member 124 are arranged to form the first width in the longitudinal arrangement of a booklet is substantially identical to the relative positional relationship between the plural second attachment holes 136 and the plural fourth attachment holes 142 when the first storage member 122 and the second storage member 124 are arranged to form the second width in the transversal arrangement of a booklet. Specifically, the positions of the attachment holes are determined so that the pitch of the attachment holes formed in the same member is the distance L and the pitch of the attachment holes between the members is a distance T different from the distance L. In the first storage member 122 , the same attachment holes 150 as the attachment holes 134 and 136 formed in the wall portion 122 C are formed in the wall portion 122 D facing the wall portion 122 C. Similarly, in the second storage member 124 , the same attachment holes 152 as the attachment holes 140 and 142 formed in the wall portion 124 C are formed in the wall portion 124 D facing the wall portion 124 C. Accordingly, the first storage member 122 and the second storage member 124 have substantially the same shape. FIG. 11 shows an example of the sizes in the first storage member 122 and the second storage member 124 having the same shape. Attachment holes formed in the side plate 116 and used to attach the booklet storage 120 to the apparatus body 10 A will be described below. As shown in FIGS. 1 and 3 , four attachment holes 160 as an example of the attachment portions corresponding to the first attachment holes 134 and the third attachment holes 140 when the first storage member 122 and the second storage member 124 are arranged to form the first width in the longitudinal arrangement of a booklet are formed in the side plate 116 . According to this configuration, fasteners 162 as an example of a fixing tool are inserted into the first attachment holes 134 and the attachment holes 160 to fix the first storage member 122 to the side plate 116 . Similarly, the fasteners 162 are inserted into the third attachment holes 140 and the attachment holes 160 to fix the second storage member 124 to the side plate 116 . As described above, the relative positional relationship between the plural first attachment holes 134 and the plural third attachment holes 140 in the longitudinal arrangement of a booklet is equal to the relative positional relationship between the plural second attachment holes 136 and the plural fourth attachment holes 142 in the transversal arrangement of a booklet. Accordingly, as shown in FIG. 2 , when the first storage member 122 and the second storage member 124 are arranged to form the second width in the transversal arrangement of a booklet, the attachment holes 160 , the second attachment holes 136 , and the fourth attachment holes 142 correspond to each other. Accordingly, the fasteners 162 are inserted into the second attachment holes 136 and the attachment holes 160 to fix the first storage member 122 to the side plate 116 . Similarly, the fasteners 162 are inserted into the fourth attachment holes 142 and the attachment holes 160 to fix the second storage member 124 to the side plate 116 . That is, the attachment holes 160 formed in the side plate 116 are used in common in the longitudinal arrangement of a booklet and in the transversal arrangement of a booklet. As shown in FIGS. 3 and 4 , even when a booklet S of an A4 size is longitudinally stored in the booklet storage 120 in the longitudinal arrangement of a booklet (see FIG. 3 ) and even when the booklet S of an A4 size is transversely stored in the booklet storage 120 in the transversal arrangement of a booklet (see FIG. 4 ), the positions of the attachment holes 160 (see FIGS. 1 and 2 ) are determined so as for the booklet S not to cover the openings of the first air inlet and outlet port 112 and the second air inlet and outlet port 114 . As shown in FIG. 5 , at the time of shipment of the image forming apparatus 10 (see FIG. 9 ) from a plant, the first storage member 122 and the second storage member 124 may be tied to each other so as to combine the opening of the first storage member 122 and the opening of the second storage member 124 . The first storage member 122 and the second storage member 124 may be shipped and carried in the tied state. As shown in FIGS. 1 and 3 , in the longitudinal arrangement of a booklet, the first storage member 122 is disposed on the left side of the drawing surface, the second storage member 124 is disposed on the right side of the drawing surface, and the opening edge 164 of the first receiver portion 122 A and the opening edge 166 of the third receiver portion 124 A are opposed to each other. Accordingly, the first storage member 122 and the second storage member 124 are arranged to form the first width in the longitudinal arrangement of a booklet. In this state, the fasteners 162 are inserted into the first attachment holes 134 and the attachment holes 160 to fix the first storage member 122 to the side plate 116 . Similarly, the fasteners 162 are inserted into the third attachment holes 140 and the attachment holes 160 to fix the second storage member 124 to the side plate 116 . In the state where a booklet S of an A4 size is longitudinally arranged in the booklet storage 120 , the booklet S does not cover the openings of the first air inlet and outlet port 112 and the second air inlet and outlet port 114 . On the other hand, in the transversal arrangement of a booklet, the first storage member 122 is disposed on the right side of the drawing surface and the second storage member 124 is disposed on the left side of the drawing surface, as shown in FIGS. 2 and 4 . Compared with the longitudinal arrangement of a booklet, the attachment directions of the first storage member 122 and the second storage member 124 are changed and the opening edge 168 of the second receiver portion 122 B and the opening edge 170 of the fourth receiver portion 124 B are brought into contact with each other. In this state, the fasteners 162 are inserted into the second attachment holes 136 and the attachment holes 160 to fix the first storage member 122 to the side plate 116 . Similarly, the fasteners 162 are inserted into the fourth attachment holes 142 and the attachment holes 160 to fix the second storage member 124 to the side plate 116 . In the state where a booklet S of an A4 size is transversely arranged in the booklet storage 120 , the booklet S does not cover the openings of the first air inlet and outlet port 112 and the second air inlet and outlet port 114 . As described above, by dividing the booklet storage 120 into the first storage member 122 and the second storage member 124 and changing the attachment directions of the first storage member 122 and the second storage member 124 , the first width and the second width different from the first width are formed. Accordingly, when the first width and the second width are used depending on applications thereof by the use of the first storage member 122 and the second storage member 124 , it is possible to select the direction in which a booklet S is placed. The same attachment holes 150 as the attachment holes 134 and 136 formed in the wall portion 122 C are formed in the wall portion 122 D facing the wall portion 122 C in the first storage member 122 . Similarly, the same attachment holes 152 as the attachment holes 140 and 142 formed in the wall portion 124 C are formed in the wall portion 124 D facing the wall portion 124 C in the second storage member 124 . The cutout 130 having the same shape as the cutout 128 formed in the first storage member 122 is formed in the second storage member 124 . Accordingly, the first storage member 122 and the second storage member 124 have substantially the same shape. The first storage member 122 may be attached to the side plate 116 by using the wall portion 122 D instead of the wall portion 122 C, and the second storage member 124 may be attached to the side plate 116 by using the wall portion 124 D instead of the wall portion 124 C. That is, without changing the arrangement of the first storage member 122 and the second storage member 124 , the first width in the longitudinal arrangement of a booklet and the second width in the transversal arrangement of a booklet may be formed by the use of the first storage member 122 and the second storage member 124 . By forming the cutout 128 in the first storage member 122 and forming the cutout 130 in the second storage member 124 , at least a part of the CD case K stored in the booklet storage 120 is externally exposed from the cutout 128 or the cutout 130 in the longitudinal arrangement of a booklet and the transversal arrangement of a booklet. In this Exemplary embodiments of the invention, the relative positional relationship between the plural (two in this exemplary embodiment) first attachment holes 134 and the plural (two in this exemplary embodiment) third attachment holes 140 when forming the first width is substantially identical to the relative positional relationship between the plural (two in this exemplary embodiment) second attachment holes 136 and the plural (two in this exemplary embodiment) fourth attachment holes 142 when forming the second width. Accordingly, the attachment holes 160 formed in the side plate 116 may be used in common in the longitudinal arrangement of a booklet and in the transversal arrangement of a booklet. Regarding the pitches of the attachment holes having the same relative positional relationship, the pitch of the attachment holes formed in the same member is the distance L and the pitch of the attachment holes between the members is the distance T different from the distance L. When a booklet S of an A4 size is arranged longitudinally (see FIG. 3 ) and when a booklet S of an A4 size is arranged transversely (see FIG. 4 ), the position of the attachment holes 160 are determined so as for the booklet S not to cover the opening of the first air inlet and outlet port 112 and the opening of the second air inlet and outlet port 114 . While the invention has been described in detail with reference to a specific exemplary embodiment, the invention is not limited to the exemplary embodiment, but may be modified in various forms without departing from the scope of the invention, which is obvious to those skilled in the art. For example, the booklet storage 120 is used in combination with the image forming apparatus 10 in the above-mentioned exemplary embodiment, but is not limited to the image forming apparatus 10 and may be used in combination with an electronic apparatus such as a facsimile. In the above-mentioned exemplary embodiment, it has been stated that a booklet S of an A4 size is arranged longitudinally and transversely. However, for example, when the size of the booklet S varies depending on the types (for example, an A4 size and an A3 size), different booklet widths (booklet sizes) may be coped with by the use of the booklet storage 120 . Although it has been stated in the above-mentioned exemplary embodiment that the first storage member 122 and the second storage member 124 have substantially the same shape, the first storage member and the second storage member are not limited to substantially the same shape or the substantially symmetric shape, but may have different shapes. It has been stated in the above-mentioned exemplary embodiment that the first receiver portion 122 A (the third receiver portion 124 A) and the second receiver portion 122 B (the fourth receiver portion 124 B) are connected to each other, but they may be separated from each other. As shown in FIGS. 6 and 7 , in the above-mentioned exemplary embodiment, the booklet storage 120 is divided into the first storage member 122 and the second storage member 124 . Accordingly, by forming a particular attachment hole 174 in the side plate 116 and moving at least one of the first storage member 122 and the second storage member 124 in the horizontal direction, a booklet S of another size may be stored therein. In the above-mentioned exemplary embodiment, the booklet storage 120 is divided into the first storage member 122 and the second storage member 124 . Accordingly, a booklet S may be stored using any one thereof. For example, as shown in FIGS. 10A and 10B , when an optional device 180 such as a sorter is attached to a side surface of the apparatus body 10 A, a stepped portion 182 may be formed between the optional device 180 and the apparatus body 10 A. The storage space for a booklet S may be formed using the first storage member 122 or the second storage member 124 and the stepped portion 182 . Although not particularly stated in the above-mentioned exemplary embodiment, the first storage member 122 or the second storage member 124 may be disposed inclined using only the first storage member 122 or the second storage member 124 and a booklet S may be stored therein. In the above-mentioned exemplary embodiment, the number of first attachment holes 134 , the number of second attachment holes 136 , the number of third attachment holes 140 , and the number of fourth attachment holes 142 are two, but the numbers are not limited to two but may be three or more. In the above-mentioned exemplary embodiment, the cutouts 128 and 130 for taking out the CD case K are formed in the first storage member 122 and the second storage member 124 , but may be formed in only any one. In the above-mentioned exemplary embodiment, the postures of the first storage member 122 and the second storage member 124 are determined in the longitudinal arrangement of a booklet by causing the opening edge 164 of the first receiver portion 122 A and the opening edge 166 of the third receiver portion 124 A to face each other. However, the shapes of the members may be determined so as to determine the postures of the first storage member 122 and the second storage member 124 by combining the opening edge 164 of the first receiver portion 122 A and the opening edge 166 of the third receiver portion 124 A with each other. In the above-mentioned exemplary embodiment, both the attachment direction of the first storage member 122 and the attachment direction of the second storage member 124 are changed in the longitudinal arrangement of a booklet and in the transversal arrangement of a booklet. However, the shapes of the members may be determined so as to distinguish the longitudinal arrangement of a booklet and the transversal arrangement of a booklet by changing only one attachment direction. In the above-mentioned exemplary embodiment, the first storage member 122 and the second storage member 124 are attached to the side plate 116 by the use of the fasteners 162 . However, the first storage member 122 and the second storage member 124 may be attached to the side plate 116 by the use of a double-sided tape or the like. In this case, the relative positional relationship between the first storage member 122 and the second storage member 124 is determined by bringing the opening edge 168 of the second receiver portion 122 B and the opening edge 170 of the fourth receiver portion 124 B into contact with each other. The foregoing description of the exemplary embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.
A booklet storage includes a first storage member that includes a first receiver portion and a second receiver portion connecting with the first receiver portion; and a second storage member that includes a third receiver portion and a fourth receiver portion connecting with the third receiver portion, wherein the first storage member and the second storage member together receive a booklet in combination, and wherein a first width between the first receiver portion or the second receiver portion and the third receiver portion and a second width between the first receiver portion or the second receiver portion and the fourth receiver portion are different from each other.
1
CLAIM OF PRIORITY This application claims priority from U.S. Provisional Patent Application Ser. No. 60/539,539, filed on Jan. 27, 2004. BACKGROUND OF THE INVENTION This application relates to water heaters. More particularly, it relates to an instantaneous water heater which uses a high temperature hot water heat source in lieu of steam. In many hot water heating systems such as institutional systems, cold water is instantaneously heated by steam in a heat exchanger. For practical reasons, the output flow from the heat exchanger is overheated and is much too hot to be used at a hot water tap. Accordingly, the overheated water is blended with cold water in a blending chamber until a mixture having a temperature suitable for the hot water tap is obtained. There have been several approaches to heat exchanger designs for hot water in existing closed loop combination systems. These approaches can be broadly categorized as follows: (1) storage tank water heaters, (2) semi-instantaneous water heaters, and (3) instantaneous water heaters. In the first approach, i.e., the storage tank water heater, a heat exchanger is immersed in a relatively large tank. This heat exchanger is usually a tube coil; the tube may be either finned or unfinned. A further characteristic of such a system is that the tankside fluid is relatively quiescent as far as the heat transfer regime is concerned. In the storage tank heater, no effort is made to promote fluid velocity over the heat exchange surface on the tank side; therefore free convection is the predominant tankside heat transfer mechanism. The storage tank heater is therefore characterized by a modest rate of heat transfer relative to the volume of water stored, and hot water demand is met largely by stored capacitance. The best way to plumb such a system is to circulate boiler fluid in the tube coil and store domestic hot water in the tank. One advantage of the storage tank water heater is inherent temperature stability in the hot water supply due to the large thermal capacitance of the stored hot water. Another advantage is that a large flow rate may be tapped, at least until the tank is drained of hot water and the boiler cannot keep up with the demand. The disadvantage is that a large tank must be used, with the associated cost, bulk, and thermal loss. Sometimes, the boiler fluid is circulated through the tank and the domestic water is plumbed through the immersed tube coil. Unfortunately, this arrangement retains the disadvantages of the storage tank while reaping little of the benefit. The thermal capacitance is not put to good use, since at high hot water draw, heat will not be transferred at a rate sufficient to maintain hot water temperature unless the coil area is made very large. The second type of heat exchanger design, i.e., semi-instantaneous water heaters typically use a compact forced convection heat exchanger and may or may not include a small storage tank of hot water which provides some thermal capacitance. The tank-heat exchanger system is designed so that heat can also be transferred from circulating boiler fluid to quiescent water in the tank when there is no domestic water flow through the heat exchanger. Therefore, the heat exchanger can operate in two modes: in the flow (forced convection) mode, heat is transferred at a high rate, thereby providing the capability for delivering an endless flow of hot water; in the recharge (free convection) mode, heat is transferred at a lower rate to quiescent water in the tank, thereby maintaining a small volume of stored hot water. There are several advantages related to maintaining this stored volume of hot water as the thermal capacitance dampens out the temperature instabilities. It also permits a looser link between the boiler heating rate and the heating rate associated with the rate of hot water draw, thereby making controller design easier. In fact, with the semi-instantaneous water heater, the flow switch can be eliminated, and hot water temperature in the heater tank can be used as the feedback control variable. The thermal capacitance also eases the boiler cycling problem that can arise from demand spikes. An instantaneous water heater is a heat exchanger without any appreciable volume, in which heat is transferred from the boiler fluid flowing through on one side to the domestic water flowing through on the other side. Typically, high fluid velocity is maintained on both sides of the heat exchanger, augmenting the heat transfer coefficient and making possible a compact design relative to the heat transfer rate capacity of the unit. Typical of these compact heat exchangers are tube-in-tube and shell-and-tube designs. Operationally, the system must have a way to sense hot water draw. One advantage of the instantaneous water heater is that no hot water is stored, so that there is no corresponding thermal loss. Past systems have relied on steam as the heating medium. However, current trends in the industry have resulted in a reduction in the number of facilities using steam. Accordingly, there is a need for an instantaneous water heater which uses high temperature hot water instead of steam as a heat source and that addresses the foregoing difficulties and others while providing better and more advantageous overall results. SUMMARY OF THE INVENTION The invention relates to water heaters. More particularly, it relates to an instantaneous water heater which utilizes a high temperature hot water source instead of steam. The present system employs hot water as the heat source, wherein a continuous flow of the hot water passes through the heat exchanger. A high temperature hot water source provides water in a range of approximately 150° to 350° F. The present invention further provides a blending valve which blends cold water with overheated water as it exits the exchanger to control exit water temperature. The blending can occur through the full range of operation of the heat exchanger. The blending valve is of the feed forward type, where the proportion of cold water and the proportion of overheated water is automatically adjusted by the valve, based on total flow rate. The flow rate is instantaneously sensed by differential pressure across the valve. Thus, in accordance with one aspect of the present invention, a system for instantaneously heating water has a heat exchanger for heating cold water to produce overheated water; a hot water supply member connected to a first intake of the heat exchanger; a cold water supply member connected to a second intake of the heat exchanger; a blending valve comprising an intake and an outtake; and a hot water outlet member connected to an outtake of the heat exchanger and to the intake of the blending valve. The cold water supply member is also connected to the blending valve. The blending valve has a chamber for blending the cold water with the overheated water from the heat exchanger to produce blended hot water at a predetermined temperature. In accordance with another aspect of the present invention, a method for instantaneously heating water includes supplying cold water into a heat exchanger via a first intake; supplying hot water into the heat exchanger via a second intake; heating the cold water within the heat exchanger to produce overheated water; and supplying the overheated water from the heat exchanger to a blending valve. Further steps include supplying cold water to the blending valve, blending the cold water and overheated water; and supplying the blending water from the blending valve. The present system conserves use of BTUs; that is, BTUs are given up only on demand. Thus, if no hot water is being used in the building, the high temperature hot water source will exit the heat exchanger at the same temperature as it enters. If a demand exists for hot water, then the high temperature hot water exits the heat exchanger 20 to 40 or more degrees Fahrenheit cooler than it enters. In existing systems which use steam as a heat source, steam flow starts and stops automatically. When there is a demand for hot water, steam condenses in the heat exchanger. The condensed steam drains into a steam trap which opens only when liquid is present. The trap opens to allow new steam to enter the heat exchanger. Steam heat exchangers are well known in the art and are shown in U.S. Pat. No. 4,653,524. If there is no demand for hot water, the steam does not condense, and the trap remains closed. New steam is prevented from entering the heat exchanger. Thus, one advantage of the present invention is the provision of using hot water instead of steam, thus preventing waste of unused steam. Another advantage of the present system is that high temperature hot water has a relatively low heating value compared to steam. For example, for every 1 lb/hr. of steam that condenses in the heat exchanger, a gain of 950 BTU/hr. is realized. In contrast, for every 1 lb/hr. of hot water that has a ΔT (change in temperature) of 40° Fahrenheit, the gain is 40 BTU/hr. This is due to the fact that steam is condensed (latent heat) while high temperature hot water is cooled (sensible heat). As an example, if a hotel or apartment building requires 100 gallons/minute of hot water, heated from 40° Fahrenheit to 140° Fahrenheit, a steam heat exchanger would require about 5,263 lbs./hr. of steam. In contrast, a high temperature hot water unit would only require 250 gallons/minute (125,000 lbs./hr.) of water, based on the water being cooled by 40° F. Another advantage of the present invention is that the heater requires only about 6 square feet of floor space, thus making retrofitting of existing systems easy, as the heater can fit in approximately the space a person can fit. Yet another advantage of the present system is that as an instantaneous water heater, it requires no storage tank, resulting in up to 30% energy savings. Still another advantage of the system is that it has an instant response to flow changes. Yet another advantage of the system is that it produces water temperature to an accuracy of +/−4 degrees Fahrenheit. Still other advantages and benefits of the invention will become apparent to those skilled in the art upon reading and understanding the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein: FIG. 1 shows a perspective view of the instantaneous water heating system in accordance with a preferred embodiment of the present invention; FIG. 2 is a schematic illustration of the instantaneous water heater of the present invention; and, FIG. 3 is a side elevational view of a blending valve of the instantaneous water heater of FIG. 1 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings wherein the showings are for purposes of illustrating a preferred embodiment of the invention only and not for purposes of limiting same, FIG. 1 shows a perspective view of the instantaneous water heating system A in accordance with a preferred embodiment of the present invention. The present system uses a Feed-Forward system which provides instant hot water on demand. Feed-Forward systems are well known in the art and are not explained in more detail here. Sensing demand requirements, a blending valve immediately positions itself to automatically proportion the mix of the overheated hot and cold water, resulting in a constant supply of hot water at +/−4° F. of the preset temperature, regardless of flow rate which is a feature that cannot be achieved with conventional feedback systems. Feedback systems rely on signals from temperature sensing devices that respond too slowly to produce hot water safely and accurately through variant flow demand. Inherent reaction lags may generate slugs of scalding hot or cold water. Damage or malfunction of any feedback system components may result in a “runaway” condition, thereby compromising the reliability of safety devices thereby jeopardizing the safety of the water user. The Feed Forward control system is time-proven to be “hands free”. That is, the process is driven mechanically by the pressure of the potable water demand, so there are no extraneous motive power sources, controls or sensors that could require maintenance. The heater is installed and the desired water temperature is manually set. The instantaneous water heater of the present invention incorporates an integral non-electric fail-safe system, blending hot and cold water to achieve the desired output temperature. Potential failure or damage to the unit will produce cooler water, or no water at all. The instantaneous water heater of the present invention is controlled by pressure differentials induced by flow, and delivers hot water safely and accurately. Existing water heaters that use temperature control feedback to the inlet of the heat exchanger are plagued by temperature fluctuations and cycling. These heaters respond late to hot water demand, as unheated water in the heat exchanger is delivered to the system at start up. This results in an accuracy of +/−10° F. or more to set point. The present system has more than double the accuracy in temperature control, that is, within +/−4° F. of the set point. More particularly, FIGS. 1 and 2 show the instantaneous water heater system A according to the present invention. A heat exchanger 10 , receives high temperature hot water from a source such as hot water supply 12 . The heat exchanger can be a plate heat exchanger, although other types of high efficiency heat exchangers can be used without departing from the scope of the present invention. The water supply source 12 provides hot water in the range of 150° to 350° F. The water flows into the plate heat exchanger via inlet pipe 13 . Cold water also enters the heat exchanger via inlet pipe 14 . The heat exchanger 10 can be used for optimum recovery and efficiency of heat transfer from the hot water to the potable water. Plate heat exchangers are well known in the art, such as shown in U.S. Pat. No. 4,635,715. The plate heat exchanger has a corrugated heat transfer surface that yields heat transfer rates as much as five times higher than those with bare tubes. For certain cases, this efficiency allows the instantaneous water heater to use 50–75% less hot water than designs using bare tubes for heat transfer. As is well known in the art, plate type heat exchangers typically consist of a number of heat transfer plates which are clamped together in a stack in face to face relationship to define flow channels between the adjacent plates. Two streams of media each flow through respective sets of alternate channels, the media being in heat exchange contact through the intervening plates. The plates are sealed together at their edges and entry and exit ports provided at the corners of the plates. Typically, the outer edges of adjacent plates, and the region around the ports, have been sealed together by gaskets which sit in a groove formed in one of the plates. The groove supports the gasket against being forced outwards by pressurized medium in the flow space. Recently, gaskets have been replaced in whole or in part by a permanent joint, such as adhesive, solder, braze, a plastic moulding or by welding. This may be done to provide a less costly seal or to provide increased security against leakage of the medium from between the plates. In a typical plate heat exchanger, a plate pair has first and second plates permanently sealed together at an edge region to form a seal. The first plate is provided in the edge region with a groove facing towards the second plate for receiving a gasket to form a seal with a second similar, adjacent, plate pair, and the underside of the groove mates with and contacts the inner face of a sealing portion of the second plate in a contact region at which the two plates are permanently joined together to form a by-pass area defined between the plates inboard of the contact region. Each plate can have a pattern of corrugations covering a heat transfer surface. The corrugations of the adjacent plates bear on one another at respective upper and lower boundary planes to hold the plates apart when they are compressed in a stack and to define a tortuous flow path. Inlet and outlet holes provide for fluid to flow through the flow space between the plates of a pair. Through flow holes are sealed from the flow space, and connected with the flow space formed between adjacent pairs of plates. Referring now to FIG. 2 , water exits the heat exchanger via outlet pipe 15 . The water exiting the heat exchanger is overheated and is much too hot to be used at a hot water tap. Thus, the overheated water then enters a blending valve 16 to be blended with cold water until a suitable temperature for the water is obtained. The blending valve is located downstream from the heat exchanger and utilizes pressure differential to control the precise mixing of hot and cold water to produce hot water within +/−4° F. of the set point. The valve operates on flow rather than temperature, guaranteeing steady hot water supply despite large fluctuations in demand. The blending valve includes a cold water inlet 17 , and an overheated water inlet 18 associated with cold water inlet 14 and overheated water outlet 15 of the heat exchanger. The feed-forward blending valve assembly, which is also well known in the art as shown in U.S. Pat. No. 4,653,524, assures safe and accurate temperature control of the heated water, through all rated flow capacities. Since the valve is controlled by flow demand, no thermostatic sensing devices are utilized. Particularly, the blending valve has a proportional valve plug 24 which is regulated by movement of a diaphragm 26 , induced by pressure differentials in a sensing head 28 . A sensing line 30 “loads” the top portion of the diaphragm with supply line cold water pressure while blended water outlet pressure is being sensed below. Flow demand imparts a pressure imbalance above (+) and below (−) the diaphragm resulting in movement of the diaphragm and proportioning plug. This movement aligns ports in the plug with supply ports in the valve body, introducing the correct proportion of overheated and cold water via inlets 18 and 17 respectively. This action automatically generates blended hot water through all rated flow capacities at the chosen preset temperature (+/−4° F.). The blended hot water exits the valve via outlet pipe 32 . An integral fail safe system (not shown) can permit valve stem travel in the event of proportioning plug restriction or parts failure, opening an auxiliary cold water port. Cold water flooding yields cooler water, or in the event of a parts failure, no water at all. Temperature of the water is easily adjusted by side to side movement of a temperature control rod 34 located on the side of the valve body. Stabilization adjustments are made during initial startup by rotation of the control rod. All settings are then locked in with a locking device such as a locking ring and set screw. Thus, the high temperature hot water instantaneous heater is an extremely durable and compact water heater that delivers unlimited hot water on demand with the reliability and dependability of the time-proven feed forward blending system. The system has many applications and uses, ranging from showers and lavatories, to cafeterias, wash down systems, safety shower/eye wash stations and jacket heating systems. The exemplary embodiment has been described above. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations.
A system for instantaneously heating water has a heat exchanger for heating cold water to produce overheated water; a hot water supply member connected to a first intake of the heat exchanger; a cold water supply member connected to a second intake of the heat exchanger; and a blending valve having two intakes and an outtake. A hot water outlet member is connected to an outtake of the heat exchanger and to the intake of the blending valve. The cold water supply member is also connected to the blending valve. The blending valve has a chamber for blending the cold water with the overheated water from the heat exchanger to produce blended hot water at a predetermined temperature.
8
FIELD OF THE INVENTION The present invention relates to a process for preparing a spherical copper fine powder having an average grain size ranging from 0.l μm to a few μm , and this powder is utilized as a conductive powder which is the main component of a conductive paste. BACKGROUND OF THE INVENTION As a copper fine powder having a narrow particle size distribution, an average grain size ranging from 0.l μm to a few μm , and a spherical form has an excellent pasting property and finely forms a thick film conductor when used in an electronic circuit, and also a copper fine powder having a spherical form can be formed into a fired film having a high density, so that the electric resistance can be reduced, such copper fine powders having the properties as described above have been required. Various processes have been known to prepare such copper fine powders, among which a liquid phase reduction precipitation process is employed as a method industrially practiced as well. This method comprises adding a reducing agent in a liquid phase containing copper ion and stirring the mixture to precipitate the metal powder directly in the liquid phase, and its examples include methods using reducing agents such as formalin (Japanese patent publication No. 76003/1980), hydrazine (Japanese patent publication No. 155302/1982) and sodium borohydride or dimethylamine borane (Japanese patent publication No. 224103/1983), and a method of reduction by hydrogen gas under pressurized condition (Japanese patent publication No. 22395/1968, Japanese patent publication No. 26727/1969), each of which affords a spherical or granular powder of several hundreds of μm to a few μm . The copper fine powders prepared by those methods have considerably narrow particle size distributions and thus powders suitable for pasting can be frequently obtained, but the problems posessed by these methods are that a method having the better grain size and the better form controlling property requires the more expensive reducing agent and the production cost is high because of using a batch system reactor. Also a method of reducing an oxide in a solid state has been known, but as this method generally results in large grain size and is affected by the form of the oxide, powders having the above properties are difficult to prepare. Recently, a process for preparing superfine powders by means of a method of evaporation in gas or a fused metal reaction method using hydrogen arc plasma have been proposed, but these methods relates to superfine powders of a maximum of about 0.l μm and have a disadvantage in which the powder is difficult to make into a paste when it is too superfine. A process for preparing fine powders by means of a method of reducing a metal halide (vapor phase chemical reaction process, a kind of CVD) (Japanese patent publication 7765/1984) has been also proposed, but according to this method, the obtained powder is granular (in most cases, cubically shaped) in the fine powder zone of 0.l μm or more. However, the vapor phase chemical reaction process has an advantage in which the used reactor is of a continuous system. SUMMARY OF THE INVENTION An object of the present invention is to provide a process by which spherical powders can be obtained both in the superfine powder zone (less than 0.1 μm) and in the fine powder zone (0.1 μm or more), by improving the method using a continuous reactor in the method for preparing copper powders having excellent properties as described above, and employing the chemical vapor phase reaction process suitable for mass production. The present invention comprises evaporating cuprous chloride, feeding this into a reaction part by the vapor pressure of itself or by using an inert gas as a carrier, and contacting and mixing the cuprous chloride with a reducing gas (hydrogen) in the reaction part. This reaction part generally has a nozzle in the center part inside the tube reactor, and the two gases are contacted at the outlet of the nozzle, and then mixed and react, moving into the outlet with precipitating the powder. In this case, the space to mix the both gases is maintained at a temperature of 900° C. to less than 1150° C. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a longitudinal sectional view of a reactor which can be preferably used to practice the present invention, FIGS. 2 and 3 are microscopic photographs showing the form of the grain of a copper fine grain prepared according to the present invention, and FIG. 4 is a microscopic photograph showing the form of the copper powders according to a comparative example. DETAILED DESCRIPTION OF THE INVENTION In the vapor phase chemical reaction process, the growth of grains are considered as follows (Funtai Kogaku-Kaishi, Vol. 21, pp. 759-767 (1984)). The moment a metal halide vapor is contacted with a reducing gas, monomers of the metal atom or cluster are formed, which collide and coalesce to form a superfine grain. The grain growth is further caused by collision, coagulation and coalescence of the superfine grains each other. The superfine grains are spherical, but they are often found to be polyhedrons having no edge or angle by more careful observations. When the grain is particularly in the superfine powder zone, the ratio of the surface energy is reduced, often showing crystal habit, so that it has been reported that the grain takes a cubic form when it is 0.1 micron or more, but the present invention has succeeded in obtaining spherical fine powders by selecting the reaction temperature suitable for the material to be prepared. The reduction reaction by hydrogen of cuprous chloride is possible at 425° C. which is a melting point of cuprous chloride and the reduction has been conventionally conducted at a temperature of about 500°-700° C., but the limitation of 900° C. or more herein is experimentally decided as a condition to conduct the reaction in vapor phase and grow the grain under a fused condition or condition close thereto. As the powder obtained at a reaction temperature of less than 900° C. is a superfine powder having 0.1 micron or less and also contains a considerable amount of copper chloride, owing to insufficient conversion resulting from low reaction rate, it is significant to limit the temperature to 900° C. or more. As the reduction reaction by hydrogen of cuprous chloride is an exothermic reaction, the temperature of the gas has a possibility to increase by the reaction to more than the melting point, even if the temperature of the outer wall of the reactor is lower than the melting point of copper (1083° C.). When the reaction is proceeded at the melting point or a temperature close thereto, growth of the grain by cohesion also proceeds in a spherical from, resulting in maintaining the spherical form also when cooled. On the other hand, the upper limit of the reaction temperature is decided as 1150° C. to avoid that the reaction at more than this temperature causes combination of large grains each other as the sufficiently grown grains are also liquid drops, forming grains which are too large against the average grain size as well, resulting in extension of the size distribution. Also from this temperature the conversion begins to decrease eminently because the equilibrium of the reduction of cuprous chloride vapor is unfavored by the increase of temperature. In order to grow the grain size, the evaporation temperature of copper chloride should be made sufficiently high to increase the vapor concentration of the copper chloride. The superfine grains formed by the reaction collide by the Brown motion and grow with coalescing each other, in the process of which the copper fine powder as it remains spherical is formed by maintaining the growth even if it is close to the fine powder zone and the forced cooling. In this case, the spherical form is maintained by rapid cooling. The cooling rate of the present method is 1500 deg/sec or more. The average grain size is mainly controlled by the evaporation temperature of cuprous chloride and the evaporation temperature of 800° C. or more is required to make 0.1 μm or more, although it varies depending on the flow rate of the carrier gas. The present invention has an effect that a copper fine powder extremely preferred as a conductive paste can be prepared at low cost. EXAMPLE 1 Using a reactor 1 as shown in FIG. 1, about 5 g of cuprous chloride was put into a quartz boat 3 of an evaporation part 2 and evaporated at 900° C., argon gas was fed into a reaction part 5 maintained at 1000° C. as a carrier gas 4 at 4 liters/min, and hydrogen gas 7 was fed through a center nozzle 6 at 2 liters/min. The formed copper fine powder 9 was passed through a water-cooling part 8 and then recovered by an cylindrical filter to collect 1.35 g of a copper fine powder. The specific surface area of the obtained copper fine powder was 4.8 square meters/g, and the powder was found to be a spherical fine powder having an average grain size of 0.l μm observed by the electron microscopy. EXAMPLE 2 When the same procedure as in the above Example 1 was conducted using the evaporation temperature and reaction temerature of 1000° C. each, the flow rate of the carrier gas of 1 liter/min, and the flow rate of the hydrogen gas 7 of 0.5 liter/min, the obtained copper fine powder had a specific surface area of 3.0 square meters/g, and the average grain size calculated from the electron microscopy was 0.2 μm. These are shown by a scanning microscopic photograph of 10000 magnifications and a transmittant electron microscopic photograph of 25000 magnifications in FIGS. 2 and 3, respectively. The copper powder is found to have a spherical form and a narrow size distribution. The powder is extremely preferred as filler powders for a paste. COMPARATIVE EXAMPLE 1 Under conditions of the evaporation temperature and reaction temperature of 1000° C. each, the argon flow rate of 2 liters/min and the hydrogen flow rate of 1 liter/min, a copper powder was prepared using the reactor having no water-cooling part 8 in FIG. 1. The powder had an average grain size of 0.3 μm, and was a globule exhibiting crystal habit as shown by a transmittant electron microscopic photograph of 25000 magnifications in FIG. 4. Under this preparation condition, the cooling rate was about 1000 deg/sec. COMPARATIVE EXAMPLE 2 The copper fine powder was prepared using the same conditions except a reaction temperature of 800° C. in the same equipment as in the above examples, and a superfine powder having a specific surface area of 13 square meters/g (0.1 μm or less) was obtained. This powder contained a considerable amount of copper chloride according to the X-ray diffraction. COMPARATIVE EXAMPLE 3 When the reaction temperature was changed to 1150° C. in the same equipment as in the above examples, a fine powder having an average grain size of 0.5 μm was obtained, with which several % of grains having a size of 1 μm or more were mixed, and the size distribution was extended. The powder contained 5% of unreacted cuprous chloride.
In a process for preparing a spherical copper fine powder having an average grain size ranging from 0.1 μm to a few μm, by use of chemical vapor deposition of cuprous chloride vapor with a reducing gas, the vapor deposition zone is maintained at a temperature ranging 900° C. to less than 1,150° C. and the generated particles are quenched subsequently. The generated powder is utilized as a conductive powder which is the main component of a conductive paste.
8
CROSS REFERENCE TO RELATED APPLICATION This is a continuation-in-part of Ser. No. 50,436 filed May 18, 1987, now U.S. Pat. No. 4,818,243. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to crosslinking of cellulosic materials to produce fabrics with wrinkle recovery properties required for durable press finishes. 2. Description of the Prior Art J. F. Walker [U.S. Pat. No. 2,548,455 (1951)] described the use of acetals for crosslinking cellulosic materials to produce improved wrinkle recovery. He reported crosslinking of paper, starch, regenerated cellulose, and cotton with 2,5-dimethoxytetrahydrofuran. However, his process required curing for 15 min at 140°C. Although Walker used 2,5-dimethoxytetrahydrofuran, he in effect obtained crosslinking with the dialdehyde, succinaldehyde, which is the hydrolysis product of 2,5-dimethoxytetrohydrofuran formed in the reaction with cellulose. Frick and Harper [J. G. Frick, Jr. and R. J. Harper, Jr., J. Appl. Polym. Sci. 29: 1433-1447 (1984); and J. G. Harper, Jr., J. Appl. Polym. Sci. 30: 3467-3477 (1985)] found that acetals derived from dialdehydes crosslinked cotton to produce improved wrinkle recovery. The most effective were tetraalkoxy acetals of succinaldehyde and gluteraldehyde applied to cotton from water solutions. They also found that 2,5-dimethoxytetrahydrofuran crosslinked cotton as walker had reported. However, Frick and Harper proposed a different crosslinking mechanism than Walker. SUMMARY OF THE INVENTION We have now discovered cellulosic fabrics with improved wrinkle recovery, which are characterized by crosslinks of the following structures: ##STR1## where "Cell" stands for cellulose and R stands for an alkyl group or cellulose. In accordance with this discovery, it is an object of the invention to provide a process for treating cellulosic materials with hydroxy derivatives of acetals or with hydroxy derivatives of dialkoxy acetals of dihydrofuran in the presence of special combination catalysts, thereby crosslinking the cellulose at a very rapid rate to produce materials with improved wrinkle recovery. A further object of the invention is to provide a process for treating cotton fabric with 2,3-dihydroxy-1,1,4,4-tetramethoxybutane in the presence of an acid catalyst and a hydroxy acid activator, thereby producing a fabric with improved wrinkle recovery. A further object of the invention is to provide a process for treating cotton fabric with 3,4-dihydroxy-2,5-dimethoxytetrahydrofuran in the presence of an acid catalyst and an hydroxy acid activator, thereby producing a fabric with improved wrinkle recovery. A further object of the invention is to provide a conventional pad-dry-cure process for treating cotton fabric with said acetals, thereby crosslinking the fabric at a very rapid rate in the presence of said catalysts to provide wrinkle-resistant fabrics for use in permanent press textiles, said textiles having the advantages of no release of toxic formaldehyde. Other objects and advantages of this invention will become obvious from the ensuing description. DETAILED DESCRIPTION OF THE INVENTION In this invention hydroxy derivatives of acetal and dialkoxy dihydrofurans are contemplated as agents for crosslinking, thereby improving the wrinkle recovery of cellulose materials. These reagents have been found to have advantages over prior process for treating cellulose. One advantage lies in the fact that the hydroxy derivatives have high boiling points, which makes it possible to cure cellulosic materials at higher temperatures and shorter reaction times than was possible with more volatile acetals that do not contain hydroxyl groups. Another advantage is that hydroxy acetals are more water soluble and thus more practical for application to cellulosic materials. Another advantage is that the polyfunctional acetals of this invention are more reactive, and thus give higher wrinkle recovery angles when applied to cellulosic textiles than difunctional materials under comparable conditions. Whereas this invention is primarily concerned with a process for treating cotton fabrics, other cellulosic materials may be used. These include regenerated cellulose, paper, starch, and the cotton in cotton/polyester blends. When the cellulosic material is cotton fabric or a cotton/polyester blend, an improvement in wrinkle recovery is obtained. An improvement in wrinkle recovery is an indication of cellulose crosslinking. Fibers from fabrics treated with hydroxy acetals are insoluble in cupriethylene-diamine dihydroxide, which is an indication of crosslinking. Since these crosslinks form an ether linkage with cellulose, they are resistant to hydrolytic conditions encountered in laundering. In the crosslinking reaction, hydroxy groups of cellulose react with alkoxy groups of acetals, and the corresponding alcohol is eliminated in the process. Acid catalysts which are suitable for use in this invention are metal salts such as aluminum sulfate, aluminum chlorohydroxide, magnesium chloride, zinc nitrate, and certain organic acids such as p-toluene sulfonic acid. The preferred catalyst is aluminum sulfate. A catalyst activator may be used also in combination with the said catalysts. These activators are from the group consisting of organic hydroxy acids. The preferred hydroxy acids are citric acid and tartaric acid or a combination thereof. Although the acid catalyst may be used alone, it is preferable to use a combination of the catalyst and hydroxy acid activator. Solutions used in treating cellulosic materials are prepared by dissolving acetal and catalyst in a suitable solvent, such as water. Concentration of acetal may vary over a range from about 5% to20%, and the combined catalyst activator concentration is from about 0.4% to 2.0% on a weight basis, depending on the particular catalyst system selected. In preparing solutions it is advantageous, although not necessary, to use a buffer to help prevent excessive strength loss of fabric due to acid catalyst. An exemplary buffer is a basic aluminum acetate borate of the formula, Al(OH) 2 OAc.1/3H 3 BO 3 . It is also advantageous, although not necessary, to add a surface-active agent and a softening agent to the solution to improve wetting of cellulosic material. The pH of the solutions can range from about 2.3 to 6.5 depending on catalyst selected. Before treating cellulosic material it is important to determine if the material contains any residual alkalinity, since this would neutralize a portion of the catalyst and render the catalyst less effective during treatment. If the material is found to be alkaline, it should be scoured prior to the impregnation step. Scouring is conveniently achieved by passing the material through dilute acetic acid and drying. The cellulosic material is impregnated with acetal solution and any excess solution is removed, preferably by padding. The material may then be cured without a drying step, or it may be dried prior to curing. It is preferable to dry prior to curing at temperatures ranging from about 70° C. to 90° C. for from about 3 to 5 minutes. After drying, the material is cured at approximately 135° C. to 170° C. for about 10 seconds to 3 minutes, the shortest time at the highest temperature. Acetals of hydroxy compounds that are suitable for this invention include methyl, ethyl, iso-propyl, and tert-butyl acetals. Preferred acetals are 3,4-dihydroxy-2,5-dimethoxytetrahydrofuran, hereinafter referred to as DHMTF, and 2,3-dihydroxy-1,1,4,4-tetramethoxybutane, hereinafter referred to as DHTMB. DHMTF was prepared by aqueous potassium permanganate oxidation of 2,5-dimethoxy-2,5-dihydrofuran as described by John C. Sheehan and Barry M. Bloom [J. Am. Chem. Soc. 74: 3825-3828 (1952)] and by Niels Clauson-Kaas [U.S. Pat. No. 2,748,147 (1956)]. DHTMB was also prepared by aqueous potassium permanganate oxidation of 1,1,4,4-tetramethoxybutene-2 as described by Karl Zeile and Alex Heusner [Chem. Ber. 90: 1869-1870 (1957), Chem. Abstr. 54: 17439d (1960)]. Other suitable acetals are glyceraldehyde diethyl acetal, hereinafter referred to as GDEA, and glyceraldehyde dimethyl acetal, hereinafter referred to as GDMA. The GDEA and GDMA used in this invention are prepared by the aqueous potassium permanganate oxidation of the appropriate acrolein acetal as described in Organic Synthesis, Volume II, pp. 307-308 (1943), the procedure of which is herein incorporated by reference. It will be obvious to those skilled in the art that other hydroxy acetals will be suitable for this invention. These would include but not be limited to mono-, di-, and polyacetals containing one or more hydroxyl groups. Fabric samples treated with DHMTF or DHTMB were yellowed during the heat curing process. A probable explanation of this was the presence of impurities in the DHMTF and DHTMB. Nuclear magnetic resonance (NMR) spectra of the compounds indicated the presence of carbonyl groups (presumably aldehydes) as well as impurities containing unsaturated groups. It is believed that pure DHMTF and DHTMB would not cause the fabric to turn yellow. The yellow color could be removed by bleaching with oxidizing agents such as magnesium peroxyphthalate, sodium perborate, hydrogen peroxide, sodium hypochlorite (NaOCl), or hypochlorous acid (HOCl). The reducing agent sodium borohydride was also effective in removing the yellow color. Preferred agents were NaOCl and HOCl, because the color could be removed in about 15 seconds or less to about 60 seconds at ambient room temperature at HOCl or NaOCl concentrations from about 0.05% to 0.10%. The fabric samples treated according to this invention are bleached and scoured 80×80 cotton printcloth, and these samples are tested for conditioned wrinkle recovery angles (WRA) by the standard method of the American Society for Testing Materials, Philadelphia, PA, 1964 Book of ASTM Standards, designation D1295-60T, herein incorporated by reference. After curing, fabric samples were thoroughly rinsed in hot running tap water and oven dried before testing. Without desiring to be bound to any particular theory of operation, it is believed that hydroxy derivatives of di- or tetraalkoxy acetals derived from dihydrofurans or from the alkene class of acetals, respectively, react with cellulosic materials to crosslink hydroxy groups, resulting in improved wrinkle recovery. The following general equations represent how the reaction of cellulose with DHMTF, DHTMB, and GDMA, respectively, proceeds: ##STR2## Where "Cell" stands for cellulose and R stands for an alkyl group or cellulose. In Equation (1) above, another mechanism for the reaction with cellulose should not be ruled out. Under acidic conditions of the reaction, an opening of the tetrahydrofuran ring is possible. Walker described this hydrolysis reaction [U.S. Pat. No. 2,548,455 (1951)]. If ring opening occurs with DHMTF the hydrolysis product would by tartraldehyde, which could not react with cellulose to give a cellulose crosslink similar to that of Equation (2) above. Niels Clauson-Kass [U.S. Pat. No. 2,748,147 (1956)] reported that 2,5-dialkoxy-3,4-dihydroxytetrahydrofurans could be readily hydrolyzed to tartaric dialdehydes. The following examples are intended only to further illustrate the invention and are not intended to limit the scope of the invention, which is defined by the claims. EXAMPLE 1 A water solution was prepared containing 10%, 2,3-dihydroxy-1,1,4,4-tetramethoxybutane (DHTMB), 0.76% aluminum sulfate of the formula, Al 2 (SO 4 ) 3 .16H 2 O, 0.76% L-(+)-tartaric acid, 0.3% Al(OH) 2 OAc.1/3 H 3 BO 3 (aluminum hydroxyacetate borate) as a buffer, and 1% silanol softener. The softener was added to the solution last. Three samples of cotton printcloth was padded with the solution to a wet pick-up of 70-80% using a laboratory padder. The samples were dried for 5 minutes in a forced draft oven at 85° C., and then cured similarly at the time and temperature indicated in Table I. The samples were rinsed in hot tap water, dried in an oven for 5 minutes, and air equilibrated. Weight gain (% add-on) and WRA (warp+fill) are also shown. All of the treated samples had good WRA, which was in the range required for permanent press fabrics. All of the samples were yellowed by the treatment. The yellow color could by substantially removed by treatment with the agents described in Example 3 and in Table III. EXAMPLE 2 A water solution was prepared exactly as in Example 1 except that 3,4-dihydroxy-2,5-dimethoxytetrahydrofuran (DHMTF) was used instead of DHTMB. The concentration of DHMTF in the solution was 10%. The solution was applied to samples of cotton printcloth in the same manner as that described in Example 1. Curing time and temperature, % add-on, and WRA (W+F) are shown in Table II. TABLE I______________________________________Cure Add-On WRA (W + F)°C./min) (%) (degrees)______________________________________140/2 5.2 278150/1 5.5 272160/0.5 4.9 277Untreated Control -- 190______________________________________ TABLE II______________________________________Cure Add-On WRA (W + F)(°C./min) (%) (degrees)______________________________________135/3 4.3 278140/0.5 3.2 270140/1 4.0 275150/0.5 4.5 282160/0.33 4.0 280Untreated Control -- 190______________________________________ TABLE III______________________________________Bleaching Agent Stain rating______________________________________None -- 32.5% Magnesium peroxyphthalate, pH 6, 20° C. 4 pH 6, 60° C. 4-5 pH 7, 20° C. 4 pH 8, 20° C. 41.5% NaBO.sub.3.H.sub.2 O pH 6, 60° C. 41.0% NaBO.sub.3.H.sub.2 O pH 6, 60° C. 42.5% H.sub.2 O.sub.2 pH 9, 60° C. 41.5% NaBH.sub.4 pH 6, 60° C. 4-5DMDHEU-Treated Control, 4-5No Bleaching______________________________________ TABLE IV______________________________________Bleaching Agent Stain Rating______________________________________None 2-32.5% Magnesium peroxyphthalate pH 6, 20° C. 4-5 pH 6, 60° C. 4-51.5% NaBO.sub.3.H.sub.2 O pH 6, 60° C. 4-52.5% H.sub.2 O.sub.2 pH 9, 60° C. 4-5DMDHEU-Treated Ccntrol, 4-5No Bleaching______________________________________ All of the treated samples had good WRA, which was in the range required for permanent press fabrics. All of the fabrics were yellowed by the treatment. The yellow color of the samples could be substantially removed by the same method described in Example 3. The results are shown in Table IV. EXAMPLE 3 Fabric samples treated with DHTMB as described in Example 1 were successfully bleached with (a) magnesium peroxyphthalate in a 2.5% aqueous solution at pH 6 at about 20° C. (ambient) or 60° (pH levels were maintained by MacIlvains's buffer solution); (b) sodium perborate in a 1.5% aqueous solution at pH 6 at 60° C.; (c) hydrogen peroxide in a 2.5% aqueous solution at pH 9 at 60° C. or (d) sodium borohydride in a 1.5% aqueous solution at pH 6 at 60° C. Treatments were carried out with a 20:1 liquid-to-fabric ratio for 15 min, followed by a 5-min rinse in deionized water and air drying. Evaluation of color removal was by the AATCC gray scale for staining [AATCC Technical Manual, Vol. 62 (1987)]. Results are shown in Table III. The control in Table III was fabric which had been treated with the typical permanent press finish, dimethloldihydroxyethyleneurea (DMDHEU). All of the bleached samples had higher stain ratings (4-5) than the DHTMB-treated samples with no bleach (3 rating), and all were equal to or nearly equal to the DMDHEU control. EXAMPLE 4 Fabric samples treated with 3,4-dihydroxy-2,5-dimethoxytetrahydrofuran (DHMTF) were successfully bleached as described in Example 3. The stain ratings are shown in Table IV. All of the samples had stain ratings equal to a DMDHEU-treated control, and much better than the unbleached DHMTF-treated fabric. EXAMPLE 5 A solution was prepared by dissolving 5 parts of a commercial-grade sodium hypochlorite bleach (containing about 5.25% NaOCl) in 500 parts of water. This solution contained about 0.05% NaOCl and had a pH of about 9.9. Samples of cotton printcloth treated with DHTMB and DHMTF, respectively, were stirred in the solution for 1 min at ambient room temperature, immediately rinsed thoroughly in deionized water, and air dried. Most of the yellow color was removed from the samples. The bleaching process was repeated in the same manner except that the solution contained about 0.1% NaOCl (pH 10.1). Fabric samples were noticeably whiter than those treated with 0.05% NaOCl bleach. The whiteness of the samples was also equal to that of samples bleached by the agents of Examples 3 and 4. EXAMPLE 6 A dilute solution of hypochlorous acid (HOCl) was prepared by dissolving 15 parts of a commercial-grade sodium hypochlorite bleach (containing about 5.25% NaOCl) in 1000 parts of water and adjusting to a pH of about 5.5 with dilute hydrochloric acid. This solution contained about 0.056% HOCl. Samples of cotton printcloth treated with DHTMB or DHMTF were stirred in the solution for periods of 1/2 min, 1 min, and 2 min, respectively, at ambient room temperature. The samples were then rinsed thoroughly in deionized water and air dried. They were bleached to the same degree of whiteness as with NaOCl in Example 5 except that HOCl bleached the samples more rapidly, requiring only about 30 seconds compared to 60 seconds for NaOCl. EXAMPLE 7 A solution of HOCl was prepared as in Example 6 except that 10 parts of commercial-grade NaOCl was dissolved in 500 parts of water and adjusted to pH 5.0. The solution contained about 0.07% HOCl. Cotton fabric samples treated with DHTMB or DHMTF were similarly bleached for 2 min. Similar results were obtained as in Example 6. EXAMPLE 8 Example 7 was repeated except that two solutions were prepared. One was adjust to pH 6.0 and the other to pH 7.0. The fabric samples were bleached for 15, 30, and 60 seconds, respectively. DHTMB-treated samples were bleached more rapidly than the DHTMF samples, requiring 15 seconds or less. About 60 seconds was required for DHTMF to reach the same degree of whiteness. The wrinkle recovery angles (WRA) of the treated cotton samples were largely unaffected by the bleaching process using hypochlorous acid. The results are shown in Table V. There was a slight reduction in WRA at the lowest curing temperature of 140° C. Similar results would be expected with NaOCl bleach at pH 9.9 to 10.1 because acetal crosslinks are known to be more stable to alkaline than to acid conditions. EXAMPLE 9 A water soluble was prepared containing 10% glyceraldehyde diethyl acetal (GDEA), 0.4% aluminum sulfate of the formula Al 2 (SO 4 ) 3 .16H 2 O and 0.4 L-(+)-tartaric acid. Samples of cotton printcloth were padded with the solution to a wet pick-up of 70-80% using a laboratory padder. The samples were then dried for 5 minutes in a forced draft oven at 85° C., and cured similarly for 1 minute at 150° C.. The fabric was then rinsed in water, oven dried, and air equilibrated. It had a weight gain of 3.0% and a wrinkle recovery angle (WRA) of 253° C. (W+F). A similar sample cured for 0.5 minutes at 160° C. had a WRA of 248° C. An untreated control sample had a WRA of 190°. TABLE V______________________________________ WRA (W + F) WRA (W + F) Cure degrees before degrees after pH ofTreatment °C./min HOCl bleach HOCl bleach HOCl______________________________________DHTMB 150/1 272 277 5DHTMB 160/0.5 262 262 5DHTMB 140/2 278 265 5DHMTF 160/0.33 267 265 6DHMTF 160/0.33 263 262 6______________________________________ TABLE VI______________________________________Cure Add-On WRA (W + F)°C./min. (%) (degrees)______________________________________125/2 4.3 226142/0.5 5.4 232115/2 3.2 222115/3 4.3 231Untreated Control 190______________________________________ EXAMPLE 10 A water solution of GDEA was prepared in the same manner as in Example 7 except that it contained 1% of a reactive silicone fabric softener containing silanol end groups. Five cotton printcloth samples were padded with the solution and cured at the following time and temperatures as indicated in Table VI. Weight gain (or % add-on) and WRA (warp & fill) are also shown. The untreated control fabric had a WRA of 190°. All of the samples of Table VI show improved results. EXAMPLE 11 A water solution was prepared containing 10% GDEA, 0.76% Al 2 (SO 4 ) 3 .16H 2 O, 0.77% tartaric acid, 0.28% Al(OH) 2 OAc.1/3H 3 BO 3 as a buffer, 1% silanol softener, and 0.1% of an alkylaryl polyether alcohol [in this case a nonionic wetting agent, Triton X-100 (Rohm and Haas)]. Cotton printcloth samples were treated as in Example 9 and cured as indicated in Table VII. Percent weight gain (add-on) and WRA are also shown. Samples shown in Table VII were dried for 5 minutes at 85° C. When a fabric sample was dried for 2 minutes at 115° C. and cured for 1 minute at 150° C., a WRA of 245° was obtained. All of the treated samples show improvement over the control. EXAMPLE 12 A water solution was prepared containing 10% GDEA, 0.57% Al 2 (SO 4 ) 3 , 2.1% L-(+)-tartaric acid, 0.35% Al(OH) 2 OAc.1/3H 3 BO 3 , and 1% polyethylene softener instead of the silanol softener used in previous examples. Samples of cotton fabric were padded with the solution, dried 2 minutes at 115° C. and cured as indicated in Table VIII. Data on % add-on and WRA are also given. EXAMPLE 13 A water solution was prepared containing 10% GDEA, 0.77% Al 2 (SO 4 ) 3 , 0.76% L-(+)-tartaric acid, 0.28% Al(OH) 2 OAc.1/3H 3 BO 3 , and 1% silanol softener. Cotton printcloth samples were padded with the solution, dried 2 minutes at 115° C. and cured as indicated in Table IX. Data on % add-on and WRA are also given. Improvement in all samples was shown over untreated control. TABLE VII______________________________________Cure Add-On WRA (W + F)°C./min. (%) (degrees)______________________________________115/3 3.5 220115/5 3.5 222150/1 3.8 244160/0.5 4.2 247160/1 4.4 254170/0.25 3.3 251170/0.17 4.2 273Untreated Control 190______________________________________ TABLE VIII______________________________________Cure Add-On WRA (W + F)°C./min. (%) (degrees)______________________________________150/0.5 2.2 231160/0.25 1.9 224160/0.5 2.4 248Untreated Control 190______________________________________ TABLE IX______________________________________Cure Add-On WRA (W + F)°C./min. (%) (degrees)______________________________________150/1 2.8 245160/0.5 2.9 236170/0.25 3.3 251Untreated Control 190______________________________________ TABLE X______________________________________Cure Add-On WRA (W + F)°C./min. (%) (degrees)______________________________________140/2 2.5 236150/1 2.5 226160/0.5 2.1 225Untreated Control 190______________________________________ EXAMPLE 14 A water solution was prepared containing 10% GDEA, 0.77% Al 2 (SO 4 ) 3 .16H 2 O, 0.37% L-(+)-tartaric acid, 0.35% citric acid, and 0.28% Al(OH) 2 OAc.1/3H 3 BO 3 . No softener was used in this formulation. This formulation differs from the preceding examples in that the catalyst activator is a combination of tartaric and citric acids. The samples were dried for 2 minutes at 115° C. Data on treated cotton printcloth samples are shown in Table X, clearly indicating improvement over untreated control. EXAMPLE 15 In this example and the following ones, dl-glyceraldehyde dimethyl acetal (GDMA) was used instead of glyceraldehyde diethyl acetal. A water solution was prepared containing 10% GDMA, 0.77% Al 2 (CO 4 ) 3 .16H 2 O, 0.76% L-(+)-tartaric acid, 0.28% Al(OH) 2 OAc.1/3H 3 BO 3 , 1% silanol softener, and 0.1% Triton X-100 wetting agent. Cotton printcloth samples were padded with the solution to a wet pick-up of about 90%, dried for 5 minutes at 85° C., and cured as indicated in Table XI, clearly indicating improved values over untreated control. Data on % add-on and WRA are also given. The WRA of the untreated control fabric was 190°. From the WRA values obtained with GDMA it is evident that GDMA is more reactive than GDEA, and therefore preferred. WRA values of 270° are within the range of those required for durable press finishes. EXAMPLES 16 Example 15 was repeated except that the fabric was not scoured with 1% acetic acid prior to treatment. The results are shown in Table XII. From the WRA values, it is obvious that better results were obtained when the fabric was given an acid scour prior to treatment. TABLE XI______________________________________Cure Add-On WPA (W + F)°C./min. (%) (degrees)______________________________________140/2 2.9 265150/1 3.7 271160/0.5 3.8 270170.0.17 2.7 241Untreated Ccntrol 190______________________________________ TABLE XII______________________________________Cure Add-On WRA (W + F)°C./min. (%) (degrees)______________________________________140/2 3.2 247150/1 3.3 260160/0.5 3.3 248Untreated Control 190______________________________________ EXAMPLE 17 A water solution was prepared containing 10% GDMA, 1% Al 2 (OH) 5 Cl.2H 2 O, 1% citric acid, and 1% polyethylene softener. A sample of cotton fabric composed of 50% cotton and 50% polyester was padded with the solution to a wet pick-up of about 65%. The fabric samples were dried for 5 minutes at 85° C. and cured as indicated in Table XIII. The WRA of an untreated sample of cotton/polyester (50/50 blend) was 257°. From the table it can be seen that there was a significant improvement in WRA at high temperatures for very short periods of time. A curing temperature of 190° C. for about 10 seconds is preferred because a higher temperature or a longer cure time yellowed the fabric slightly. TABLE XIII______________________________________Cure Add-On WRA (W + F)°C./min. (%) (degrees) Fabric Color______________________________________200/0.17 2.5 299 slight yellow190/0.17 2.6 288 white190/0.25 2.9 296 slightly yellow______________________________________
The acetals, 2,3-dihydroxy-1,1,4,4-tetramethoxybutane, 3,4-dihydroxy-2,5-dimethoxytetrahydrofuran, and glyceraldehyde dimethylacetal, when applied to cotton fabric by conventional pad-dry-cure procedures using special combined acid catalysts, were found to crosslink cellulose hydroxy groups at a very rapid rate (e.g., 20 seconds at 160° C.), thereby imparting improved wrinkle recovery in the range of that required for durable press finishing. Cotton fabrics treated with these acetals have the advantage of no formaldehyde release.
3
This application is a continuation-in-part of application Ser. No. 07/017,866, filed Feb. 24, 1987, and now abandoned. BACKGROUND OF THE INVENTION (1) Field of the Invention This invention relates to a method for increasing strength properties and refinability of high yield chemical wood pulp by oxygen and alkali treatment. The enhanced properties of the pulp are particularly advantageous for manufacturers of linerboard paper. (2) Description of the Prior Art Sulfate pulp with a lignin content corresponding to a Kappa number of from about 60 to about 120 is conventionally used for the production of unbleached linerboard. Linerboard pulp manufactured this way has good strength properties at relatively high yields (55-60%). The dry weight of washed fibers which are recovered after pulping is generally reported as a percentage of the weight of dry lignocellulosic material which was charged to the digestion process. This percentage is termed "yield." Any decrease in yield caused by loss of lignocellulosic materials is undesirable in papermaking. Two of the more important strength properties of linerboard are burst and edgewise compressive strength. To obtain the desired burst and compressive strength, pulp is refined before the linerboard is formed. The action of refining fibrillates and collapses the pulp fibers, allowing them to form a more strongly bonded and dense board. Linerboard density is strongly correlated with burst and compressive strength levels. However, the pulp cannot be refined too severely since this will cause the pulp to drain poorly on the linerboard machine, resulting in low production rates. Board density is therefore achieved by a combination of refining and wet pressing on the paper machine. It is known generally that delignification of pulp with oxygen and alkali is a commercially accepted process. The process is usually applied to low yield chemical pulps as a pre-bleaching stage, before final bleaching with chlorine-containing chemicals. The Kappa number of the pulp is usually reduced from 30-35 to 15-20, signifying a reduction in lignin content of at least 40-50%. Reductions in lignin content to such a degree would result in paper of insufficient strength properties for linerboard manufacture. Also, such reductions in yield would be uneconomical. Kleppe et al. ("Delignifying high yield pulps with oxygen and alkali," TAPPI, vol. 68, no. 7, p. 71, 1985) teach that sulfate pulp having a Kappa number within the range of 140-150 can be delignified with oxygen and alkali to pulp with a Kappa number of 110. In both of these treatments, however, oxygen, alkali, and pulp are reacted at temperatures (105° C.) and pressures (0.5 mPa, 58 psig) which were optimized for the removal of lignin from the pulp. Delignification rates and strength levels of high yield soda pulps are strongly influenced by temperature during oxygen and alkali treatment. Thus, reaction temperatures above 100° C. increase the extent and rate of delignification and promote oxidative degradation of wood carbohydrates. Because of the relatively severe conditions of the above treatments, the pulps are stabilized against carbohydrate degradation by treatment with magnesium salts (0.05-0.15%, based on o.d. (oven dried) pulp). These salts, however, reduce the yield loss associated with the carbohydrate fraction of the pulp, allowing for further delignification. An example of this approach is U. S. Pat. No. 3,657,065 to Smith et al. which specifically claims and requires the inclusion of chemical protectors to inhibit cellulose pulp degradation. The patentees teach delignification of up to 89% to result from the conditions of alkali and oxygen treatment. The instant invention seeks to minimize the degree of delignification resulting from the treatment of a chemical wood pulp with oxygen and alkali, as well as to minimize cellulose degradation without reliance on chemical protectors. It is the object of this invention, therefore, to provide an improved method of linerboard paper production to provide an industrial means to produce high strength kraft linerboard requiring reduced refining energy, by treating high yield chemical wood pulp with oxygen and alkali at a temperature of from about 50° C. to about 100° C. and a pressure of up to 150 psig. SUMMARY OF THE INVENTION The instant invention achieves the above objective by an improved linerboard manufacture method which, in the absence of cellulose protectors, uses oxygen and alkali as a means to chemically modify residual lignin present in high yield sulfate pulp without a substantial decrease in pulp yield as evidenced by a kappa number reduction (from the untreated pulp) no greater than 25%. The process conditions utilized in this invention are much less severe than those used in prior art oxygen and alkali delignification processes resulting in minimized lignin and carbohydrate loss. BRIEF DESCRIPTION OF THE DRAWINGS The figures present graphs which illustrate the ability to control linerboard pulp properties by regulating the beating time of pulps treated according to the present invention. FIG. 1 shows the relationship between the oxygen and alkali treatment of pulp and Williams Slowness at different beating times. FIG. 2 shows the relationship between the oxygen and alkali treatment of pulp and linerboard compressive strength at different beating times. FIG. 3 shows the relationship between the oxygen and alkali treatment of pulp and linerboard burst factor at different beating times. FIG. 4 shows the relationship between the oxygen and alkali treatment of pulp and linerboard tensile breaking lengths at different beating levels. DESCRIPTION OF THE PREFERRED EMBODIMENT It has been discovered that a high strength kraft linerboard can be accomplished by subjecting industrially prepared kraft pulp to a mild oxygen and alkali treatment. The oxygen and alkali treatment of a high yield (55-60%) pulp produced from wood chips cooked in an alkaline cooking liquor allows production of a linerboard grade of paper with higher densities and physical strength levels than conventionally prepared linerboard. Upon refining, the oxygen and alkali treated pulp reach a given Williams Slowness and strength level more quickly than untreated pulp, indicating that treated pulp is easier to refine than conventional linerboard pulp. (The Williams Slowness is the amount of time in seconds for one liter of water to drain through a three-gram sample of pulp.) The oxygen and alkali treatment is carried out on a pulp of medium consistency (8-20%, preferably 12%) at lower temperatures and pressures than those used in conventional oxygen delignification processes and in the absence of cellulose protectors. Employment of the pulp produced by this process in linerboard results in linerboard strength properties (burst, density, compressive strength) significantly higher than that measured in linerboard employing conventional (untreated) kraft pulp of the same Kappa number. The process has the effect of modifying the residual lignin present in high yield kraft pulp rather than substantially reducing pulp yield through lignin dissolution as is conventionally practiced with oxygen and alkali processes. The invention is described in more detail by the following tables and figures which summarize laboratory experiments in which industrial and laboratory prepared linerboard pulps were treated with oxygen and alkali. CONTROL EXAMPLE A This pulp was an industrially produced kraft southern pine pulp with a Kappa number of 96.5. The pulp was washed in the laboratory which reduced the Kappa number to 87.7. The pulp was then beaten in a Valley Beater to various Williams Slowness levels and test handsheets were made. CONTROL EXAMPLE B The same pulp as in Control Example A was treated in a laboratory oxygen reactor for one hour at 78° C. in the absence of oxygen. The pulp consistency was 12% and the initial pH was 10.9. After the treatment the pulp was washed and the Kappa number determined. The pulp was then beaten in a Valley Beater to various Williams Slowness levels, and test handsheets were made. EXAMPLE 1 The same pulp as in Control Example A was mixed with sodium hydroxide solution and sufficient water to bring the pulp consistency to 12%. The sodium hydroxide charge was 1% based on the o.d. weight of the pulp. The initial pH of the pulp was 12.1. The pulp was then treated in a laboratory oxygen reactor for one hour at 78° C. with an oxygen pressure of 15 psig. After the treatment, the pulp was washed, and the Kappa number was determined to be 81.1 (a 7.5% reduction). The pulp was then beaten in a Valley Beater to various Williams Slowness levels and test handsheets were made. The pH of the pulp after the treatment was 10.3. EXAMPLE 2 The same pulp as in Control Example A was mixed with sodium hydroxide solution and sufficient water to bring the pulp consistency to 12%. The sodium hydroxide charge was 2% based on o.d. pulp weight. The initial pH of the pulp was 12.2. The pulp was then treated in a laboratory oxygen reactor for one hour at 78° C. with an oxygen pressure of 15 psig. After treatment the pulp was washed and the Kappa number determined to be 77.1 (a 12% reduction). The pulp was then beaten in a Valley Beater to various Williams Slowness levels, and test handsheets were made. The pH of the pulp after the treatment was 10.9. EXAMPLE 3 The same pulp as in Control Example A was mixed with sodium hydroxide solution and sufficient water to bring the pulp consistency to 12%. The sodium hydroxide charge was 5% based on o.d. pulp weight. The initial pH of the pulp was 13.0. The pulp was then treated in a laboratory oxygen reactor for one hour at 78° C. and an oxygen pressure of 15 psig. After treatment the pulp was washed and the Kappa number determined to be 68.2 (a 22.2% reduction). The pulp was then beaten in a Valley Beater to various Williams Slowness levels, and test handsheets were made. The beating times, William Slowness, handsheet densities, and pulp strength properties are shown in Table I. TABLE I______________________________________EFFECT OF OXYGEN-ALKALION STRENGTH PROPERTIES OF KRAFT PINE PULPSBeat- STFI Tensileing Williams Handsheet Compressive BreakingTime Slowness Density Strength Burst Length(min.) (sec.) (kg/m.sup.3) (lb./in.) Factor (10.sup.-2 m)______________________________________ControlExample A 0 4.3 409 11.5 24.0 39.110 5.8 483 15.8 36.0 59.415 6.0 510 16.9 41.7 67.920 6.3 549 17.5 44.2 67.230 8.6 610 19.2 57.0 75.335 10.9 645 19.5 58.5 73.3ControlExample B 0 4.6 444 12.9 22.7 44.810 5.8 500 17.8 38.8 61.815 6.4 541 18.8 43.3 70.320 7.2 571 19.4 44.7 72.530 10.1 602 18.9 54.0 79.635 11.6 645 20.4 58.7 77.4Example 1 0 5.5 465 14.4 28.7 44.610 6.8 552 19.3 46.1 72.815 7.8 585 19.5 50.4 72.120 9.2 606 19.9 55.2 77.730 18.7 667 22.3 64.3 86.535 33.0 685 22.6 66.7 91.8Example 2 0 5.1 467 15.2 28.7 48.710 6.5 549 18.6 44.5 69.815 7.5 592 20.2 48.3 74.320 9.9 621 20.3 54.2 83.530 19.3 676 22.3 64.6 94.535 33.4 699 22.2 68.0 86.8Example 3 0 5.0 505 15.9 33.9 50.710 7.9 633 20.0 55.3 70.115 13.5 699 21.8 63.8 84.020 27.1 733 22.9 68.8 86.025 57.0 769 23.2 71.6 95.3______________________________________ As seen from the examples, treatments of pulp with oxygen and alkali produced pulps with higher sheet densities and strength properties in the unbeaten state (0 minutes beating time) than untreated pulps. FIG. 1 shows the beating times plotted against Williams Slowness. Upon a study of FIG. 1 it becomes evident that the oxygen and alkali treatment allows the pulp to reach a given slowness with a lower amount of beating. On an industrial scale, this result translates into decreased refining energy for equivalent pulp slowness levels. Control Example B shows that some of the strength increases are due to mechanical treatment received by the pulp in the laboratory oxygen reactor. However, these increases are significantly lower than those found after the addition of oxygen and alkali. Increases in the sodium hydroxide charge in the presence of oxygen improved pulp strength properties and lowered the beating times required to achieve a given strength and slowness level. This can be determined from a study of FIGS. 2, 3, and 4. The most significant improvements were observed with a caustic application of 5% based on the o.d. weight of pulp. Another result of the oxygen-alkali treatment was a reduction in pulp Kappa number. As shown in the following examples, the degree of Kappa number reduction was directly related to the sodium hydroxide charge. A comparison of the strength properties of oxygen and alkali treated laboratory pulp with the same pulp cooked to a Kappa number similar to that of the oxygen and alkali treated pulp is shown in Table II. CONTROL EXAMPLE C This pulp is a laboratory prepared kraft southern pine pulp with a washed Kappa number of 98.1. The pulp was then beaten in a Valley Beater to various Williams Slowness levels and test handsheets were made. CONTROL EXAMPLE D This pulp is a laboratory prepared kraft southern pine pulp with a washed Kappa number of 68.6. The pulp was then beaten in a Valley Beater to various Williams Slowness levels and test handsheets were made. EXAMPLE 4 The same pulp as in Control Example C was mixed with sodium hydroxide solution and sufficient water to bring the pulp consistency to 12%. The sodium hydroxide charge was 5% based on o.d. pulp weight. The initial pH of the pulp was 13.0. The pulp was then treated in a laboratory reactor for one hour at 78° C. with an oxygen pressure of 15 psig. After the treatment the pulp was washed and the Kappa number was determined to be 75.5. the pulp was then beaten in a Valley Beater to various Williams Slowness levels, and test handsheets were made. The pH of the pulp after treatment was 11.5. TABLE II__________________________________________________________________________COMPARISON OF OXYGEN AND ALKALI TREATED PINE PULPS WITHKRAFT PULPS OF SIMILAR AND DIFFERENT KAPPA NUMBERSTreatment Conditions:Laboratory Pine Pulp Prepared from Charleston Pine Chipsl2% Consistency78° C.One Hour Reaction Time5% NaOH Applied to Oxygen-Alkali Treated Pulp15 psig Oxygen STFI Tensile Beating Williams Sheet Compressive BreakingTreatment Time Slowness Density Strength Length Burst TearDescription (min.) (sec.) (g/cc) (lb./in.) (10.sup.-2) Factor Factor__________________________________________________________________________Control Example C 0 5.1 0.383 10.1 32.1 17.3 214.3(Kappa No. 98.1) 10 5.7 0.485 14.6 57.1 37.9 262.6 15 5.9 0.516 16.2 63.3 41.5 263.4 20 6.9 0.558 17.3 70.2 47.5 236.9 30 9.4 0.637 20.1 86.3 58.3 220.0 35 12.2 0.665 20.5 86.5 63.5 209.8Control Example D 0 5.3 0.445 11.7 38.4 21.9 272.0(Kappa No. 68.6) 10 5.6 0.550 16.2 65.8 41.3 304.7 15 6.6 0.610 18.4 73.1 50.1 272.3 20 7.9 0.640 19.9 80.2 58.6 259.2 30 14.1 0.713 21.5 92.2 69.9 224.3 35 24.8 0.732 22.4 98.6 73.0 215.8Oxygen-Alkali 0 5.1 0.492 14.5 40.5 32.0 294.6Treated Example 4 10 6.6 0.599 18.9 69.0 51.0 250.4(Kappa No. 75.5) 15 7.8 0.652 19.7 77.3 59.9 230.7 20 9.7 0.680 20.8 82.1 63.5 210.5 30 23.5 0.743 22.6 94.7 69.8 196.1 35 40.5 0.779 23.7 99.6 75.0 185.5__________________________________________________________________________ As seen from Table II, the oxygen and alkali treated pulp was significantly higher in compressive strength, burst factor, breaking length, and handsheet density when compared to the two kraft pulp at constant beating time. It is evident, therefore, that strength properties are more favorably enhanced by oxygen and alkali treatment than by an equivalent reduction in pulp Kappa number achieved through kraft pulping changes. While this invention has been described and illustrated herein by reference to various specific materials, procedures and examples, it is understood that the invention is not restricted to the particular materials, combinations of materials, and procedures selected for that purpose. Numerous variations of such details can be employed, as will be appreciated by those skilled in the art.
Pulp of improved refinability for the production of high strength linerboard is obtained by digesting wood chips in alkaline cooking liquor, defibering, treating with oxygen and alkali in the absence of a cellulose protector, and refining. Linerboard pulp produced by this method results in improved paper strength properties. The treatment is conducted in its best mode at temperatures below 100° C. to minimize pulp yield losses.
3
[0001] This application is a continuation-in-part of co-pending prior application Ser. No. 09/371,321, filed Aug. 10, 1999, which was a continuation of prior application Ser. No. 09/205,862, filled Dec. 4, 1998, now U.S. Pat. No. 5,947,639. This application claims the benefit of U.S. Provisional application no. 60/070,518 filed Jan. 6, 1998. Application serial nos. 09/371,321 09/205,862, and 60/070,518 are hereby incorporated by reference. BACKGROUND OF THE INVENTION [0002] The present invention relates to a lifting apparatus used to portage a boat. More specifically, the present invention relates to a mechanism for vertically lifting a boat out of one body of water, transferring the boat horizontally over a barrier, and then vertically lowering the boat into a second body of water. [0003] Known within the prior art are devices for lifting boats out of water for such purposes as making repairs, protecting boats from dock collision caused by tidal action, and preventing damage to a boat's hull from excessive exposure to water. U.S. Pat. No. 5,184,914 describes and shows a boat lift that consists of a frame which cradles and lifts a boat from the water by the means of a hydraulic ram. The device requires a person to enter the water to secure several members of the device around the bottom of the hull. U.S. Pat. No. 5,593,247 describes a programmable boat lift control system that with the push of a button, the lift may either raise or lower the boat to a pre-programmed elevation. [0004] Both of these devices are useful for lifting boats out of water, but are both limited to lifting and lowering the boat in a vertical direction which is indicative of the general state of the art in boat lifting devices. The prior art fails to teach an apparatus that can both, lift and lower a boat in a vertical direction and transfer the boat in a horizontal direction. Applicant has discovered the need to transfer boats over barriers, such as water divider walls. In many areas salt water and fresh water are separated by various types of barriers. Barriers are needed to separate fresh water from salt water due to the various types of organisms, plants and animals which can only survive in either salt or fresh water, but not both. Regardless of the need to isolate salt from fresh water, boats and other types of water vehicles still require access to and from these separate bodies of water. [0005] The foregoing illustrates limitations known to exist in present boat lift apparatuses. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter. SUMMARY OF THE INVENTION [0006] In one aspect of the present invention, this is accomplished by providing a boat lift apparatus comprising: a moveable hoist assembly erected over a barrier separating a first body of water and a second body of water, the hoist assembly including a moveable lift frame and a load distribution subassembly connected to the lift frame, wherein the load distribution subassembly includes a pair of load distribution supports extending longitudinally and spaced laterally relative to one another and a cradle connected between the load distribution supports and capable of receiving a boat to be carried across the barrier by the apparatus; a mechanism for raising and lowering the lift frame; and a mechanism for conveying the hoist assembly between a first position over the first body of water to a second position over the second body of water. [0007] After the boat has entered the lift it is positioned over a pair of slings which are placed under the boat. One sling is located near the bow or front portion of the boat while the second sling is located near the stern or rear portion of the boat. The slings are fastened to a lift frame which is lowered or raised by hydraulic power. [0008] Once the boat is in a fully raised position, the boat lift translates the boat in a horizontal direction over the particular barrier. Translation of the hoist is controlled by a motor which powers a set of flanged wheels to move the boat lift back and fourth in a horizontal direction. An operator is able to easily control the functioning of the boat lift through a control panel located near or within the boat lift. [0009] It is therefore an object of the present invention to provide a new and improved boat lift capable of lifting a boat in and out of water in both a vertical and horizontal direction. [0010] It is a further object of the present invention to provide a boat lift which can be easily and safely operated by one or more individuals, who are operators of the boat and not require an operator full time for the boat lift. [0011] It is still a further object of the present invention to provide a boat lift which allows a boat to be lifted and carried over various types of barriers. [0012] The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures. BRIEF DESCRIPTION OF THE DRAWING FIGURES [0013] [0013]FIG. 1 is a front elevational view of the boat lift apparatus of the present invention; [0014] [0014]FIG. 2 is a side elevation view of the boat lift apparatus shown in FIG. 1 as the boat initially enters the boat lift apparatus. [0015] [0015]FIG. 3 is a side elevation view of a first embodiment of the lift frame of the boat apparatus shown in FIG. 1; and [0016] [0016]FIG. 4 is a side elevation view of a second embodiment of the lift frame of the boat apparatus shown in FIG. 1 DETAILED DESCRIPTION [0017] In the following description of a preferred embodiment of the present invention, reference is made to the accompanying drawings which, in conjunction with this detailed description, illustrate and describe a boat lift capable of hoisting a boat out of one body of water, translating the boat in a horizontal direction over a barrier and then lowering the boat into a second body of water. Referring to FIG. 2, boat lift 10 consists of vertically moveable lift frame 24 mounted on a horizontally moveable lift frame support bed 26 which rolls on tracks 32 which are placed alongside a first body of water 18 and a second body of water 20 divided by barrier 16 . Many areas having both salt and fresh water bodies must take care not to allow the two bodies of water to mix thereby contaminating the fresh water. Various types of organisms, plants and animals can only survive in either salt water or fresh water. To accomplish this many communities construct barriers separating the two bodies of water. The down side to using barriers is that boats are prevented from freely traveling between the fresh and salt water bodies. [0018] In FIG. 1, boat 12 enters boat lift 10 at either one of two ends via either first body of water 18 or second body of water 20 . Channel 14 of boat lift 10 is divided into two sections by barrier 16 . Barrier 16 is located between and divides the first and second bodies of water, 18 and 20 respectively, at approximately the middle of the channel 14 effectively creating two isolated bodies of water. [0019] The vertically moveable lift frame 24 consists of two sub-frames 24 a , 24 b , one on each side of channel 14 . As shown in FIG. 3, each lift sub-frame 24 a , 24 b consists of two sections, an upper platform 36 and a lower scissors platform 38 . The upper platform 36 includes a lower beam 52 attached to upper beams 56 by a plurality of fixed supports 54 . On the inner (or channel side) side of each lift sub-frame 24 a , 24 b , a load distribution subassembly 58 is attached to the upper beams 56 . A cradle 80 is attached to the load distribution subassemblies 58 at cradle connectors 60 . Preferably one connector 60 a is a fixed connection and the other connector 60 b is slideable along load distribution subassembly 58 . Lift sub-frames 24 a , 24 b are connected to one another by transversely extending trusses 68 which span channel 14 . Trusses 68 are connected to upper beams 56 . To accommodate varying loads, ground settlement and other alignment problems, trusses 68 may be fixed to one lift sub-frame 24 a and slidingly connected to the other lift sub-frame 24 b to allow for movement of the tops of the lift sub-frames 24 a , 24 b towards or away from each other. To provide additional support and stiffness to the upper platform, cross supports 62 can be provided. The load distribution subassemblies 58 can be omitted and cradle 80 can be attached to other portions of upper platform 36 . [0020] Preferably, cradle 80 is a pair of slings, as shown in the Figures. Slings 80 , preferably, are fabricated from high strength polyester which is resistant to damage from abrasion and deterioration from exposure to water, particularly salt water. The slings 80 may also be fabricated materials offering similar damage resistance, such as nylon and the like. It is also possible that the cradle for carrying boat 12 may be comprised of other suitable means, including but not limited to, a heavy gauge net which may be coupled at its extremities to connectors 60 a , 60 b . Like the slings 80 , such net may also be produced from high strength polyester or nylon. In order that the slings 80 , or alternatively a net, will readily submerge rather than float, lead weights are provided with the slings 80 and the net. In the case of the slings 80 , the lead weights are sewn into packets provided in the slings 80 . Preferably cradle 80 is does not retain any water around the boat 12 when the boat 12 is lifted out of the water. [0021] The lower scissors platform 38 consists of a lift frame support bed 26 connected to upper platform lower beam 52 by double scissors mechanisms 40 . The lift frame support bed 26 has a plurality of support legs 28 attached thereto with wheels 30 attached to axles 34 at the lower ends thereof. The wheels 30 engage a track 32 which extends along the channel 14 on both sides of the channel 14 . The wheels 30 and track 32 permit the boat lift 10 to move horizontally along the channel 14 to transport a boat 12 over the barrier 16 from the first body of water 18 to the second body of water 20 or vice versa. A transit motor 70 is attached to a lower side of the lift frame support bed 26 . The transit motor 70 preferably drives one set of wheels 30 through a chain and sprocket (not shown). [0022] The scissors mechanisms 40 each consist of two scissors legs 40 a , 40 b , pivotally connected by scissors connector 46 . One end 42 of each scissors mechanism legs 40 a , 40 b is fixed to the lower scissors platform 38 . The other end 44 slides along either an upper surface of lift frame support bed 26 or a lower surface of upper platform lower beam 52 . Upper hydraulic cylinder beams 48 are provided between scissors legs 40 a , 40 b (See FIG. 1). Hydraulic cylinders are connected between the lift frame support bed 26 and the upper hydraulic cylinder beams 48 . The left side of FIG. 1 illustrates the lift frame 24 when the hydraulic cylinders 50 are retracted and the lift frame 24 is in its lower position. The left side of FIG. 1 also illustrates the left sling position (shown in FIG. 2) with the slideable sling connector 60 b . The left side of FIG. 1 shows in phantom lines the upper position of lift frame 24 . The right side of FIG. 1 illustrates the lift frame 24 when the hydraulic cylinders 50 are fully extended pressing against upper hydraulic cylinder beam 48 causing the scissors mechanisms 40 to lift the upper platform 36 to a raised or upper position. In the preferred embodiment, the upper platform raises about 7 feet. A hydraulic power source (not shown) is provided on the lift frame 24 . Retractable cords (not shown) are provided to provide electrical power and control signals to the transit motor 70 and the hydraulic power source. The intended maximum boat weight that boat lift 10 can lift is 20,000 lbs. By changing the strength and configurations of the structural members, the size of the hydraulic cylinders, higher boat weights can be accommodated. [0023] Although the preferred embodiment shows a lift frame 24 which uses double scissors mechanisms 40 , other configuration of hydraulic lifting devices may be used. One example is shown in FIG. 4 where a single scissors mechanism 40 is used for each lift sub-frame 24 a , 24 b. Another configuration could use multiple levels of lift frame support beds, each support bed being connected to the one above it by a set of hydraulic cylinders. The scissors mechanisms 40 or other lift multiplier mechanisms are preferred. [0024] In use, the boat lift 10 is positioned over the first body of water 18 with the lift frame 24 in the lower position. Boat 12 is driven into channel 14 and positioned with the slings 80 about the boat 12 as shown in FIG. 2. Because of the slideable connector 60 a , the left most sling 80 (as shown in FIG. 2) can be moved to accommodate different length boats. Hydraulic power is provided to the hydraulic cylinders 50 causing the hydraulic cylinders 50 to extend and lifting the upper platform 36 , attached slings 80 and boat 12 . Transit motor 70 is energized moving boat lift 10 from over the first body of water 28 over the barrier 16 and over the second body of water 20 . The hydraulic power is turned off and the hydraulic pressure to the hydraulic cylinders 50 is relieved allowing the hydraulic cylinders 50 to retract, thereby lowering the upper platform 36 along with slings 80 and boat 12 to its lower most position, lowering the boat 12 into the body of water 20 . The boat 12 , having successfully transited barrier 16 , can now be driven in the second body of water 20 .
The present invention relates to a stationary boat lift in which a boat is able to enter and exit with little difficulty. The boat lift allows a boat to bypass various barriers in a efficient and safe manner by vertically lifting the boat out of one body of water, translating the boat horizontally over a desired barrier, and then vertically lowering the boat into a second body of water.
4
BACKGROUND OF THE INVENTION-FIELD OF APPLICATION This invention relates to apparatus for use by invalids; and, more particularly, to apparatus for use in lifting and transporting invalids. BACKGROUND OF THE INVENTION-DESCRIPTION OF THE PRIOR ART Many devices and various constructions and configurations of apparatus exist for use in lifting and/or, transporting persons who for one reason or another are disabled or are an invalid. Such disabled or invalid persons may be hospitalized and temporarily relegated to an invalid condition due to the hospitalization; or they may be permanently disabled or invalid whether resident at home or in a hospital, nursing home or other institution. Some such devices and apparatus may merely facilitate the lifting of the disabled and invalid person as shown, for example, in U.S. Pat. No. 2,187,283 granted on Jan. 16, 1940 to J. A. Scheutz for Elevator Apparatus; or they may facilitate the lifting and movement of the disabled and invalid person as shown, for example, in U.S. Pat. No. 4,138,750 granted on Feb. 13, 1979 to J. Michalowski for Apparatus For Handling Disabled Persons and in U.S. Pat. No. 4,700,416 granted on Oct. 20, 1987 to P. J. Johansson for Patient Transfer Mat. However, the elevator shown in the Scheutz patent does not and cannot function in conjunction with and as a transport device; while the sling of the Michalowski device and the transfer mat of Johansson must be placed under the invalid or disabled person, including their buttock area and that requires lifting of the person in order to position the person with respect to the device prior to its use in lifting the person. Lifting an invalid or disabled person more often than not requires the lifting of dead weight which may, for relatively heavy people, be considerable and necessitate the use of two or more persons to do so. This may be costly, time consuming and necessitates the availability of personnel which renders such lifting and transport devices inconvenient and undesirable. Some apparatus for use by disabled and invalid persons, as shown: in U.S. Pat. No. 3,165,314 granted on Jan. 12, 1965 to J. P. Clearman et al for Invalid Walker And Ambulatory Aid; in U.S. Pat. No. 3,394,933 granted on Jul. 30, 1968 to R. A. Benoit for Invalid Lifting And Supporting Device; in U.S. Pat. No. 3,629,880 granted on Dec. 28, 1971 to J. N. van Rhyn for Apparatus For Assisting Invalids; and in U.S. Pat. No. 4,807,897 granted on Feb. 28, 1989 to J. R. Schultz for Standing Support all require the invalid user to assume a standing position which may not be possible due to the user's physical condition or disability or their available strength at a particular time or which may be painful and difficult for the user due to such conditions. These types of apparatuses do not provide support for the user's back if needed, and effect their lifting and support by applying forces to the user's chest only (as shown for the Clearman et al device) or beneath the user's armpits (as shown for the Benoit and Van Rhyn devices). Apparatus, such as shown in U.S. Pat. No. 3,041,636 granted on Jul. 3, 1962 to A. B. Twedt for Invalid Lifter And Transporting Device, firstly places the user in an uncomfortable and awkward position and then effects the lifting of the person by applying sufficient force against only the person's back to effect movement of the person from their seated position. Such devices are additionally undesirable because they cannot lift a person from one level to another, appear to be quite unstable and place the user in a most awkward and obviously uncomfortable position during transport. An invalid may be more comfortable being lifted and transported by an apparatus of the construction shown in U.S. Pat. No. 2,747,652 granted on May 29, 1956 to G. E. Marsh for Device For Moving Invalids And The Like which only supports the user by rigid panels that must be disposed beneath the user's buttocks; or by an apparatus of the construction shown in U.S. Pat. No. 4,569,094 granted on Feb. 11, 1986 to L. D. Hart et al for Self-Powered Lift which only supports the user by a flexible strap that must be disposed beneath the user's buttocks. Alternatively, the lifting and transport apparatus may support the user under their buttocks and behind their back as well as shown in U.S. Pat. No. 3,623,169 granted on Nov. 30, 1971 to D. R. James for Apparatus For Handling Disabled Persons, in U.S. Pat. No. 4,510,633 granted on Apr. 16, 1985 to M. W. Thorne for Invalid Transfer Means, in U.S. Pat. No. 3,732,584 granted on May 15, 1973 to D. R. James for Apparatus For Handling Disabled Persons or under their buttocks against their knees and with a chest support as shown in U.S. Pat. No. 4,157,593 granted on Jun. 12, 1979 to N. L. O. Kristensson for Patient Lift And Transport Apparatus. The undesirability and unacceptability of inserting a patient lifting apparatus beneath a patients buttocks is described at length above. Efforts required to lift the person or otherwise place the under buttocks support beneath the patients buttocks requires people, strength and time and in many instances may prove to be uncomfortable and/or painful to the patient. Many of these devices also place the patient in a most uncomfortable position while being lifted and during transport. U.S. Pat. No. 3,996,632 granted on Dec. 14, 1976 to A. C. Bakker nee Viel for Detachable Coupling and U.S. Pat. No. 4,409,696 granted on Oct. 18, 1983 to J. P. Bakker for Apparatus For Carrying A Person In Sitting Condition show lifting and transport devices which support and lift the person beneath their upper leg proximate their knees and which provide a back support. However, the disposition of the persons weight when being lifted and transported by such devices may render the device unstable and unsafe unless the person's weight is counterbalanced by the weight and disposition of the structure of the device. This may very well render the device relatively unduly heavy, cumbersome and costly. None of the lifting and/or transport devices described above are constructed to assure that the person to be lifted is properly and safely secured in position, or that the person's weight is distributed in such a manner that the device is stable and secure while lifting and transporting the person without unduly adding to the weight and cost of the device. Even a device such as shown in U.S. Pat. No. 4,704,749 granted on Nov. 10, 1987 to B. A. Aubert for Body Lift And Walker For Paralytics which interconnects its under arm supports to its leg supports, does not insure the security of the person when carried by the device. In addition this type of device requires the application of the user's weight to supports that are disposed beneath the user's arm pits in order to function. If the medical or physical condition of the user does not permit application of the user's weight in this manner the device is inoperable and of no value or use to lift or transport the person. SUMMARY OF THE INVENTION It is therefore an object of this invention to provide a new and improved invalid lift. It is another object of this invention to provide a new and improved invalid transport device. It is still another object of this invention to provide a new and improved invalid lift and transport apparatus. It is yet still another object of this invention to provide a new and improved invalid lift and transport apparatus wherein the weight of the person to be lifted and transported is distributed so as to facilitate a stable lifting and transporting of the person. It is a further object of this invention to provide a new and improved invalid lift and transport device wherein the person to be lifted and transported is disposed to facilitate a stable lifting and transportation. It is still a further object of this invention to provide a new and improved invalid lift and transport device which disposes the person to be lifted so that their buttocks are unobstructed to facilitate medical treatment and body functions. It is yet still a further object of this invention to provide a new and improved invalid lift and transport device which provides a relatively high level of patient safety. It is yet still a further object of this invention to provide a new and improved invalid lift and transport apparatus which enforces use of a backrest in order to render the apparatus effectively usable and thus provides for a relatively high degree of person safety. It is yet still a further object of this invention to provide a new and improved invalid lift and transport apparatus which enforces a particular disposition of the person to be lifted and transported and thereby use of a backrest in order to render the apparatus effectively usable and thus provides for a relatively high degree of person safety. Other objects, features and advantages of the invention in its details of construction and arrangement of parts will be seen from the above and from the following description of the preferred embodiments when considered with the drawing and from the appended claims. BRIEF DESCRIPTION OF THE DRAWING In the drawing: FIG. 1 is a side elevation view of an invalid lift and transport apparatus incorporating the instant invention and schematically showing a person disposed thereon; FIG. 2 is an end elevation view of the apparatus of FIG. 1; FIG. 3 is a partial top view of the apparatus of FIGS. 1 and 2 enlarged to better show details thereof; FIG. 4 is an exploded view of the back support device and part of the support arm of the apparatus of FIGS. 1 and 2 enlarged to better show details thereof; FIG. 5 is a sectional view taken on line 5--5 of FIG. 1 further enlarged to better show details thereof; FIG. 6 is a perspective view of the leg support device of the apparatus of FIGS. 1 and 2 shown removed therefrom to better show details thereof; FIG. 7 is a vertical sectional view of the lifting mechanism of the device of FIGS. 1 and 2; FIG. 8 is a partial elevational view of a chest support device, support arm and back support holder of an alternate embodiment of invalid lift and transport apparatus showing a locking lever therefore and incorporating the instant invention and showing the locking lever in a free position; FIG. 9 is a partial plan view of the apparatus of FIG. 8; FIG. 10 is a sectional view taken on line 10--10 of FIG. 8; FIG. 11 is a sectional view taken on line 11--11 of FIG. 8; FIG. 12 is a view similar to that of FIG. 8 but showing the locking lever in a working position; FIG. 13 is a side elevational view of an alternate construction of invalid lift and transport apparatus incorporating the instant invention and showing an alternative construction of chest support device; FIG. 14 is a side elevational view of another alternate construction of invalid lift and transport apparatus incorporating the instant invention and showing a width adjustable support for the carriage thereof; and FIG. 15 is an end elevation view of the width adjustable support for the carriage of FIG. 14. DESCRIPTION OF THE PREFERRED EMBODIMENTS With reference to FIGS. 1 and 2 there is generally shown at 30 an invalid lift and transport device or apparatus for lifting a person 34 (FIG. 1) from a seating position on a chair or other support (not shown), for transporting that person 34 once positioned on apparatus 30 for transport and for again lifting person 34 and depositing person 34 on another or the same chair or support. Apparatus 30 includes a carriage assembly 40, a lifting mechanism 42 (which also lowers) carried by carriage assembly 40 and a body support assembly 44 carried by lifting mechanism 42. Body support assembly 44, in turn, includes a first body support portion 50 which functions as a back support device, a second body support portion 52 which functions as a leg support device and a third body support portion 54 which functions as a chest support device; with all such devices 50, 52, 54 of body support assembly 44 being mounted atop lifting mechanism 42 through a mounting assembly 60 (FIGS. 1-3). A lifting tube 70, of lifting mechanism 42, has fixedly secured proximate its top 72 a pair of lifting arms 74 and 76 (FIGS. 2 and 3) of mounting assembly 60 symmetrically mounted with respect to lifting tube 70 and secured thereto as by welding or other suitable and conventional means. A chest support plate 80 (FIGS. 1-3) is secured on top of arms 74, 76 and in turn supports a chest support pillow 82; with plate 80 and pillow 82 comprising chest support device 54 of body support assembly 44. Plate 80 may be formed of metal, plastic wood or other suitable material and forms a base for pillow 82 which may be formed with a firm core (not shown) and covered with a suitable material such as leather, plastic, cloth or the like. A pair of handles 90 and 92 (FIG. 2) are carried by handle arms 94, 96 respectively which, in turn, extend from and are suitably secured to lifting arms 74, 76 respectively. Chest support plate 80 and its pillow 82 may, if desired, also be supported by handle arms 94, 96. It should be noted that lifting arms 74, 76 and handle arms 94, 96 support chest support plate 80 at a predetermined angle to the horizontal and which facilitates disposition and support of person 34 thereupon as will be hereinafter described. The predetermined angle for plate 80 and pillow 82 of chest support device 54 may be selected to be between six and 45 degrees. Each lifting arm 74, 76 at the respective ends 100, 102 (FIG. 2) thereof, opposite to where such arms 74, 76 are secured to lifting tube 70, carries a substantially "C" shaped channel member 103 (FIGS. 4 and 5) which may either be formed integrally therewith or secured thereto by suitable means such as welding or the like. A pair of opposed and spaced sidewalls 104 extend out from a back wall 105 of channel member 103, and front strips 106 extend inwardly from each sidewall 104 to terminate in edges 107 spaced from each other and defining therebetween an opening 108 extending the length of channel member 103. The inner surfaces of sidewalls 104, back wall 105 and front strips 106 define therewithin a channel 109 extending the length of channel member 103 and communicating its entire length with opening 108. Channel 109 is of a size and configuration to receive a back support holder 110 (FIGS. 1, 4 and 5) of back support device 50 of body support assembly 44. Since channel members 103, formed at respective ends 100, 102 of lifting arms 74, 76 are identical only channel member 103 of arm 74 has been shown in detail (in FIGS. 4 and 5), with channel member 103 of arm 76 being identical to and a mirror image thereof. A back support holder 110 (FIG. 2) is disposed at each side of back support device 50. Each back support 110 includes a seat device support rivet 112 (FIGS. 4 and 5) disposed proximate one end thereof and formed with a shank portion 114 and a head portion 116 (FIG. 5). Back support holders 110, are each respectively disposed in their channels 106 with their respective rivets 112 pointing outwardly through openings 120 (FIG. 4) which extend the lengths of the respective channels 106. A back support safety belt 130 (FIGS. 2 and 4) connects back support holders 110 together at their respective upper ends (i.e. the ends thereof opposite from rivets 112) and forms with back support holders 110 back support device 50 of body support assembly 44. The length of back support holders 110 is selected so that back support safety belt 130 is disposed behind but in proximity to the back of person 34 when carried by lift 30. Heads 116 (FIGS. 1 and 5) and shanks 114 (FIG. 5) of support rivets 112 are sized and configured to be received through support openings 150 (FIGS. 1, 5 and 6) of clevises 152, and 154 (FIG. 6) respectively of leg support device 52 of body support assembly 44. Openings 150 are shown to be of a substantially triangular configuration wider at their respective bottoms and coming to a point at their respective tops. As such heads 116 of rivets 112 can pass through the wide portions of openings 150 and be disposed outside of clevises 152, 154 when shanks 114 of rivets 112 are disposed proximate the respective tops of openings 150 where clevises 152, 154 will rest upon their respective shanks 114. When so disposed heads 116 of rivets 112 prevent clevises 152, 154 from moving off of shanks 114 of rivets 112 and thus hold clevises 152, 154 and leg support 160 suspended therefrom. Three support openings 150a, 150b and 150c, each of identical configuration and arrangement, are formed through each clevis 152, 154, but at different but aligned levels to facilitate dispositions of leg support 160 at different levels as will be hereinafter described. While support openings 150 are shown with a triangular configuration it should be understood that other suitable configurations, such as tear drop, keyhole or the like may also be utilized. Each clevis 152, 154 (FIG. 6) is formed with a hand hole 170, 172 respectively extending therethrough proximate their upper ends and a seat support bar 174, 176 and openings 178, 180 extending therethrough proximate their lower ends. Leg support 160 is formed of relatively rigid material and so as to receive at its respective ends 186, 188 support bars 174, 176 respectively of clevises 152, 154 to be mounted thereon and supported thereby. Belt openings 190, 192 are formed through leg support 160 at ends 186, 188 respectively thereof of a size and configuration to permit passage therethrough of ends 194, 196 respectively of a leg belt 200. A pair of fasteners 202, such as rivets or the like, secure belt 200 to leg support 160 proximate the respective centers thereof. Velcro type fasteners 204a, 204b are carried by end 194 of belt 200 for respective coaction to secure end 194 of belt 200 in position about a leg of person 34 when disposed on leg support 160 as will be hereinafter described, and similar velcro type fasteners (not shown) are carried by end 196 of belt 200 is similar but mirror positions of fasteners 204a, 204b for positioning about the other leg of a person disposed on leg support 160. The respective ends 194, 196 of belt 200 are to be threaded through openings 190, 192 respectively (after passing over the respective legs of person 34 disposed on leg support 160) then under and about support bars 174, 176 respectively to be thereafter secured in place through mating coaction of their respective velcro type fasteners 204a, 204b as shown for belt end 196. Belt 200 may be formed of suitable and appropriate material such as leather, plastic or the like, with alternate suitable fastening means for the ends thereof, and, if preferred, as two separate belts each secured at one of its ends to leg support 160. Carriage assembly 40 (FIGS. 1 and 2) includes a pair of spaced frame members 220 and 222 (FIG. 2) interconnected in spaced relationship by a cross-member 224 (FIGS. 1 and 2). A pair of wheels 230 are each rotatively carried at the respective ends of each frame member 220, 222; each such wheel 230 being equipped with conventional wheel brakes that may be selectively applied and released. The spacing between frame members 220, 222 is selected to accommodate therebetween a seated person 34 to be lifted, transported and reseated. A vertically disposed lifting mechanism support column 240 (FIGS. 1, 2 and 3) extends up from cross-member 224 and is suitably and securely carried thereby. Support column 240 is hollow and supports therewithin lifting tube 70 for vertical up and down movement. While support column 240 and tube 70 are both shown as hollow tubes of substantially square cross-section they may just as well be formed to any other convenient hollow tubular cross-section. A suitable bushing 242 (FIG. 7) is fixedly secured proximate an upper end 244 of support column 240 and receives for sliding movement therewithin lifting tube 70. A lower end 250 of lifting tube 70 rests upon a bushing 252. The latter rests on a ball nut 253 disposed for coaction with a ball screw 254 vertically disposed within column 240 and tube 70. Ball nut 252 and ball screw 254 are conventionally available and coacting devices with ball screw 254 thereof driven by a motor 260 suitably and appropriately interconnected to ball screw 254 and mounted to carriage assembly 40. Motor 260 may be connected by conventional means to a source of drive power or by conventional conductive means therefore. Appropriate and suitable controls are connected to and provided for motor 260 to energize and de-energize same, and to control the operation thereof for lifting and lowering of tube 70 and body support assembly 44 carried thereby. When invalid lift and transport 30 is to be utilized it is wheeled to where person 34 is sitting and disposed with frame members 220, 222 positioned to each side of person 34 and their seat. Person 34 then leans over positioning their chest upon pillow 82 of chest support device 54 and grasping handles 90, 92 with their hands (as shown in FIG. 1). Prior to person 34 so positioning themselves lifting mechanism 42 may need to be operated to position chest support device 54 at a proper height. Once person 34 has been positioned upon chest support device 54 back support holders 110 are inserted into channels 109 with rivets 112 extending outwardly through openings 108 and until shoulders 280 (FIG. 4) formed on holders 110 bottom against an upper surface 282 of channel members 103. When holders 110 are so disposed back support safety belt 130 will be disposed behind the back of person 34 to secure them in position and prevent them from falling off lift 30 should they accidentally or unintentionally attempt to move back or to a sitting position. Leg support 160 is then positioned beneath the thighs of person 34 proximate their knees and belt 200 thereof is secured in place over the legs of person 34 as hereinabove described. Clevises 152, 154 are then respectively positioned on back support holders 110 by passing openings 150 thereof over heads 116 of rivets 112 and having shanks 114 of rivets 112 rest beneath upper ends of openings 150. A suitable set of openings 150a, 150b or 150c is selected when so positioning leg support device 52 to accommodate the physical size and proportions of person 34. It should be noted that support bars 174, 176 of clevises 152, 154 are disposed at an angle to accommodate the seated disposition of person 34 and urge person 34 to a position against pillow 82. With person 34 positioned as above described lifting mechanism 42 may be operated to raise lifting tube 70, body support assembly 44 and person 34. Once person 34 is free of their seat carriage 40 may be rolled (after the brakes for wheels 230 have been released if they have been applied) on wheels 230 to a new seat, toilet or other position. While person 34 is so positioned their buttocks are available for medical treatment or for performing body functions. Lifting mechanism 42 is then operated to lower body support assembly 44 (after wheels 230 are locked if so desired) and person 34 is deposited at their new location or back where they were originally. After person 34 is safely seated clevises 152, 154 may be raised, lifted off of rivets 112, leg belt 200 may thereafter be unstrapped and leg support device 52 removed from under the legs of person 34. Back support holders 110 may then be slid out from channels 109 of channel members 103, carriage wheels 230 unlocked and carriage 40 rolled away. Lift and transport apparatus 30 shown and described above is relatively simple to use and can be operated by one person. The person being lifted and transported is disposed in a very stable position during lifting and transport. The apparatus is highly safe and reliable. When person 34 is disposed in position to be lifted and transported a substantial portion of their weight is supported on the chest support device 54. Leg support 160 is disposed at an angle to the horizontal to effect a force component that moves the body of person 34 forward. The requirement that back support device 50 be in position in order to attach leg support device 52 insures the relatively high degree of personal safety provided by lift and transport 30. In the embodiment of FIGS. 8-12 an upper plate 300 (FIGS. 8 and 9) is secured, as by welding or the like, to the top 302 of a lifting tube 304 slidably disposed within a support column 306 of a lifting mechanism 308 of an alternative construction for an invalid lift and transport device 310. Lifting tube 304, support column 306 and lifting mechanism 308 are identical in construction and operation to lifting tube 70, support column 240 and lifting mechanism 42 of the embodiment of FIGS. 1-7. A pair of lifting arm mounting plates 320 (FIGS. 8-10) [only one shown] are each secured to and depend down from upper plate 300 at respective sides 322 thereof. A lifting arm 324 is secured to each such lifting arm mounting plate 320 as by threaded fasteners 326 (FIGS. 8 and 9). Each lifting arm 324, at its respective end 326, opposite to where arms 324 are secured to their respective mounting plates 320, carries a substantially "C" shaped channel member 330 (FIGS. 8-10) which may either be formed integrally therewith or secured thereto by suitable means such as welding or the like. Channel members 330 are substantially identical in configuration and function to each other so only one such channel member 330 has been shown. They are also substantially identical in configuration and function to channel members 103 (FIGS. 4 and 5) of the embodiment of FIGS. 1-7 in that each such channel member 330 includes back wall 332 opposed and spaced sidewalls 334, 336 extend up from back wall 332 and front strips 338 terminating in edges 340 spaced from each other and defining an opening 342 extending the length of each respective channel member 330. The inner surfaces of back wall 332, sidewalls 334, 336, and front strips 338 define a channel 350 also extending the length of each channel member 330 and which communicates with opening 342. Each channel 350, of channel members 330, is of a size and configuration to receive a back support holder 360 [only one shown in phantom in FIGS. 8 and 9]. Each back support holder 360 is constructed with a pair of shoulders 362 disposed to bottom against an upper surface 364 of channel members 330 when back support holders 360 are inserted into channels 350, and each back support holder carries a seat device support rivet 366 extending outwardly therefrom and carried thereby to extend out through openings 342. Back support holders 360 cooperate to mount therebetween and position a back support device 368, in the same manner that back support holders 110 (FIG. 1) support back support safety belt 130 of the FIGS. 1-7 embodiment, and, through rivets 366, a leg support device 368 in the same manner that rivets 112 of back support holders 110 support and mount leg support device 52 of FIGS. 1-7 embodiment. Channel members 330, however, differ from channel members 103 (FIGS. 4 and 5) in that each channel member 330 includes a slot 370 (FIGS. 8 and 10) that extends through sidewall 336, near to upper surface 364 of channel member 330, and through the front strip 338 that extends inwardly from sidewall 336. Slot 370 is of a size and configuration to receive a locking finger 372 carried at one end of a locking lever 374 of a locking lever assembly 375 that is pivotally mounted at 376 to lifting arm 324. An actuating finger 380 (FIGS. 8-10) is carried at the other end of locking lever 374 extending out therefrom for coaction with an end of a flat spring 382 (FIGS. 8 and 9) the other end of which is secured to upper plate 300 as by threaded members 384 (FIG. 9) or the like. Spring 382 acts against actuating finger 380 and urges locking lever 374 in the counterclockwise direction about pivot 376 (FIG. 8) so that locking finger 372 seats in slot 370. When locking finger 372 is so seated in slot 370 it obstructs channel 350 so that a back support holder 360 cannot be inserted therein and by doing so prevents that side of the leg support device from being mounted on the rivet 366 carried by back support holder 360. Spring 382 also acts against an underside 390 (FIG. 8) of a chest support plate 392 of a chest support pillow 394 of a chest support device 396 proximate a front edge 398 thereof. A chest support pivot 400 carried by chest support plate 392 and upper plate 300 pivotally mounts chest support device 396 to upper plate 300. Spring 382 urges chest support device 396 in the clockwise direction (FIG. 8) about pivot 400 and into its unsupporting position of FIG. 8.. The application of suitable force upon chest support pillow 394 of chest support device 396, such as when a person 34 (FIG. 1) lays upon pillow 394 (FIG. 8) when preparing to and being moved by invalid lift and transport 310, pivots chest support device 396 counterclockwise (FIG. 8) about pivot 400 from its FIG. 8 unsupporting position to a person supporting position as shown in FIG. 12. The pivoting movement of chest support device 396, through front edge 398 thereof, acts upon actuating finger 380 pivot locking lever 374, against the urging of spring 382, in the clockwise direction (FIG. 8) about pivot 376 and moves locking finger 372 thereof out from slot 370 (FIG. 9). This removes finger 372 from obstructing channel 350 and will permit a back support holder 360 to be inserted in channel 350. Once so inserted rivet 366 is disposed to mount a leg support device and invalid lift and transport 310 is available to lift, transport and deposit a person. Chest support device 396, back support device 368 and lifting mechanism 308 are otherwise identical in construction and operation to comparable devices of the lift and transport device of FIGS. 1-7 and serve to mount and operate a leg support device [not shown] such as leg support device 52 (FIG. 4). The described construction disposition and operation of locking lever assembly 375 and its coaction with chest support device 396 and back support holders 360 provides yet an additional measure of safety for device 310 in that it requires the person to be lifted and transported to be positioned upon chest support device 396 before the back support safety belt can be properly positioned. Without the proper positioning of the back support safety belt the leg support device cannot be properly positioned and without that the lift cannot be operated to lift and transport a person. In FIG. 13 there is shown an alternative construction of a chest support device 450 for an invalid lift and transport device 452. Device 452 otherwise utilizes a lifting mechanism 42, a back support device 50, and a leg support device 52 that are identical to such devices as described for lift 30 of FIGS. 1-7. In addition, chest support device 450 is identical to chest support device 54 of the FIGS. 1-7 embodiment except that its chest support pillow is carried by a chest support plate 462 that is pivoted proximate its forward end 464 by a pivot 466 carried by plate 462 and lifting arms 470 [only one shown] of lifting mechanism 472. Lifting arms 470 and lifting mechanism 472 are otherwise constructed, carried and function like lifting arms 74 and 76 of lifting mechanism 42 of lift 30 of the FIGS. 1-7 embodiment. A pair of adjusters 480 (FIG. 13) [only one shown] are each secured at respective first ends 482 thereof to the underside of plate 462 proximate respective sides thereof and at respective second ends 484 thereof to handle arms 486 [only one shown]. Adjusters 480 are of conventional construction which readily permit increase or decrease of the respective lengths thereof (as by turning a center portion thereof) such that chest support device 450 can be disposed with its pillow 460 disposed at substantially an infinite number of selected angles between approximately six degrees to the horizontal as shown by person 34 in outline in FIG. 13 and forty-five degrees to the horizontal as shown by person 34a filled-in in FIG. 13. In FIGS. 14 and 15 there is shown a width adjustable carriage assembly 500 including a pair of spaced frame members 520 and 522 (FIG. 15) interconnected in spaced relationship by a pair of cross-beams 530, 532. A pair of wheels 540 are each rotatively carried at the respective ends of each frame member 520, 522; each such wheel 540 being equipped with conventional wheel brakes that may be selectively applied and released. Cross-beams 530, 532 mount a support column 550 with an internal lifting tube 552 and motor 554 of a lifting mechanism 560 which is constructed and functions like lifting mechanism 42 of the FIG. 1-7 embodiment. Each cross-beam 530 and 532 includes an internal cross shaft 570 with external threads and an internally threaded adjustment nut 572 which upon adjustment effects uniform movement of frames 520, 522 (and wheels 540) inwardly or outwardly with respect to each other. Such adjustment facilitates spacing of frame members 520, 522 to accommodate seat of different width (such as chairs, wheelchairs, commodes, and the like). From the above description it will thus be seen that there has been provided a new and improved invalid lift and transport apparatus which provides relatively safe lifting, transport, and deposition of a person by enforcing positioning of a person to be lifted and transported in a relative apparatus stable position and which provides and insures use of a back safety belt in order to utilize the apparatus. It is understood that although I have shown preferred forms of my invention that various modifications may be made in the details thereof without departing from the spirit as comprehended by the following claims.
A lifting mechanism, on a carriage assembly, supports a body support assembly to lift transport and thereafter set down a person. A back safety belt, carried by a pair of belt support holders, provides a first body support. The holders must be disposed in slots defined by "C" shaped members carried by arms carried by the lifting mechanism, before a leg support device can be hung from rivets carried by the holders. The leg support device is disposed beneath the person's legs proximate their knees and includes a board supported at its ends by clevises hung from the rivets, and a belt or belts passed over a person's legs and belted in place; and constitutes a second body support. A chest support device, constituting a third body support, is also carried by the lifting mechanism and is disposed to receive thereagainst the chest of a person being lifted, transported and lowered. The leg support device cannot be utilized unless the back support device is in place. In an alternative embodiment the chest support is spring biased and pivotally mounted to coact with a locking lever which includes a finger projecting into the path of disposition of at least one back support holder to prevent disposition thereof and hanging of the leg support device, unless force is applied to the chest support device as by a person leaning thereagainst. Another embodiment provides for adjustment of the chest support device between six degree and forty-five degree positions; while a still further embodiment provides screw adjustable spacing of carriage frame members.
0
[0001] The following specification particularly describes the invention and the manner in which it is to be performed: FIELD OF THE INVENTION [0002] The present invention relates to an expression construct for enhancing the carbon (C), nitrogen (N), biomass and yield of plants. [0003] Further, the present invention provides the process for enhancement of C and N levels and subsequent improvement in the biomass and yield of plant by using the aforesaid expression construct which utilizes co-overexpression of genes from enzymes phosphoenolpyruvate carboxylase (hereinafter, referred as “PEPCase”), glutamine synthetase (hereinafter, referred as “GS”) and aspartate aminotransferase (hereinafter, referred as “AspAT”). In particular, the present invention is directed to transgenic plants where nucleic acid sequences encoding the said proteins are expressed in plant cells. More particularly, the present invention relates to the transformation of a plant with genetic construct involving co-overexpression of three genes wherein one gene PEPCase encodes enzyme responsible to capture CO 2 and the other two encode for enzymes (AspAT and GS) involved in N assimilation wherein the N assimilation requires C skeleton which is met by PEPCase, under the control of constitutive promoter comprising plant Arabidopsis thaliana transformed with AspAT+GS+PEPCase gene and expression of this gene in plants, thereby enhancing the status of C and N, biomass and yield of plant. BACKGROUND OF THE INVENTION AND PRIOR ART [0004] The present invention relates to a transformed plant with co-overexpression of three genes, viz. [0005] AspAT, GS and PEPCase, leading to enhanced C, N content, biomass, and yield component. PEPCase (EC. 4.1.1.31) is a ubiquitous enzyme in plants that catalyses the β-carboxylation of phosphoenolpyruvate (hereinafter, referred as “PEP”) in the presence of HCO 3 − and Mg 2 + to yield oxaloacetate (hereinafter, referred as “OAA”) and inorganic phosphate (hereinafter, referred as “Pi”), and it primarily has an anaplerotic function of replenishing the tricarboxylic acid cycle with intermediates. In higher plants, there are several isoforms of PEPCase of different organ specificities and they are involved in a variety of functions including stomata opening, fruit ripening and seed maturation. The leaves of C4 and CAM plants contain high levels of PEPCase, which catalyze the initial CO 2 fixation of photosynthesis. The much lower levels of PEPCase seen in the leaves of C3 plants contribute to an anaplerotic function and play a role in regulation of the cellular pH. [0006] GS (EC 6.3.1.2) catalyses the ATP-dependent condensation of ammonia (hereinafter, referred as “NH 3 ”) with glutamate (hereinafter, referred as “Glu”) to produce glutamine (hereinafter, referred as “Gln”). Subsequently, glutamate synthase (GOGAT) transfers the amide group of Gln to α-ketoglutarate producing two molecules of Glu. Both Gln and Glu are the primary source of organic N for proteins, nucleic acid and chlorophyll. [0007] AspAT (EC 2.6.1.1) catalyzes the reversible transfer of the amino group of asparate (hereinafter, referred as “Asp”) to α-ketoglutarate to form OAA and Glu. In plants, AspAT has been proposed to play several metabolic roles including: recycling of C skeletons during NH 3 + assimilation in roots, providing amide precursors for biosynthesis of major nitrogen transport molecules such as asparagines (hereinafter, referred as “Asn”) and ureides, recruiting Asn nitrogen during seed filling and participating in intracellular C shuttles in C4 plants providing precursors for the biosynthesis of the Asp family of amino acids. [0008] Plant performance in terms of biomass production, yield or harvest index depends upon number of internal and environmental factors. Among all these factors, plant C and N level is one of the important factors governing plant productivity. The emerging details of C and N assimilation suggest that a regulatory system coordinates the uptake and distribution of these nutrients in response to both metabolic and environmental cues. Plants sense changes in their C and N status and relay this information to the nucleus where changes in gene expression are brought about. Since plant growth and crop yield are largely influenced by the assimilated C and N, many attempts have been made in the past to engineer efficient C and N assimilation. However, there is no report yet which show significant improvement in the status of C, N, biomass and yield in plants. [0009] Table 1 illustrates the status of information available on the various strategies to improve C and/or N and biomass in different plants. [0000] TABLE 1 Transformation Functions System adopted Results Reference NAD kinase2 Arabidopsis NADK2 NADK2 overexpressors Takahashi, H., (NADK2) overexpressor and were characterized by Takahara, K., Catalyzes the nadk2 mutant were increase in calvin cycle Hashida, S., synthesis of studied to investigate intermediates and Hirabayashi, T., NADP from NAD the impact of altering amino acid like Glu Fujimori, T., in chloroplasts NADP level on plant and Gln. However, Yamada, M. K., metabolism. there is no clear Yamaya, T., evidence on role of Yanagisawa, S. NADK2 influencing C and Uchimiy, H. and N metabolism. 2009. Plant Physiol. 151: 100- 113. Dof 1 Maize Dof1 cDNA was Dof1 overexpression Yanagisawa, S., Dof1 is a overexpressed in in Arabidopsis has led Akiyama, A., transcription Arabidopsis plants to co-operative Kisaka, H., activator for under derivative of modification of plant C Uchimiya, H. and multiple gene the 35S promoter and N content, with Miwa, T. 2004. expressions designated as improved growth Proc. Natl. Acad. associated with 35SC4PPDK. under low N Sci. USA. 101: the organic acid conditions. However, 7833-7838 metabolism, effect of CN including alteration on plant PEPCase. biomass or yield was not discussed. GS i.) A soybean cytosolic Over expression of Vincent, R., GS catalyses the GS gene (GS15) fused cytosolic GS Fraisier, V., ATP- dependent with the constitutive accelerated plant Chaillou, S., condensation of CaMV 35S promoter in development, leading Limami, M. A., NH 3 with (Glu) to order to direct its over- to early senescence Deleens, E., produce (Gln). expression in Lotus and premature Phillipson, B., corniculatus L. plants. flowering when grown Douat, C., NH 4 + rich medium. Boutin, J.-P. and Limitation of C Hirel, B. skeleton and energy 1997. Planta. for enhanced NH 4 + 201: 424-433. assimilation were anticipated. ii.) A pea cytosolic GS Overexpression of Oliveira, I.., gene was cytosolic GS in relation Brears, T., overexpressed in to N, light and Knight, T., Clark, tobacco plants photorespiration A. and Coruzzi, suggested an G. 2002, Plant alternative route to Physiol. chloroplastic GS for 129: 1170-1180 assimilation of photorespiratory ammonium. iii.) Full-length cDNAs An increased metabolic Cai, H., Zhou, Y., encoding rice cytosolic level in GS- Xiao, J., Li, X., GS genes (OsGS1;1 overexpressed plants Zhang, Q. and and OsGS1;2) along was obtained, which Lian, X. 2009, with E. coli GS gene showed higher total GS Plant Cell Rep. (glnA) were activities and soluble 28: 527-537 overexpressed in the protein concentrations rice plant under in leaves and higher constitutive CaMV 35S total amino acids and promoter. total N content in the whole plant. However, decrease in both grain yield production and total amino acids were observed in seeds of GS-overexpressed plants compared with wild-type plants. iv) cDNA encoding alfa Transgenic plants Fuentes, S., Allen, alfa cytosolic GS over grew better under N D., Ortiz-Lopez, A. expressed in tobacco starvation by and Hernandez, plants maintaining G. 2001. J. Exp. photosynthesis at rate Bot. 52: 1071- comparable to those 1081. of plants under high N, while photosynthesis in control plants was inhibited by 40-50%. These results further reflect the need for cooperative modification of CN metabolism for developing plants with better agronomic traits. PEPCase i) The intact maize Transgenic plants Agarie, S., Miura, PEPCase catalyses gene encoding C4- exhibited higher A., Sumikura, R., the β- specific PEPCase used PEPCase activity with Tsukamoto, S., carboxylation of for transformation of reduced O 2 inhibition Nose, A., Arima, S., PEP in the rice plants of photosynthesis. It Matsuoka, M. and presence of HCO 3 − was found that the Tokutomi, M. M. and Mg 2 + to yield reduced O 2 inhibition 2002. Plant Sci. OAA and Pi. photosynthesis was 162: 257-265. primarily due to reduction of Pi rather than increase in the partial direct fixation of atmospheric CO 2 via the enhanced maize PEPCase. However, no report on biomass accumulation or yield as a consequence of PEPCase overexpression was reported. ii) Maize PEPCase Higher levels of maize Hudspeth, introduced in to PEPCase transcript of R. L., Grula, tobacco plants under the correct size were J. W., Dai, Z., the control maize obtained using tobacco Edwards, G. E. and PEPCase and tobacco (chlorophyll a/b Ku, M. S. B. 1992. chlorophyll a/b binding protein gene Plant Physiol. 98: binding protein gene promoter. With two 458-464 promoter. fold incerase in PEPCase activities in leaf, transgenic plants had significantly elevated levels of titratable acidity and malic acid. However, these biochemical differences did not produce any significant physiological changes with respect to photosynthetic rate or CO 2 compensation point. AspAT i) Panicum miliaceum mAspAT- or cAspAT- Sentoku, N., AspAT L. mitochondrial and transformed plants Taniguchi, M., catalyzes cytosolic AspAT had about threefold or Sugiyama, T., the reversible (mAspAT and cAspAT, 3.5-fold higher AspAT Ishimaru, K., transfer of the respectively) genes activity in Ohsugi, R., amino group of were expressed in the leaf than non- Takaiwa, F. and (Asp) to a- tobacco plants under transformed plants, Toki, S. 2000. ketoglutarate to CaMV 35S promoter. respectively. Plant Cell Rep. form OAA and Leaves of both 19: 598-603. Glu transformed plants had increased levels of PEPCase and transformed plants with cAspAT also had increased levels of mAspAT in the leaf. These results further suggested interaction between C and N metabolism. ii) Three AspAT genes Compared with Zhou. Y., Cai, H., from rice (OsAAT3) control Xiao, J. and one AspAT gene plants, the Li, X., Zhang, Q. from E. coli (EcAAT) transformants showed and Lian, X. 2009. were over expressed significantly increased Theor Appl under CaMV 35S leaf AspAT activity and Genet. 118: 1381- promoter in rice greater seed amino 1390 plants. acid and protein contents. However, influence of CN level on biomass or yield was not discussed. [0010] Higher activity of PEPCase shall facilate CO 2 capturing and makes the carbon backbone available for routing of nitrogen in to organic form through joint activity of AspAT and GS. As a result, the inventors have found that object of the present invention can be attained by concomitant increase in expression of genes encoding AspAT, GS and PEPCase to establish the present invention. [0011] Below is given a state of the art knowledge in relation to the present invention and the attempts previously made to enhance either carbon and/or nitrogen levels in the plant. Reference may be made to article by Hudspeth, R. L., Grula, J. W., Dai, Z., Edwards, G. E. and Ku, M. S. B., entitled “Expression of miaze phosphoenolpyruvate carboxylase in transgenic tobacoo” (1992, Plant Physiology, 98: 458-464), wherein PEPCase from maize was expressed under a tobacco ( Nicotiana plumbaginifolia ) chlorophyll a/b binding protein gene promoter in tobacco plants. Up to two fold higher activity of PEPCase was observed in the transgenic leaves as compared to non-transformants with elevated levels of titratable acidity and malic acid. However, these biochemical differences did not produce any significant physiological changes with respect to photosynthetic rate or CO 2 compensation point. [0012] Reference may be made to article by Lebouteiller, B., Dupont, A. G., Pierre, J. N., Bleton, J., Tchapla, A., Maucourt, M. and Moing, A., Rolin, D., and Vidal, J. entitled “Physiological impacts of modulating phosphoenolpyruvate carboxylase levels in leaves and seeds of Arabidopsis thaliana ” (2007, Plant Science, 172:256-272,), wherein the PEPCase of sorghum was expressed under CaMV 35S promoter in Arabidopsis plant. The leaves of the primary transformants showed up to ten-fold increase in PEPCase activity and up to 30% increase in the dry weight and total protein content of seeds. However, the transformants (primary and progeny) did not show any improved growth phenotype or modification in seed production per plant [0013] Reference may be made to yet another article by Chen, L. M., Li, K. Z. Miwa, T. and Izui, K. entitled “Overexpression of a cyanobacterial phosphoenol pyruvate carboxylase with diminished sensitivity to feedback inhibition in Arabidopsis changes amino acid metabolism” (2004, Planta, 219: 440-419.), wherein the cyanobacterial Synechococcus vulcanus phosphoenolpyruvate carboxylase (SvPEPCase) with diminished sensitivity to feed back inhibition, was over expressed under the control of CaMV 35S promoter in Arabidopsis plant. One third of the T 1 transformants showed severe phenotypes as bleached leaves and were infertile when grown on soil. However, no such phenotype was observed with Arabidopsis transformed with maize PEPCase (ZmPEPC) for C 4 photosynthesis, which is normally sensitive to a feedback inhibitor, L-malate. The growth inhibition of SvPEPC transformed T 2 plants was presumed to be primarily due to a decreased availability of phosphoenolpyruvate (PEP), one of the precursors for the shikimate pathway for the synthesis of aromatic amino acids and phenylpropanoids. [0014] Reference may be made to yet another article by Fukayama, H., Hatch, M. D., Tamai, T., Tsuchida, H., Sudoh, S., Furbank, R. T. and Miyao, M., entitled “Activity regulation and physiological impacts of maize C (4)-specific phosphoenolpyruvate carboxylase overproduced in transgenic rice plants” (2003, Photosynthesis Research, 77: 227-239), wherein the intact maize PEPCase gene was overexpressed in the leaves of rice plants. Introduced PEPCase in transgenic rice leaves underwent activity regulation through protein phosphorylation in manner similar to endogenous rice PEPCase but contrary to that occurring in maize leaves, being downregulated in the light and upregulated in the dark. Compared with untransformed rice, the level of PEP was slightly lower and the product (OAA) was slightly higher in transgenic rice, suggesting that maize PEPCase was functioning even though it remained dephosphorylated and less active in the light. 14 CO 2 labeling experiments indicated that maize PEPCase did not contribute significantly to the photosynthetic CO 2 fixation of transgenic rice plants. Rather, it slightly lowered the CO 2 assimilation rate. This effect was ascribable to the stimulation of respiration in the light, which was more marked at lower O2 concentrations. It was concluded that overproduction of PEPCase does not directly affect photosynthesis significantly but it suppresses photosynthesis indirectly by stimulating respiration in the light. [0015] Reference may be made to yet another article by Vincent, R., Fraisier, V., Chaillou, S., Limami, M. A., Deleens, E., Phillipson, B., Douat, C., Boutin, J. P. and Hirel, B., entitled “Overexpression of a soybean gene encoding cytosolic glutamine synthetase in shoots of transgenic Lotus corniculatus L. plants triggers changes in ammonium assimilation and plant development” (1997, Planta. 201:424-433), wherein a soyabean cytosolic GS gene GS15 was fused with CaMV 35S promoter to achieve constitutive expression in the lotus corniculatus L. plants. On growing the transgenic plants under different N regimes an increase in free amino acids and ammonium was observed accompanied by a decrease in soluble carbohydrates in the transgenic plants cultivated with 12 mM NH 4+ in comparison to the wild type grown under the same conditions. Labelling experiments revealed that both ammonium uptake in the roots and the subsequent translocation of amino acids to the shoots was lower in plants over expressing GS. However the early floral development in the transformed plants suggested the role of GS in the early senescence and premature flowering when plants were grown on an ammonium-rich medium. Limitation of C skeleton and energy for enhanced NH 4 + assimilation were anticipated. [0016] Reference may be made to yet another article by Fuentes, S. I., Allen, D. J., Ortiz-Lopez, A. and Hernandez, G., entitled “Overexpression of cytosolic glutamine synthetase increases photosynthesis and growth at low nitrogen conditions” (2001, Journal of Experimental Botany, 52:1071-1081), wherein the alfa alfa GS driven by constitutive CaMV 35S promoter introduced into tobacco plants. Leaf GS activity in the transgenic plants increased up to six times of untrasformed plants. Under N starvation GS transgenic grew better by maintenance of photosynthesis at rates indistinguishable from plants under high N, while photosynthesis in the control plants was inhibited by 40-50% by N deprivation. However, under optimum N fertilization conditions, no effect of GS overexpression on photosynthesis or growth was observed. [0017] Reference may be made to yet another article by Oliveira, I., Brears, T., Knight, T., Clark, A. and Coruzzi, G., entitled “Overexpression of cytosolic glutamine synthetase. Relation to nitrogen, light, and photorespiration” (2002, Plant Physiology, 129: 1170-1180), wherein the overexpression of pea cytosolic GS was studied in relation to nitrogen, light and photorespiration. Tobacco plants, which ectopically overexpress cytosolic GS1 in leaves, display a light-dependent improved growth phenotype under N-limiting and N-non-limiting conditions as evident by increase in fresh weight, dry weight, and leaf soluble protein. The cytosolic GS1 transgenic plants also exhibit an increase in the CO 2 photorespiratory burst and an increase in levels of photorespiratory intermediates, suggesting changes in photorespiration. However, the effect of stimulation of photorespiration by GS overexression on plant productivity was not discussed. [0018] Reference may be made to yet another article by Cai, H., Zhou, Y., Xiao, J., Li, X., Zhang, Q. and Lian, X., entitled “Overexpressed glutamine synthetase gene modifies nitrogen metabolism and abiotic stress response in rice” (2009, Plant Cell Reports. 28: 527-537), wherein the full-length cDNAs encoding rice ( Oryza sativa ) cytosolic GS genes (OsGS1;1 and OsGS1;2) along with E. coli GS gene (glnA) were overexpressed in the rice plant under constitutive CaMV 35S promoter. An increased metabolic level in GS-overexpressed plants was obtained, which showed higher total GS activities and soluble protein concentrations in leaves and higher total amino acids and total N content in the whole plant. However, decrease in both grain yield production and total amino acids were observed in seeds of GS-overexpressed plants compared with wild-type plants. [0019] Reference may be made to yet another article by Sentoku, N., Taniguchi, M., Sugiyama, T., Ishimaru, K., Ohsugi, R., Takaiwa, F. and Toki, S., entitled “Analysis of the transgenic tobacco plants expressing Panicum miliaceum aspartate aminotransferase genes” (2000, Plant Cell Reports, 19: 598-603), wherein the effects of the overexpression of Panicum mitochondrial and cytoplasmic AspAT (mAspAT and cAspAT respectively) under the control of CaMV 35S promoter were evaluated on transgenic tobacco plants. The mAspAT- or cAspAT-transformed plants had about threefold or 3.5-fold higher AspAT activity in the leaf than non-transformed plants, respectively. Interestingly, the leaves of both transformed plants had increased levels of PEPCase and transformed plants with cAspAT also had increased levels of mAspAT in the leaf. These results suggest that the increased expression of Panicum cAspAT in transgenic tobacco enhances the expression of its endogenous mAspAT and PEPCase, and the increased expression of Panicum mAspAT enhances the expression of its endogenous PEPCase. However, there is no account on effect of AspAT overexpression on plant growth and productivity. [0020] Reference may be made to yet another article by Zhou, Y., Cai, H., Xiao, J., Li, X., Zhang, Q. and Lian, X., entitled “Over-expression of aspartate aminotransferase genes in rice resulted in altered nitrogen metabolism and increased amino acid content in seeds” (2009, Theoretical and Applied Genetics, 118:1381-1390), wherein three AspAT genes from rice (OsAAT1-3) encoding chloroplastic, cytoplasmic, and mitochondrial AspAT isoenzymes, respectively and one AspAT gene from E. coli (EcAAT) were overexpressed in rice plant under the control of CaMV 35S promoter. The OsAAT1, OsAAT2, and EcAAT transformants showed significantly increased leaf AspAT activity and greater seed amino acid and protein contents. However no significant changes were found in leaf AspAT activity, seed amino acid content or protein content in OsAAT3 over-expressed plants. [0021] Reference may be made to yet another article by Murooka, Y., Mori, Y. and Hayashi, M., entitled “Variation of the amino acid content of Arabidopsis seeds by expressing soyabean aspartate aminotransferase gene” (2009, Journal of Bioscience and Bioengineering, 94: 225-230), wherein AspAT5 encoding the chloroplast AspAT from Soyabean was linked to CaMV 35S promoter for achieving its overexpression in the Arabidopsis plant. Expression of AspAT5 in transformants caused 3-, 4-, 23-, and 50-fold increases in the contents of free glycine, alanine, asparagine, and Glu, respectively, in the T 3 seeds. However, a decrease in the contents of valine, tyrosine, isoleucine, leucine, and phenylalanine by several folds was also observed. Further, there is no report on effect of overexpression of AspAt on plant growth and productivity. [0022] Reference may be made to yet another article by Yanagisawa, S., Akiyama, A., Kawaka, H., Uchimiya, H. and Miwa, T. entitled “Metabolic engineering with Dof1 transcription factor in plants: Improved nitrogen assimilation and growth under low-nitrogen conditions” (2004, Proceedings of the National Academy of Sciences (USA), 101:7833-7838), wherein over-expression of Dof1 transcription factor from maize improves N assimilation in transgenic Arabidopsis plants. Dof1 expressing plants showed up-regulation of genes encoding enzymes for C skeleton production, a marked increase of amino acid contents, and a reduction of the glucose level. The results suggest cooperative modification of C and N metabolisms on the basis of their intimate link. Elementary analysis revealed that the N content increased in the Dof1 transgenic plants (≈30%), indicating promotion of net N assimilation. However, effect of C N alteration on plant biomass or yield was not discussed. [0023] Reference may be made to still another article by Takahashi, H., Takahara, K., Hashida, S., Hirabayashi, T., Fujimori, T., Kawai-Yamada, M., Yamaya, T., Yanagisawa, S, and Hirofumi Uchimiya, H., entitled “Pleiotropic Modulation of carbon and nitrogen metabolism in Arabidopsis plants overexpressing the NAD kinase2 gene” by (2009, Plant Physiology. 151:100-113), wherein transgenic Arabidopsis plants with over expression of NAD kinase2 (NADK2) along with NADK2 mutants were raised to investigate the impacts of altering NADP level on plant metabolism. Metabolite profiling revealed that NADP(H) concentrations were proportional to NADK activity in NADK2 overexpressors and in the NADK2 mutant. Several metabolites associated with the calvin cycle were also higher in the overexpressors, accompanied by an increase in overall Rubisco activity. Furthermore, enhanced NADP(H) production due to NADK2 overexpression increased N assimilation. Gln and Glu concentrations, as well as some other amino acids, were higher in the overexpressors. However, there is no clear evidence on role of NADK2 influencing C and N metabolism. [0024] The improvement in the C and N status of plants is a major concern to improve productivity. However, there is no report yet which show enhancement of C and N levels and subsequent improvement in the biomass and yield of plant. [0025] Further, no attempt has been made to co-over express three genes, viz. AspAT, GS and PEPCase, leading to enhanced status of C and N, biomass, and yield. OBJECTIVES OF THE INVENTION [0026] The main objective of the present invention is to provide an expression construct for enhancing the carbon, nitrogen, biomass and yield of plants which obviates the drawbacks of the hitherto known prior art as detailed above. [0027] Another objective of the present invention is to provide an expression construct for co-overexpression of AspAT (SEQ ID NO: 1), GS (SEQ ID NO: 2). and PEPcase (SEQ ID NO: 3) wherein PEPCase efficiently captures CO 2 whereas the other two genes encoding for enzymes (AspAT and GS) have role in N assimilation, using the carbon backbone provided by PEPCase mediated reaction resulting in the enhancement of C and N status with improved biomass and yield of plants. [0028] Yet another objective of the present invention is to raise transgenic plant exhibiting co-overexpression of genes AspAT, GS and PEPCase. [0029] Still another objective of the present invention is to evaluate the expression of AspAT, GS and PEPCase genes in transgenic plants. [0030] Still another objective of the present invention is to evaluate the transgenic plants for status of C and N, biomass and yield compared to wild plants. SUMMARY OF THE INVENTION [0031] Accordingly, the present invention provides an expression construct represented by SEQ ID NO. 7 for co-expression of the genes AspAT, GS and PEPCase comprising nucleotide sequences represented by SEQ ID NO: 1, SEQ ID NO: 2 and SEQ ID NO: 3, wherein SEQ ID NO: 1 represents AspAT genes, SEQ ID NO: 2 represents GS genes and SEQ ID NO: 3 represents PEPCase genes linked to at least one control sequence and a transcription terminator sequence, useful for enhancing the carbon, nitrogen, biomass and yield of plants as compared to wild type or untransformed plant. [0032] In an embodiment of the present invention, the control sequence is preferably represented by SEQ ID NO: 4. [0033] In another embodiment of the present invention, the transcription terminator sequence is represented by SEQ ID NO: 5. [0034] In an embodiment, the present invention provides an expression construct prepared from the cytosolic AspATgene from soyabean, cytosolic GS gene from tobacoo and cytosolic PEPCase gene from maize. [0035] In another embodiment of the present invention, the polynucleotide having SEQ ID No: 7 is overexpressed in plants. [0036] In still another embodiment of the present invention, the control sequence used is a constitutive promoter selected from the group consisting of CaMV 35S promoter, rubisco promoter, ubiquitin promoter, actin promoter. [0037] In still another embodiment of the present invention, the terminator used is preferably selected from the group consisting of Nos terminator and CaMV 3′ UTR. [0038] In still another embodiment of the present invention, a process for preparing the expression construct wherein the process comprising the steps of: i) amplifying cDNA sequences encoding genes represented by SEQ ID NO: 1 using primers represented by SEQ ID NO: 10 and SEQ ID NO: 11, SEQ ID NO: 2 using primers represented by SEQ ID NO: 8 and SEQ ID NO: 9 and SEQ ID NO: 3 using primers represented by SEQ ID NO: 12 and SEQ ID NO: 13; ii) cloning independently the amplified product of SEQ ID NO: 1, 2 and 3 as obtained in step (i) into pGEM-T easy vector; iii) digesting independently the plasmid from the positive clones as obtained in step (ii) along with pCAMBIA 1302 and further ligating the digested gene products and pCAMBIA 1302 and transforming into E. coli DH5 α cells; iv) sequencing the plasmid from the positive colonies obtained in step (iii) confirming the inframe cloning of AspAT::pCAMBIA1302; GS::pCAMBIA1302 and PEPCase::pCAMBIA 1302. v) amplifying the products obtained in step (iv) by using primers represented by SEQ ID NO: 10 and SEQ ID NO: 16; SEQ ID NO: 14 and SEQ ID NO: 15 and SEQ ID NO: 17 and SEQ ID NO: 18. vi) cloning, digesting, ligating and sequencing was again performed independently for the amplified GS coding sequence to form GS+pCAMBIA1302 which was further digested and ligated with the plasmids of positive clones of amplified AspAT coding sequence to form AspAT+GS+pCAMBIA1302 expression cassette; vii) ligating the digested plasmids of positive clones of amplified PEPCase coding sequence with the destination pCAMBIA1302 which was previously cloned with the AspAT+GS+ expression cassette as obtained in step (vi) such that the genes AspA, GS and PEPCase were controlled by independent CaMV 35S promoter and Nos transcriptional terminator to form single plant expression construct AspAT+GS+PEPCase represented by SEQ ID NO: 7. [0047] In still another embodiment of the present invention, a process for enhancing the carbon, nitrogen, biomass and yield of plants using the expression construct, wherein the said process comprising the steps of: a) transforming Agrobacterium tumefacians strain with the expression construct as claimed in claim 1 ; b) transforming the explants with the recombinant Agrobacterium tumefacians strain as obtained in step (a); c) selecting the transformed explants of step (b) to obtain the desired transformed plants having enhanced level of carbon, nitrogen, biomass and yield of plants as compared to wild type plant. In still another embodiment of the present invention, a process wherein the transformed plants display an increase of about 45-50% in PEPCase activity, at least 55% in GS activity and 55-60% in AspAT activity as compared to wild type, resulting in increase in carbon and nitrogen levels in the plant. [0052] In another embodiment of the present invention, the Agrobacterium strain provided is selected from a group consisting of GV3101 with ATCC number Agrobacterium tumefaciens (GV3101 (pMP90RK) (C58 derivative) ATCC® Number: 33970 Reference: Hayashi H, Czaja I, Lubenow H, Schell J, Walden R. 1992. [0053] In yet another embodiment of the present invention, the transformed plants are selected from the group consisting of grain crops, pulses, vegetable crops, oilseed crop and ornamentals. [0054] In yet another embodiment, the transformed plants are selected from the group consisting of arabidopsis , tomato, potato, tobacco, maize, wheat, rice, cotton, mustard, pigeon pea, cowpea, pea, sugarcane, soya bean and sorghum. [0055] In still another embodiment, the transformed plants as compared to wild type display increased yield and/or biomass, indicated by increased seed yield and/or pod yield. [0056] In still another embodiment, the transformed plants display enhanced growth characteristics characterized by increased shoot fresh weight, shoot dry weight, root fresh and dry weight as compared to wild type or untransformed plant. [0057] In yet another embodiment of the present invention, the transformed plant shows enhanced levels of carbon, nitrogen, biomass and yield as compared to wild plants. [0058] In still another embodiment of the present invention, the expression and functionality of over expressed enzymes in transgenic plants is evaluated. [0059] In yet another embodiment of the present invention, the selectable marker used is hpt gene (hygromycin phosphotransferase) represented by SEQ ID NO: 6 for hygromycin resistance controlled by duplicated CaMV 35S promoter and terminated by CaMV 3′UTR (polyA signal). [0060] In another embodiment of the present invention, biochemical assays and RT-PCR were performed to evaluate the expression of introduced genes and the functionality of over expressed enzymes in transgenic plants. [0061] In a further embodiment of the present invention, the transgenic plants were investigated for different growth and yield parameters and compared to wild plants cultivated under the same conditions. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS [0062] FIG. 1 represents a schematic view of T-DNA region of plant transformation vector pCAMBIA1302 for co-overexpression of AspAT, GS and PEPCase (a) and amplification of coding sequences for AspAT, GS and PEPCase from respective plant sources (b) as discussed in Examples 1 to 4. [0063] FIG. 2 represents DNA analysis (a) and RNA analysis (b) of WT, L1 and L2, where WT=wild; L1 and L2=two different transgenic lines co-overexpressing AspAT, GS and PEPCase. [0064] FIG. 3 represents shoot fresh weight (FW) (a), shoot dry weight (DW) (b), root fresh weight (c) and root dry weight (d) of WT and AspAT+GS+PEPCase transgenic plants at 60 days of sowing. Data is mean of five separate biological replicates with standard deviation marked on each bar. [0065] FIG. 4 represents AspAT activity (a) GS activity (b) and PEPCase activity (d) of WT, L1 and L2 at 42 days of sowing. Data is mean of three separate biological replicates with standard deviation marked on each bar. [0066] FIG. 5 represents Analyses of N (a) and C (b) content from different plant parts of WT, L1 and L2 lines at 65 days of sowing. Data is mean of three separate biological replicates with standard deviation marked on each bar. [0067] FIG. 6 represents a representative WT and AspAT+GS+PEPCase transgenic plants at 75 days of sowing. [0068] FIG. 7 represents pod number (a) and seed yield (b) in WT, L1 and L2 at 75 days of sowing. Data is mean of five separate biological replicated with standard deviation marked on each bar. DETAILED DESCRIPTION OF THE INVENTION [0069] The present invention relates to genetic engineering of C and N metabolism in plants. In particular, the present invention relates to an expression construct for co-overexpression of AspAT, GS and PEPCase for concomitant alteration in the enzymes involved in C and N assimilation or utilization and/or their expression in order to engineer plants with increased C and N levels thereby promoting better growth and biomass production and enhanced yield. [0070] The term “vector” refers to a construct made up of nucleic acids wherein gene from a foreign source can be ligated and isolated when needed. The construct is usually a plasmid (i.e. extra chromosomal self replicating nucleic acid) and is propagated, for example bacterial cell of E. coli . The vector in the present invention was used to transfer the gene from one source to another. [0071] The term “gene” refers to the sequence of nucleic acids that can produce a polypeptide chain. [0072] The term “gene expression” refers to the level/amount of RNA (i.e. sequence of ribonucleic acid) of choice transcribed (i.e. the process of synthesis of RNA by DNA) by DNA (i.e. sequence of deoxyribonucleic acid). When the gene was transcribed in higher amounts as compared to the control, it was referred to as “over-expression” of gene. [0073] The term “selectable marker” refers to a gene, which allows a cell to survive in the presence of an otherwise toxic antibiotic [0074] The term “transgenic plant” refers to genetically transformed plants with stable integration of introduced gene in to its genome The term “promoter” refers to the specific DNA sequence, usually located upstream (5′) to the DNA sequence involved in transcription, wherein the enzyme RNA polymerase binds for the process of transcription. “Constitutive promoters” direct expression of the gene in all tissues and during all periods regardless of the surrounding environment and development stage of the organism. [0075] The term ‘expression cassettes” refers to vector comprising of (a) a constitutive promoter; (b) all the three genes cloned 3′ to the constitutive promoter, (c) a polyadenylation signal located 3′ to the coding sequence. [0076] and capable of passing genetic information on to successive generations. [0077] ‘Wild-type” plants are untransformed plants. [0078] The term “T 0 ” refers to the first set of genetically transformed plants that can be identified and selected upon growth in presence of a selection agent antibiotic, for which the transgenic plant contains the corresponding resistance gene. The term “T 1 ” refers to the generation of plants obtained after self-fertilization of the flowers of T 0 generation plants, previously selected as being transgenic. “T 2 ” plants are generated from T 1 plants, and so on. The present invention will be illustrated in greater details by the following examples. EXAMPLES [0079] The following examples are given by way of illustration of the present invention and therefore should not be construed to limit the scope of the present invention. [0080] Sequences of the primers used in the present invention are listed as follows: [0000]   Se- Name quence  of the ID sequence Sequence Purpose No. AspAT  atggcttctc acgacagcat ctccgcttct ccaacctccg cttctgattc cgtcttcaat 60 Represents 1 cDNA cacctcgttc gtgctcccga agatcctatc ctcggggtaa ctgtcgctta taacaaagat 120 nucleotide sequence ccaagtccag ttaagctcaa cttgggagtt ggtgcttacc gaactgagga aggaaaacct 180 sequences cttgttttga atgtagtgag gcgagttgaa cagcaactca taaatgacgt gtcacgcaac 240 of AspAT  aaggaatata ttccgatcgt tgggcttgct gattttaata aattgagtgc taagcttatt 300 genes tttggggctg acagccctgc tattcaagac aacagggtta ccactgttca atgcttgtct 360 for ggaactggtt ctttaagagt tgggggtgaa tttttggcta aacactatca ccaacggact 420 making atatacttgc caacaccaac ttggggcaat cacccgaagg ttttcaactt agcaggcttg 480 an tctgtcaaaa cataccgcta ctatgctcca gcaacacgag gacttgactt tcaaggactt 540 expression ctggaagacc ttggttctgc tccatctgga tctattgttt tgctacatgc atgcgcacat 600 aaccccactg gtgtggatcc aacccttgag caatgggagc agattaggca gctaataaga 660 tcaaaagctt tgttaccttt ctttgacagt gcttatcagg gttttgctag tggaagtcta 720 gatgcagatg cccaacctgt tcgtttgttt gttgctgatg gaggcgaatt gctggtagca 780 caaagctatg caaagaatct gggtctttat ggggaacgtg ttggcgcctt aagcattgtc 840 tgcaagtcag ctgatgttgc aagcagggtt gagagccagc tgaagctagt gattaggccc 900 atgtactcaa gtcctcccat tcatggtgca tccattgtgg ctgccattct caaggaccgg 960 aatttgttca atgactggac tattgagttg aaggcaatgg ctgatcgcat catcagtatg 1020 cgccaagaac ttttcgatgc tttatgttcc agaggcacac ctggcgattg gagtcacatt 1080 atcaaacaga ttggaatgtt tactttcact ggattgaatg cggaacaagt ttccttcatg 1140 actaaagagt tccatatata catgacatct gatgggagga ttagcatggc tggtctgagt 1200 tccaaaactg tcccacttct ggcggatgcg atacatgcag ctgtaacccg agttgtctaa 1260 GS  atggctcatc tttcagatct cgttaatctc aatctctctg actccactca gaaaattatt 60 Represents 2 cDNA gctgaataca tatggattgg tggatcagga atggacgtca ggagcaaagc cagaacactt 120 nucleotide sequence tctggacctg ttgatgatcc ttcaaagctt cccaaatgga attatgatgg ttctagcaca 180 sequences ggacaagctc ctggagaaga cagtgaagag atcctatatc ctcaagcaat tttcaaggat 240 of GS  ccattcagaa ggggcaacaa tatcttggtc atttgtgatt gttacacccc agctggtgaa 300 genes cccattccaa caaacaaaag gcacagtgct gccaagattt tcagccaccc tgatgttgtt 360 for   gttgaggaac cctggtatgg tcttgagcaa gaatacacct tgttgcaaaa agatatcaat 420 making tggcctcttg gatggcctct tggtggtttt cctggaccac agggaccata ctattgcgga 480 an attggagctg gaaaggtctt tggacgcgat atcgttgact ctcattataa ggcatgtctc 540 expression tatgctggga ttaacatcag tggtatcaat ggagaagtga tgcccggaca gtgggaattt 600 construct caagttggac cttcagttgg catttcagca gctgatgaat tgtgggcagc tcgttacatt 660 cttgagagga ttactgagat tgctggagtt gtggtctcat ttgaccccaa acctattccg 720 ggtgactgga atggtgctgg agctcacaca aactacagca caaagtctat gaggaatgaa 780 ggaggctatg aagtcattaa gaaggcaatt gagaaccttg gactgaggca caaggagcat 840 attgcagcat atggtgaagg caacgagcgt cgtctcactg gaagacacga aacagctgac 900 atcaacacat tcaaatgggg agttgcgaac cgtggtgcat ctattcgtgt gggaagagac 960 acggagagag aagggaaggg atacttcgag gataggaggc ctgcttcgaa tatggatcca 1020 ttcgtcgtga cttccatgat tgctgagacc actatcctat ccgagccttg a 1071 PEPCase ctcgtcgacc gcttcctcaa catcctccag gacctccacg ggcccagcct tcgcgaattt 180 Represents 3 cDNA gtccaggagt gctacgaggt ctcagccgac tacgagggca aaggagacac gacgaagctg 240 nucleotide sequence ggcgagctcg gcgccaagct cacggggctg gcccccgccg acgccatcct cgtggcgagc 300 sequences tccatcctgc acatgctcaa cctcgccaac ctggccgagg aggtgcagat cgcgcaccgc 360 of   cgccgcaaca gcaagctcaa gaaaggtggg ttcgccgacg agggctccgc caccaccgag 420 PEPCase tccgacatcg aggagacgct caagcgcctc gtgtccgagg tcggcaagtc ccccgaggag 480 genes gtgttcgagg cgctcaagaa ccagaccgtc gacctcgtct tcaccgcgca tcctacgcag 540 for  tccgcccgcc gctcgctcct gcaaaaaaat gccaggatcc gaaattgtct gacccagctg 600 making aatgccaagg acatcactga cgacgacaag caggagctcg atgaggctct gcagagagag 660 an  atccaagcag ccttcagaac cgatgaaatc aggagggcac aacccacccc gcaggccgaa 720 expression atgcgctatg ggatgagcta catccatgag actgtatgga agggtgtgcc taagttcttg 780 construct cgccgtgtgg atacagccct gaagaatatc ggcatcaatg agcgccttcc ctacaatgtt 840 tctctcattc ggttctcttc ttggatgggt ggtgaccgcg atggaaatcc aagagttacc 900 ccggaggtga caagagatgt atgcttgctg gccagaatga tggctgcaaa cttgtacatc 960 gatcagattg aagagctgat gtttgagctc tctatgtggc gctgcaacga tgagcttcgt 1020 gttcgtgccg aagagctcca cagttcgtct ggttccaaag ttaccaagta ttacatagaa 1080 ttctggaagc aaattcctcc aaacgagccc taccgggtga tactaggcca tgtaagggac 1140 aagctgtaca acacacgcga gcgtgctcgc catctgctgg cttctggagt ttctgaaatt 1200 tcagcggaat cgtcatttac cagtatcgaa gagttccttg agccacttga gctgtgctac 1260 aaatcactgt gtgactgcgg cgacaaggcc atcgcggacg ggagcctctt ggacctcctg 1320 cgccaggtgt tcacgttcgg gctctccctg gtgaagctgg acatccggca ggagtcggag 1380 cggcacaccg acgtgatcga cgccatcacc acgcacctcg gcatcgggtc gtaccgcgag 1440 tggcccgagg acaagaggca ggagtggctg ctgtcggagc tgcgaggcaa gcgcccgctg 1500 ctgcccccgg accttcccca gaccgacgag atcgccgacg tcatcggcgc gttccacgtc 1560 ctcgcggagc tcccgcccga cagcttcggc ccctacatca tctccatggc gacggccccc 1620 tcggacgtgc tcgccgtgga gctcctgcag cgcgagtgcg gcgtgcgcca gccgctgccc 1680 gtggtgccgc tgttcgagag gctggccgac ctgcagtcgg cgcccgcgtc cgtggagcgc 1740 ctcttctcgg tggactggta catggaccgg atcaagggca agcagcaggt catggtcggc 1800 tactccgact ccggcaagga cgccggccgc ctgtccgcgg cgtggcagct gtacagggcg 1860 caggaggaga tggcgcaggt ggccaagcgc tacggcgtca agctcacctt gttccacggc 1920 cgcggaggca ccgtgggcag gggtggcggg cccacgcacc ttgccatcct gtcccagccg 1980 ccggacacca tcaacgggtc catccgtgtg acggtgcagg gcgaggtcat cgagttctgc 2040 ttcggggagg agcacctgtg cttccagact ctgcagcgct tcacggccgc cacgctggag 2100 cacggcatgc acccgccggt ctctcccaag cccgagtggc gcaagctcat ggacgagatg 2160 gcggtcgtgg ccacggagga gtaccgctcc gtcgtcgtca aggaggcgcg cttcgtcgag 2220 tacttcagat cggctacacc ggagaccgag tacgggagga tgaacatcgg cagccggcca 2280 gccaagagga ggcccggcgg cggcatcacg accctgcgcg ccatcccctg gatcttctcg 2340 tggacccaga ccaggttcca cctccccgtg tggctgggag tcggcgccgc attcaagttc 2400 gccatcgaca aggacgtcag gaacttccag gtcctcaaag agatgtacaa cgagtggcca 2460 ttcttcaggg tcaccctgga cctgctggag atggttttcg ccaagggaga ccccggcatt 2520 gccggcttgt atgacgagct gcttgtggcg gaagaactca agccctttgg gaagcagctc 2580 agggacaaat acgtggagac acagcagctt ctcctccaga tcgctgggca caaggatatt 2640 cttgaaggcg atccattcct gaagcagggg ctggtgctgc gcaaccccta catcaccacc 2700 ctgaacgtgt tccaggccta cacgctgaag cggataaggg accccaactt caaggtgacg 2760 ccccagccgc cgctgtccaa ggagttcgcc gacgagaaca agcccgccgg actggtcaag 2820 ctgaacccgg cgagcgagta cccgcccggc ctggaagaca cgctcatcct caccatgaag 2880 ggcatcgccg ccggcatgca gaacactggc tag 2913 CaMV 35S catggagtca aagattcaaa tagaggacct aacagaactc gccgtaaaga ctggcgaaca 60 Represents 4 promoter gttcatacag agtctcttac gactcaatga caagaagaaa atcttcgtca acatggtgga 120 control sequence gcacgacaca cttgtctact ccaaaaatat caaagataca gtctcagaag accaaagggc 180 sequence aattgagact tttcaacaaa gggtaatatc cggaaacctc ctcggattcc attgcccagc 240 tatctgtcac tttattgtga agatagtgga aaaggaaggt ggctcctaca aatgccatca 300 ttgcgataaa ggaaaggcca tcgttgaaga tgcctctgcc gacagtggtc ccaaagatgg 360 acccccaccc acgaggagca tcgtggaaaa agaagacgtt ccaaccacgt cttcaaagca 420 agtggattga tgtgatatct ccactgacgt aagggatgac gcacaatccc actatccttc 480 gcaagaccct tcctctatat aaggaagttc atttcatttg gagagaacac gggggact   538 nos cgttcaaaca tttggcaata aagtttctta agattgaatc ctgttgccgg tcttgcgatg 60 Represents 5 (nopaline attatcatat aatttctgtt gaattacgtt aagcatgtaa taattaacat gtaatgcatg 120 tran- synthase) acgttattta tgagatgggt ttttatgatt agagtcccgc aattatacat ttaatacgcg 180 scription 3′UTR atagaaaaca aaatatagcg cgcaaactag gataaattat cgcgcgcggt gtcatctatg 240 terminator (poly- sequence Asignal) sequence hygro- ctatttcttt gccctcggac gagtgctggg gcgtcggttt ccactatcgg cgagtacttc 60 Represents 6 mycin- tacacagcca tcggtccaga cggccgcgct tctgcgggcg atttgtgtac gcccgacagt 120 hpt gene phospho- cccggctccg gatcggacga ttgcgtcgca tcgaccctgc gcccaagctg catcatcgaa 180 (hygro- trans- attgccgtca accaagctct gatagagttg gtcaagacca atgcggagca tatacgcccg 240 mycin ferase gagtcgtggc gatcctgcaa gctccggatg cctccgctcg aagtagcgcg tctgctgctc 300 phospho- catacaagcc aaccacggcc tccagaagaa gatgttggcg acctcgtatt gggaatcccc 360 trans- gaacatcgcc tcgctccagt caatgaccgc tgttatgcgg ccattgtccg tcaggacatt 420 ferase) gttggagccg aaatccgcgt gcacgaggtg ccggacttcg gggcagtcct cggcccaaag 480 for  catcagctca tcgagagcct gcgcgacgga cgcactgacg gtgtcgtcca tcacagtttg 540 hygromycin ccagtgatac acatggggat cagcaatcgc gcatatgaaa tcacgccatg tagtgtattg 600 resistance accgattcct tgcggtccga atgggccgaa cccgctcgtc tggctaagat cggccgcagc 660 gatcgcatcc atagcctccg cgaccggttg tagaacagcg ggcagttcgg tttcaggcag 720 gtcttgcaac gtgacaccct gtgcacggcg ggagatgcca taggtcaggc tctcgctaaa 780 ctccccaatg tcaagcactt ccggaatcgg gagcgcggcc gatgcaaagt gccgataaac 840 ataacgatct ttgtagaaac catcggcgca gctatttacc cgcaggacat atccacgccc 900 tcctacatcg aagctgaaag cacgagattc ttcgccctcc gagagctgca tcaggtcgga 960 gacgctgtcg aacttttcga tcagaaactt ctcgacagac gtcgcggtga gttcaggctt 1020 tttcat 1026 express- catggagtcaaagattcaaatagaggacctaacagaactcgccgtaaagactggcgaacagttcataca Represents 7 ion  gagtctcttacgactcaatgacaagaagaaaatcttcgtcaacatggtggagcacgacacacttgtctact an  cassettes ccaaaaatatcaaagatacagtctcagaagaccaaagggcaattgagacttttcaacaaagggtaatatc expression for  cggaaacctcctcggattccattgcccagctatctgtcactttattgtgaagatagtggaaaaggaaggtgg construct  AspAT,  ctcctacaaatgccatcattgcgataaaggaaaggccatcgttgaagatgcctctgccgacagtggtccca for GS and aagatggacccccacccacgaggagcatcgtggaaaaagaagacgttccaaccacgtcttcaaagcaag co-  PEPCase tggattgatgtgatatctccactgacgtaagggatgacgcacaatcccactatccttcgcaagaccct expression coding of se- gcttctcacgacagcatctccgcttctccaacctccgcttctgattccgtcttcaatcacctcgttcgtg the genes quences, ctcccgaagatcctatcctcggggtaactgtcgcttataacaaagatccaagtccagttaagctcaacttggg AspAT, cloned  agttggtgcttaccgaactgaggaaggaaaacctcttgttttgaatgtagtgaggcgagttgaacagcaact GS and  under cataaatgacgtgtcacgcaacaaggaatatattccgatcgttgggcttgctgattttaataaattgagtgct PEPCase control  aagcttatttttggggctgacagccctgctattcaagacaacagggttaccactgttcaatgcttgtctggaac SpeI of tggttctttaagagttgggggtgaatttttggctaaacactatcaccaacggactatatacttgccaacaccaa CamV 35S cttggggcaatcacccgaaggttttcaacttagcaggcttgtctgtcaaaacataccgctactatgctccagc promoter aacacgaggacttgactttcaaggacttctggaagaccttggttctgctccatctggatctattgttttgctaca (   )  tgcatgcgcacataaccccactggtgtggatccaacccttgagcaatgggagcagattaggcagctaataag and atcaaaagctttgttacctttctttgacagtgcttatcagggttttgctagtggaagtctagatgcagatgccca Nos acctgttcgtttgtttgttgctgatggaggcgaattgctggtagcacaaagctatgcaaagaatctgggtcttt termin- atggggaacgtgttggcgccttaagcattgtctgcaagtcagctgatgttgcaagcagggttgagagccagc ator tgaagctagtgattaggcccatgtactcaagtcctcccattcatggtgcatccattgtggctgccattctcaag (   ) in gaccggaatttgttcaatgactggactattgagttgaaggcaatggctgatcgcatcatcagtatgcgccaag pCAMBIA aacttttcgatgctttatgttccagaggcacacctggcgattggagtcacattatcaaacagattggaatgttt 1302 actttcactggattgaatgcggaacaagtttccttcatgactaaagagttccatatatacatgacatctgatgg PrnII gaggattagcatggctggtctgagttccaaaactgtcccacttctggcggatgcgatacatgcagctgtaacc ctgttgccggtcttgcgatgattatcatataatttctgttgaattacgttaagcatgtaataattaacatgtaa tgcatgacgttatttatgagatgggtttttatgattagagtcccgcaattatacatttaatacgcgatagaaa acaaaatatagcgcgcaaactaggataaattatcgcgcgcggtgtcatctatgt gccttcagtttagctt catggagtcaaagattcaaatagaggacctaacagaactcgccgtaaagactggc gaacagttcatacagagtctcttacgactcaatgacaagaagaaaatcttcgtcaacatggtggagcacg acacacttg tctactccaaaaatatcaaagatacagtctcagaagaccaaagggcaattgagacttttcaacaaagggt aatatccggaaacctcctcggattccattgcccagctatctgtcactttattgtgaagatagtggaaaagga aggtggctcctacaaatgccatcattgcgataaaggaaaggccatcgttgaagatgcctctgccgacagtg gtcccaaagatggacccccacccacgaggagcatcgtggaaaaagaagacgttccaaccacgtcttcaaa NeaI gcaagtggattgatgtgatatctccactgacgtaagggatgacgcacaatcccactatccttcgcaagacc c gatctcgttaatctcaatctctctgactccactcagaaaattattgctgaatacatatggattggtggatcagg aatggacgtcaggagcaaagccagaacactttctggacctgttgatgatccttcaaagcttcccaaatggaa ttatgatggttctagcacaggacaagctcctggagaagacagtgaagagatcctatatcctcaagcaattttc aaggatccattcagaaggggcaacaatatcttggtcatttgtgattgttacaccccagctggtgaacccattc caacaaacaaaaggcacagtgctgccaagattttcagccaccctgatgttgttgttgaggaaccctggtatg gtcttgagcaagaatacaccttgttgcaaaaagatatcaattggcctcttggatggcctcttggtggttttcct ggaccacagggaccatactattgcggaattggagctggaaaggtctttggacgcgatatcgttgactctcatt ataaggcatgtctctatgctgggattaacatcagtggtatcaatggagaagtgatgcccggacagtgggaat ttcaagttggaccttcagttggcatttcagcagctgatgaattgtgggcagctcgttacattcttgagaggatt actgagattgctggagttgtggtctcatttgaccccaaacctattccgggtgactggaatggtgctggagctc acacaaactacagcacaaagtctatgaggaatgaaggaggctatgaagtcattaagaaggcaattgagaa ccttggactgaggcacaaggagcatattgcagcatatggtgaaggcaacgagcgtcgtctcactggaagac BstEII acgaaacagctgacatcaacacattcaaatggggagttgcgaaccgtggtgcatctattcgtgtgggaaga gacacggagagagaagggaagggatacttcgaggataggaggcctgcttcgaatatggatccattcgtcgt ctcgaatttccccgat cgttcaaacatttggcaataaagtttcttaagattgaatcctgttgccggtcttgcga tgattatcatataatttctgttgaattacgttaagcatgtaataattaacatgtaatgcatgacgttatttatg agatgggtttttatgattagagtcccgcaattatacatttaatacgcgatagaaaacaaaatata gcgcgcaaactaggataattatcgcgcgcggtgtcatctatgttactagatcggg aattaaactatcagt tttcccgccttcagtttagctt catggagtcaaagattcaaatagaggacctaacagaactcgccgtaaaga ctggcgaacagttcatacagagtctcttacgactcaatgacaagaagaaaatcttcgtcaacatggtggag cacgacacacttgtctactccaaaaatatcaaagatacagtctcagaagaccaaagggcaattgagactt ttcaacaaagggtaatatccggaaacctcctcggattccattgcccagctatctgtcactttattgtgaagat agtggaaaaggaaggtggctcctacaaatgccatcattgcgataaaggaaaggccatcgttgaagatgcc tctgccgacagtggtcccaaagatggacccccacccacgaggagcatcgtggaaaaagaagacgttccaa ccacgtcttcaaagcaagtggattgatgtgatatctccactgacgtaagggatgacgcacaatcccactat ccttcgcaagacccttcctctatataaggaagttcatttcatttggagagaacacgggggact cttgacca cgtcagctggtcccaggcaaggtctccgaggacgacaagctcatcgagtacgatgcgctgctcgtcgaccgc ttcctcaacatcctccaggacctccacgggcccagccttcgcgaatttgtccaggagtgctacgaggtctcag ccgactacgagggcaaaggagacacgacgaagctgggcgagctcggcgccaagctcacggggctggcccc cgccgacgccatcctcgtggcgagctccatcctgcacatgctcaacctcgccaacctggccgaggaggtgca gatcgcgcaccgccgccgcaacagcaagctcaagaaaggtgggttcgccgacgagggctccgccaccacc gagtccgacatcgaggagacgctcaagcgcctcgtgtccgaggtcggcaagtcccccgaggaggtgttcga ggcgctcaagaaccagaccgtcgacctcgtcttcaccgcgcatcctacgcagtccgcccgccgctcgctcctg caaaaaaatgccaggatccgaaattgtctgacccagctgaatgccaaggacatcactgacgacgacaagc aggagctcgatgaggctctgeagagagagatccaagcagccttcagaaccgatgaaatcaggagggcac aacccaccccgcaggccgaaatgcgctatgggatgagctacatccatgagactgtatggaagggtgtgcct aagttcttgcgccgtgtggatacagccctgaagaatatcggcatcaatgagcgccttccctacaatgtttctct cattcggttctcttcttggatgggtggtgaccgcgatggaaatccaagagttaccccggaggtgacaagaga tgtatgcttgctggccagaatgatggctgcaaacttgtacatcgatcagattgaagagctgatgtttgagctct ctatgtggcgctgcaacgatgagcttcgtgttcgtgccgaagagctccacagttcgtctggttccaaagttacc aagtattacatagaattctggaagcaaattcctccaaacgagccctaccgggtgatactaggccatgtaagg gacaagctgtacaacacacgcgagcgtgctcgccatctgctggcttctggagtttctgaaatttcagcggaat cgtcatttaccagtatcgaagagttccttgagccacttgagctgtgctacaaatcactgtgtgactgcggcga caaggccatcgcggacgggagcctcctggacctcctgcgccaggtgttcacgttcgggctctccctggtgaa gctggacatccggcaggagtcggagcggcacaccgacgtgatcgacgccatcaccacgcacctcggcatcg ggtcgtaccgcgagtggcccgaggacaagaggcaggagtggctgctgtcggagctgcgaggcaagcgccc gctgctgcccccggaccttccccagaccgacgagatcgccgacgtcatcggcgcgttccacgtcctcgcgga gctcccgcccgacagcttcggcccctacatcatctccatggcgacggccccctcggacgtgctcgccgtggag ctcctgcagcgcgagtgcggcgtgcgccagccgetgcccgtggtgccgctgttcgagaggctggccgacctg cagtcggcgcccgcgtccgtggagcgcctcttctcggtggactggtacatggaccggatcaagggcaagcag caggtcatggtcggctactccgactccggcaaggacgccggccgcctgtcc gcggcgtggcagctgtacagggcgcaggaggagatggcgcaggtggccaagcgctacggcgtcaagctca ccttgttccacggccgcggaggcaccgtgggcaggggtggcgggcccacgcaccttgccatcctgtcccagc cgccggacaccatcaacgggtccatccgtgtgacggtgcagggcgaggtcatcgagttctgcttcggggagg agcacctgtgcttccagactctgcagcgcttcacggccgccacgctggagcacggcatgcacccgccggtct ctcccaagcccgagtggcgcaagctcatggacgagatggcggtcgtggccacggaggagtaccgctccgtc gtcgtcaaggaggcgcgcttcgtcgagtacttcagatcggctacaccggagaccgagtacgggaggatgaa catcggcagccggccagccaagaggaggcccggcggcggcatcacgaccctgcgcgccatcccctggatct tctcgtggacccagaccaggttccacctccccgtgtggctgggagtcggcgccgcattcaagttcgccatcga caaggacgtcaggaacttccaggtcctcaaagagatgtacaacgagtggccattcttcagggtcaccctgga cctgctggagtggttttcgccaagggagaccccggcattgccggcttgtatgacgagctgcttgtggcggaa gaactcaagccctttgggaagcagctcagggacaaatacgtggagacacagcagcttctccttccagatcgct gggcacaaggatattcttgaaggcgatccattcctgaagcaggggctggtgctgcgcaacccctacatcacc accctgaacgtgttccaggcctacacgctgaagcggataagggaccccaacttcaaggtgacgccccagcc gccgctgtccaaggagttcgccgacgagaacaagcccgccggactggtcaagctgaacccgg cgagcgagtacccgcccggcctggaagacacgctcatcctcaccatgaagggcatcgccgccggcatgcag caataaagtttcttaagattgaatcctgttgccggtcttgcgatgattatcatataatttctgttgaattacgt taagcatgtaataattaacatgtaatgcatgacgttatttatgagatgggtttttatgattagagtcccgca attatacatttaatacgcgatagaaaacaaaatatagcgcgcaaactaggataaattatcgcgcgcggtg tcatctatgttactagatcggg GS NcoI  F 5′-TG CCATGG CTCATCTTTCGGATCTCGTT-3′ Forward  8 primer for  amplifi-  cation  of   tobacco  GS coding sequence, including restriction site for enzyme  NcoI. GS BstEII  R 5′-G GGTGACC TCAAGGCTCGGATAGGATAGTG -3′ Reverse  9 primer for   amplifi-  cation  of tobacco  GS coding sequence, including restriction site  for enzyme BstEII. AspAT BgIII  5′-CAT AGATCT TATGGCTTCTCACGACAGCATCT -3′ Forward  10  F primer  for  amplifi-  cation  of  Soyabean   AspAT coding sequence, including restriction site for enzyme BgIII. AspAT PmII  5′-GC CACGTG TTAGACAACTCGGGTTACAGCTG-3′ Reverse  11  R primer  for  amplifi-  cation of  Soyabean   AspAT coding sequence,  including restriction site for enzyme PmII. PEP-  5′-AT AGATCT TATGGCGTCGACCAAGGCTCCG -3′ Forward  12  Case BgIII primer F for   amplifi- cation  of maize    PEPCase coding  sequence, including restriction site for enzyme BgIII. PEP-  5′-AG ACTAGT GCCAGTGTTCTGCATGCCGGCGG3′ Reverse  13  Case SpeI primer  R for  amplifi-  cation  of maize  PEPCase coding sequence, including restriction site for  enzyme  SpeI. 35S SpeI  F 5′-GG ACTAGT AATGGCGAATGCTAGAGCAGCTTGAG -3′ Forward  14  primer for   amplifi- cation of  CaMV 35S    promoter  sequence, including restriction site for enzyme SpeI. NosT AscI,   5′-GC CACGTG T CCTCAGC T GGCGCGCC CGCCAATATATCCTGTCAAACACTGATAGT-3′ Reverse  15  BbvCI,PmII  R primer  for  amplifi- cation of Nos  terminator  sequence,    including restriction site for enzyme  AscI, BbvCI PmII NosT SpeI  R 5′-GG ACTAGT TTAATTCCCGATC TAGTAACA TAGATG-3′ Reverse  16  primer  for  amplifi-  cation   of Nos  terminator sequence, including restriction site for enzyme SpeI. 35G AscI  F 5′-ATCF GGCGCGCC AATGGCGAATGCTAGAGCAGCTTGAG -3′ Forward  17  primer  for amplifi- cation of  CaMV 35S   promoter sequence, including restriction site  for enzyme  AscI. PEP- 5′-GTG CCTCAGCC TAGCCAGTGTTCTGCATGCCGG -3′ Reverse  18  Case BbvCI primer R for  amplifi-  cation  of maize  PEPCase   coding sequence, including restriction site for enzyme BbvCI. hpt F 5′-GAGGGCGAAGAATCTCGTGC -3′ Forward  19  primer for   amplifi- cation of  hygromycin  phospho- trans- ferase for screening transgenic plants. hpt R 5′-GATECTGGCGACCTCGTATTGG -3′ Reverse  20  primer  for  amplifi-  cation of  hygromycin  phospho- trans- ferase for screening transgenic plants. PEPCase  5′-ACGTCAGGAACTTCCAGGTIC-3′ Forward  21  Exp F primer   for  maize  PEPCase,  used for RT-PCR  based evaluation of PEPCase transgene expression. PEPCase  5′-CTTGTTCTCGTCGGCGAAC-3′ Reverse  22  Exp R primer   for   maize  PEPCase,  used for RT-PCR based evaluation of PEPCase transgene expression. GS Exp  5′-ACTTTCTGGACCTGTTGAT-3′ Forward  23  F primer  for tobacco  GS, used for RT-PCR  based evaluation of GS transgene expression. GS Exp  5′-GGCAGCACTGTGCCTT-3′ Reverse  24  R primer   for tobacco GS, used for RT-PCR based evaluation  of GS transgene  expression. AspAT  5′-ATGGCTTCTCACGACAGCATC-3′ Forward  25  Exp F primer   for  soyabean AspAT, used for RT-PCR based evaluation  of GS transgene expression. AspAT  5′-TTGCGTGACACGTCATTTATGAGT-3′ Reverse  26  Exp R primer  for  soyabean  AspAT, used for RT-PCR based  evaluation of GS  transgene expression. 26S F 5′-CACAATGATAGGAAGAGCCGAC-3′ Forward  27  primer   for 26SrRNA,  used as internal control for RT-PCR  based evaluation  of transgene expression. 26S R 5′-CAAGGGAACGGGCTTGGCAGAATC-3′ Reverse  28  primer  for   26SrRNA,   used as internal control for RT-PCR based evaluation  of transgene expression AspAT  MASHDSISASPTSASDSVFNHLVRAPEDPILGVTVAYNKDPSPVKLNLGVGAYRTEEG Represents 29  Pr KPLVLNVVRRVE Proteins QQLINDVSRNKEYIPIVGLADFNKLSAKLIFGADSPAIQDNRVTTVQCLSGTGSLRVGG of AspAT  EFLAKHYHQRT genes IYLPTPTWGNHPKVFNLAGLSVKTYRYYAPATRGLDFQGLLEDLGSAPSGSIVLLHACA HNPTGVDPTLE QWEQIRQLIRSKALLPFFDSAYQGFASGSLDADAQPVRLFVADGGELLVAQSYAKNLG LYGERVGALSIV CKSADVASRVESQLKLVIRPMYSSPPIHGASIVAAILKDRNLFNDWTIELKAMADRIISM RQELFDALCS RGTPGDWSHIIKQIGMFTFTGLNAEQVSFMTKEFHIYMTSDGRISMAGLSSKTVPLLA DAIHAAVTRVV GSPr MAHLSDLVNLNLSDSTQKIIAEYIWIGGSGMDVRSKARTLSGPVDDPSKLPKWNYDG Represents 30  SSTGQAPGEDSEE Proteins ILYPQAIFKDPFRRGNNILVICDCYTPAGEPIPTNKRHSAAKIFSHPDVVVEEPWYGLEQ of GS  EYTLLQKDIN genes WPLGWPLGGFPGPQGPYYCGIGAGKVFGRDIVDSHYKACLYAGINISGINGEVMPGQ WEFQVGPSVGISA ADELWAARYILERITEIAGVVVSFDPKPIPGDWNGAGAHTNYSTKSMRNEGGYEVIKK AIENLGLRHKEH IAAYGEGNERRLTGRHETADINTFKWGVANRGASIRVGRDTEREGKGYFEDRRPASN MDPFVVTSMIAET TILSEP PEPCase MASTKAPGPGEKHHSIDAQLRQLVPGKVSEDDKLIEYDALLVDRFLNILQDLHGPSLRE Represents 31  Pr FVQECYEVSAD Proteins YEGKGDTTKLGELGAKLTGLAPADAILVASSILHMLNLANLAEEVQIAHRRRNSKLKKG of PEPCase  GFADEGSATTE genes SDIEETLKRLVSEVGKSPEEVFEALKNQTVDLVFTAHPTQSARRSLLQKNARIRNCLTQL NAKDITDDDK QELDEALQREIQAAFRTDEIRRAQPTPQAEMRYGMSYIHETVWKGVPKFLRRVDTAL KNIGINERLPYNV SLIRFSSWMGGDRDGNPRVTPEVTRDVCLLARMMAANLYIDQIEELMFELSMWRCN DELRVRAEELHSSS GSKVTKYYIEFWKQIPPNEPYRVILGHVRDKLYNTRERARHLLASGVSEISAESSFTSIEE FLEPLELCY KSLCDCGDKAIADGSLLDLLRQVFTFGLSLVKLDIRQESERHTDVIDAITTHLGIGSYRE WPEDKRQEWL LSELRGKRPLLPPDLPQTDEIADVIGAFHVLAELPPDSFGPYIISMATAPSDVLAVELLQR ECGVRQPLP VVPLFERLADLQSAPASVERLFSVDWYMDRIKGKQQVMVGYSDSGKDAGRLSAAW QLYRAQEEMAQVAKR YGVKLTLFHGRGGTVGRGGGPTHLAILSQPPDTINGSIRVTVQGEVIEFCFGEEHLCFQ TLQRFTAATLE HGMHPPVSPKPEWRKLMDEMAVVATEEYRSVVVKEARFVEYFRSATPETEYGRMNI GSRPAKRRPGGGIT TLRAIPWIFSWTQTRFHLPVWLGVGAAFKFAIDKDVRNFQVLKEMYNEWPFFRVTLD LLEMVFAKGDPGI AGLYDELLVAEELKPFGKQLRDKYVETQQLLLQIAGHKDILEGDPFLKQGLVLRNPYITT LNVFQAYTLK RIRDPNFKVTPQPPLSKEFADENKPAGLVKLNPASEYPPGLEDTLILTMKGIAAGMQN TG Example 1 Amplification and Cloning of AspAT Gene [0081] Nucleotide sequence encoding soyabean cytosolic AspAT gene (SEQ ID NO: 1) was obtained from the NCBI database of nucleotide sequences (GenBank Accession No. AF034210.1; (http://www.ncbi.nlm.nih.gov/nuccore/AF034210.1) RNA from soyabean plant was isolated using IRIS Plant RNA Kit (Ghawana et al., US Patent no 0344NF2004/IN). cDNA was synthesized using total RNA preparations (2 μg) in the presence of 1 μg oligo(dT) 12-18 and 400 U of reverse transcriptase Superscript II (Invitrogen) after digesting with 2 U DNase I (amplification grade, Invitrogen, USA) following the manufacturer's instructions. The full coding region of AspAT was then amplified from soyabean cDNA using primers AspAT BgfII F (SEQ ID NO: 10) and AspAT Pmfl R (SEQ ID NO: 11) such that restriction sites BglII ( AGATCT ) and PmlI ( CACGTG ) is incorporated in the coding sequence for AspAT. Qiagen High Fidelity Taq polymerase enzyme was used for the PCR using the following conditions: initial denaturating at 94° C. for 3 minutes, 30 cycles of 94° C. for 30 seconds, annealing at 59° C. for 30 seconds, extension at 72° C. for 1 minute 20 seconds, with a final extension of 72° C. for 7 minutes. The amplification product was cloned in to pGEM-T easy vector (Promega, USA). Plasmid from the positive clones and pCAMBIA 1302 plasmid were digested with BglII and PmlI and digested products isolated from an agarose gel electrophoresis were ligated and transformed in to E. coli DH5α cells which were obtained from Takara Bio Company, Japan (Cat. No. 9057). Plasmid from the positive colonies were sequenced to verify the in frame cloning of the AspAT coding sequence placed between CaMV 35S promoter (SEQ ID NO: 4) and Nos terminator (SEQ ID NO: 5) of pCAMBIA1302 and resulting vector was designated as AspAT::pCAMBIA1302. Example 2 Amplification and Cloning of GS Gene [0082] Nucleotide sequence encoding tobacco cytosolic GS gene (SEQ ID NO: 2) was obtained from the NCBI database of nucleotide sequences (GenBank Accession No. X95932.1; (http://www.ncbi.nlm.nih.gov/nuccore/X95932.1). RNA from tobacco plant was isolated using IRIS Plant RNA Kit (Ghawana et al., US Patent no 0344NF2004/IN). cDNA was synthesized using total RNA preparations (2 μg) in the presence of 1 μg oligo(dT) 12-18 and 400 U of reverse transcriptase Superscript II (Invitrogen) after digesting with 2 U DNase I (amplification grade, Invitrogen, USA) following the manufacturer's instructions. [0083] The full coding region of GS was amplified from tobacco cDNA using primers GS NcoI F with restriction sites NcoI ( CCATGG ) (SEQ ID NO: 8) and GS BstEII R with restriction sites for BstEII ( GGTGACC ) (SEQ ID NO: 9). GS NcoI F primers was modified so as to eliminate the BglII site by replacement of ‘A’ nucleotide by ‘G’ at position 15. [0084] Qiagen High Fidelity Taq polymerase enzyme was used for the PCR using the following conditions: initial denaturating at 94° C. for 3 minutes, 30 cycles of 94° C. for 30 seconds, annealing at 59° C. for 30 seconds, extension at 72° C. for 1 minute 10 seconds, with a final extension of 72° C. for 7 minutes. The amplification product was cloned in to pGEM-T easy vector (Promega, USA). Plasmids from the positive colonies and binary vector pCAMBIA 1302 were digested with NcoI and BstEII and digested product isolated from an agarose gel electrophoresis were ligated such that GS is placed downstream of CaMV 35S promoter of pCAMBIA vector. The ligation product was transformed in to E. coli DH5α cells and transformants were sequenced to verify the in frame cloning of the GS coding sequence and the resulting vector was designated as GS::pCAMBIA1302. Example 3 Amplification and Cloning of Maize PEPCase Gene [0085] Nucleotide sequence encoding maize PEPCase gene (SEQ ID NO: 3) was obtained from the NCBI database of nucleotide sequences (NCBI Reference Sequence: NM — 001111948.1; (http://www.ncbi.nlm.nih.gov/nuccore/NM — 001111948.1) RNA from maize plant was isolated using iRIS Plant RNA Kit (Ghawana et al., US Patent no 0344NF2004/IN). cDNA was synthesized using total RNA preparations (2 μg) in the presence of 1 μg oligo(dT) 12-18 and 400 U of reverse transcriptase Superscript II (Invitrogen) after digesting with 2 U DNase I (amplification grade, Invitrogen, USA) following the manufacturer's instructions. [0086] The full coding region of PEPCase was amplified from maize cDNA using primers PEPCase BglII F with restriction sites for BglII ( AGATCT ) (SEQ ID NO: 12) and PEPCase SpeI R with restricition sites for SpeI ( ACTAGT ) (SEQ ID NO: 13). Qiagen High Fidelity Taq polymerase enzyme supplemented with Q-solution (facilitating amplification of GC-rich templates) was used for PCR using the following conditions: initial denaturating at 94° C. for 3 minutes, 32 cycles of 94° C. for 30 seconds, annealing at 58° C. for 30 seconds, extension at 72° C. for 3 minute, with a final extension of 72° C. for 7 minutes. The amplification product was cloned in to pGEM-T easy vector (Promega, USA). Plasmid from the positive clones and pCAMBIA 1302 plasmids were digested with BglII and SpeI and digested product isolated from an agarose gel electrophoresis were ligated and then transformed in to E. coli DH5α cells. Transformants were sequenced to verify the in frame cloning of the PEPCase coding sequence and resulting vector was designated as PEPCase::pCAMBIA 1302. Example 4 Assembly of Expression Cassettes for AspAT, GS and PEPCase in Single pCAMBIA 1302 Vector (Generous Gift from “Centre for Application of Molecular Biology to International Agriculture”, Australia) [0087] A stepwise method for amplification and integration of expression cassettes each for AspAT, GS and PEPCase in to single plant transformation vector pCAMBIA 1302 is described as follows: [0088] GS expression cassette comprising CaMV35S promoter, downstream cloned GS and nopaline synthase (hereinafter, referred as “Nos”) terminator was amplified from GS:: pCAMBIA 1302 vector [0089] (Example 2), using primers 35 SpeI F (SEQ ID NO: 14) and NosT AscI, BbvCI, PmlI R (SEQ ID NO: 15). The primers were designed to incorporate the SpeI ( ACTAGT ) in the forward primer and AscI ( GGCGCGCC ), BbvCI ( CCTCAGC ) and PmlI ( CACGTG ) in reverse primer to facilitate the subcloning of GS expression cassette in to SpeI and PmlI sites of pCAMBIA 1302 vector as well as to create the additional restriction sites (AscI, BbvCI) at 3′ end in the vector backbone. Qiagen High Fidelity Taq polymerase enzyme was used for the PCR using the following conditions: initial desaturating at 94° C. for 3 minutes, 30 cycles of 94° C. for 30 seconds, annealing at 59° C. for 30 seconds, extension at 72° C. for 2 minutes, with a final extension of 72° C. for 7 minutes. The amplification product was cloned in to pGEM-T easy vector (Promega, USA). Plasmids from the positive clones was digested with SpeI and PmlI, and the digested product was then isolated from an agarose gel electrophoresis and ligated in to SpeI and PmlI sites of pCAMBIA 1302 vector. The ligation product was transformed in to E. coli DH5α cells and transformants were verified by sequencing of plasmid. [0090] AspAT coding sequence along with 3′Nos terminator sequence was amplified from AspAT:: pCAMBIA 1302 vector (Example 1) using primers AspAT BglII F (SEQ ID NO: 10) and NosT SpeI (SEQ ID NO: 16) with restriction sites for BglII ( AGATCT ) and SpeI ( ACTAGT ) respectively. [0091] Qiagen High Fidelity Taq polymerase enzyme was used for the PCR using the following conditions: initial denaturation at 94° C. for 3 minutes, 30 cycles of 94° C. for 30 seconds, annealing at 59° C. for 30 seconds, extension at 72° C. for 2 minutes, with a final extension of 72° C. for 7 minutes. The amplification product was cloned in to pGEM-T easy vector (Promega, USA). Plasmids from the positive clones upon digestion with BglII and SpeI, cloned downstream of CaMV 35S promoter of destination pCAMBIA 1302 (previously cloned with GS expression cassette). The ligation product was then transformed in to E. coli DH5α cells and transformants were sequenced to verify the in frame cloning of the AspAT coding sequence. [0092] CaMV 35S promoter along with the downstream cloned PEPCase gene from PEPCase:: pCAMBIA 1302 vector (example 3) was amplified with the primers 35S AscI F (SEQ ID NO: 17) having restriction site for AscI ( GGCGCGCC ) and PEPCase BBvCI R (SEQ ID NO: 18) having restriction site for BbVCI ( CCTCAGC ). [0093] Qiagen High Fidelity Taq polymerase enzyme was used for the PCR using the following conditions: initial denaturation at 94° C. for 3 minutes, 30 cycles of 94° C. for 30 seconds, annealing at 60° C. for 30 seconds, extension at 72° C. for 4 minutes, with a final extension of 72° C. for 7 minutes. The amplification product was cloned in to pGEM-T easy vector (Promega, USA), plasmid from the positive clones was digested with AscI ( GGCGCGCC ) and BbVCI ( CCTCAGC ) and digested product isolated from an agarose gel electrophoresis ligated upstream of Nos terminator sequence of destination pCAMBIA 1302 previously cloned with GS and AspAT expression cassettes. The ligation product was transformed in to E. coli DH5α cells and transformants sequenced to verify the in frame cloning of the PEPCase coding sequence. Resultant plant expression vector was designated as AspAT+GS+PEPCase for co-overexpression of AspAT, GS and PEPcase. A hygromycin resistance gene (SEQ ID NO. 6) was included as a selectable marker for screening transgenic plants. Schematic diagram of expression construct is shown in FIG. 1 , represented by SEQ ID NO. 7 for plant transformation such that the transgenic plant produces higher amount of proteins represented by SED ID NO. 29, 30, and 31. Example 5 Raising of Transgenic Arabidopsis Plants Co-Over Expressing Genes AspAT, GS and PEPCase [0094] Generation of Plant Expression Vector (AspAT+GS+PEPCase) [0095] Briefly, the plant expression vector was constructed as follows: cDNA sequences encoding soybean AspAT gene (SEQ ID NO: 1), tobacco cytosolic GS gene (SEQ ID NO: 2) and maize PEPCase gene (SEQ ID NO: 3), were first independently cloned in to pCAMBIA 1302 vector. The elements for expression cassette for AspAT, GS and PEPCase were then amplified and assembled in to destination pCAMBIA1302 such that genes AspAT, GS and PEPCase were controlled by independent CaMV 35S promoter and Nos transcriptional terminator. [0096] Agrobacterium Mediated Plant Transformation: [0097] AspAT+GS+PEPCase were transferred to Agrobacterium tumefaciens strain GV3101 with ATCC number Agrobacterium tumefaciens (GV3101 (pMP90RK) (C58 derivative) ATCC® Number: 33970 Reference: Hayashi H, Czaja I, Lubenow H, Schell J, Walden R. 1992 using standard triparental mating method. [0098] Briefly, E. coli DH5α cells harboring the recombinant construct AspAT+GS+PEPCase and those harboring helper plasmid pRK2013 were cultured overnight at 37° C. Agrobacterium strain GV3101 grown at 28° C. for 48 hrs. All the three cultures were then pelleted, washed, and mixed, followed by plating on YEM (Yeast Extract Mannitol) plates supplemented with the antibiotics kanamycin (50 ug/ml) and rifampcin (50 ug/ml). Antibiotic resistant colonies were verified by colony PCR to assure the transformation of Agrobacterium with the recombinant construct AspAT+GS+PEPCase. [0099] Arabidopsis Seeds of the Columbia Ecotype were Generous Gift by Dr. Christine H Foyer Of, IACR-Rothamsted, Harpenden, UK [0100] Arabidopsis plants were transformed with Agrobacteria harboring AspAT+GS+PEPCase using vacuum infiltration method. Briefly, liquid 5-ml cultures were established from single transformed Agrobacterium colony and grown in YEM medium supplemented with 50 ug/ml kanamycin, 50 ug/ml rifampicin at 28° C. up to the late logarithmic phase. Next, 1 ml of bacterial suspension was diluted with 100 ml of YEB culture medium supplemented with the same antibiotics. The culture was grown overnight until their optical density reached 1.2-1.8 at 600 nm. The bacteria were spinned for 20 min at 2000 g at room temperature and suspended in a solution for infiltration containing half strength MS (Murashige and Skoog) medium with 2% sucrose, 0.05% MES (Sigma,) and 0.01% of Silwet L-77 (Lehle Seeds, United States). Arabidopsis inflorescences were dipped in bacterial suspension and infiltrated under vacuum for 10 minutes. Plants were then transferred to growth chamber and grown under controlled long day conditions (16-h light at 22-23° C. and 8-h darkness at 20° C.) for seed set. [0101] Selection of Primary Transformant T o Transgenic Arabidopsis Plant: [0102] Seeds from transformed plants were surface sterilized by immersion in 70% (v/v) ethanol for 2 min, followed by immersion in 10% (v/v) sodium hypochlorite solution. Seeds were then washed four times with sterile distilled water and sown onto 1% agar containing MS medium supplemented with hygromycin B at a concentration of 20 μml −1 (Sigma # H3274). Seeds were then stratified for 2 days in the dark at 4° C. After stratification plates were transferred to a growth chamber with 16 h light and 8 h dark cycle for germination. After 14-days, hygromycin resistant seedlings were selected as putative primary transformants (T 0 ) and transferred to pots containing vermiculite, perlite and cocopeat mix (1:1:1) and grown to maturity under controlled condition of light, temperature and humidity for growth and seed set. [0103] Raising T1 and T 2 Generation AspAT+GS+PEPCase Transgenic Plants: [0104] Seeds harvested from T 0 transgenic plants were germinated on MS+hygromycin B (at a concentration of 20 μml −1 ) plates and transgenic lines exhibiting a segregation ratio of 3:1 (scored by their sensitivity to hygromycin B) were selected to raise T1 generation of transgenic plants. Homozygous transgenic plants were obtained in the T 2 generation and evaluated for different physiological and biochemical parameters in comparison to wild control plants. Example 6 Analysis of the Genomic DNA from Arabidopsis thaliana Plants Transformed with AspAT+CS+PEPCase [0105] Arabidopsis plants from two independent transgenic lines transformed with AspAT+GS+PEPCase were selected to verify the insertion of transgenes in to plant genome. The genomic DNA was isolated using DNeasy Plant mini kit (QIAGEN Co.). PCR was carried out by using the isolated DNA as template with primers hpt F (SEQ ID NO: 19) and hpt R (SEQ ID NO: 20) annealing to the hygromycin phosphtransferaes (hpt) gene (SEQ ID NO: 6) (plant selection marker from pCAMBIA 1302 vector). [0106] PCR cycling conditions defined by initial denaturation at 94° C. for 3 minutes, 28 cycles of 94° C. for 30 seconds, annealing at 58° C. for 30 seconds, extension at 72° C. for 1 minute, with a final extension of 72° C. for 7 minutes. [0107] The result is shown in FIG. 2A , in which WT represents the wild and L1 and L2 represent two different transgenic lines. The amplification of hpt gene was observed only with transgenic confirming insertion of AspAT+GS+PEPCase in to Arabidopsis plants. Example 7 Evaluation of AspAT+GS+PEPCase Transgenics by Reverse Transcriptase—Polymerase Chain Reaction (RT-PCR) [0108] RNA analysis of transformants was done to confirm the expression of AspAT, GS and PEPCase. Total RNA was isolated from leaf and root of transgenic plants using iRIS Plant RNA Kit (Ghawana et al., US Patent no 0344NF2004/IN). cDNA was synthesized using total RNA preparations (2 μg) in the presence of 1 μg oligo(dT) 12-18 and 400 U of reverse transcriptase Superscript II (Invitrogen) after digesting with 2 U DNase I (amplification grade, Invitrogen, USA) following the manufacturer's instructions). Expression of transgenes was evaluated using gene specific primer for AspAT, GS and PEPCase, designated as PEPCase Exp F (SEQ ID NO: 21), PEPCase Exp R (SEQ ID NO: 22), GS Exp F (SEQ ID NO: 23), GS Exp R (SEQ ID NO: 24), AspAT Exp F (SEQ ID NO: 25) and AspAT ExpR (SEQ ID NO: 26). As a positive control for RT-PCR, 26S rRNA was amplified using primers 26S F (SEQ ID NO: 27) and 26S R (SEQ ID NO: 28). [0109] The results of analyses are shown in FIG. 2B , in which WT represents wild and L1 and L2 represent two transgenic lines. The amplification of RT-PCR products were observed only in trangenics confirming the expression of introduced genes. Example 8 Enzymatic Assays from Wild Type and AspAT+GS+PEPCase Transgenic Arabidopsis Plants [0110] Enzymatic assays were performed with AspAT+GS+PEPCase transgenic and wild plants as follows: [0111] PEPCase Activity Measurement: Frozen leaf samples (200 mg) ground with a mortar and pestle in 1 ml of extraction buffer containing 50 mM Tris-Cl buffer (pH 7.5), 1.0 mM MgCl2, 5.0 mM DTT, 1.0 mM PMSF, 2% (w/v) PVPP, 10% (v/v) glycerol and 0.1% (v/v) Triton X-100. The extract was centrifuged at 12,000 g for 10 min at 4° C. and the supernatant was used for the determination of enzyme activity. PEPCase was assayed spectrophotometrically at 340 nm in the presence of excess MDH and lactate dehydrogenase (Ashton et al. 1990). The reaction mixture contained 50 mM Tris-Cl (pH 8.0), 5 mM MgCl2, 5 mM DTT, 1 mM NaHCO 3 , 5 mM glucose-6-phosphate, 0.2 mM NADH, 2 units MDH, 0.1 units lactate dehydrogenase and crude extract. The reaction was initiated by the addition of 5 mM PEP. [0112] AspAT Activity Measurement: Extraction buffer for AspAT consisted of 200 mM Tris-Cl buffer (pH 7.5), 2.0 mM EDTA and 20% glycerol. [0113] The enzyme was assayed in an MDH-coupled reaction essentially as described by Ireland and Joy (1990). Briefly the reaction mixture contained 10 mM 2-oxoglutarate, 2 mM aspartate, 0.2 mM NADH, and 50 mM HEPES buffer (pH 8.0). Reaction was started by addition of 2-oxoglutarate. Assay control was run by excluding the 2-oxoglutarate from the reaction mix. [0114] GS Activity Measurement: [0115] GS (glutamine synthetase) was extracted in the grinding medium containing 50 mM Tris-Cl buffer (pH 7.8), 1 mM EDTA, 10 mM MgSO 4 , 5 mM sodium glutamate, 10% (v/v) glycerol and insoluble PVPP (2% w/v). Enzyme assay was performed as described earlier by Lea et al. (1990) and the activity was calculated from the standard curve prepared with γ-glutamylhydroxamate. [0116] The results of the analyses are shown in the FIG. 5A to 5C , an increase of about 45 to 50% in PEPCase activity, 55% in GS activity and 55 to 60% in AspAT activity was observed with two independent AspAT+GS+PEPCase transgenic plants compared to wild plants. Example 9 [0117] C and N Analyses in Wild and AspAT+GS+PEPCase Transgenic Arabidopsis Plants [0118] Seeds of AspAT+GS+PEPCase transformed Arabiopdsis thaliana plants and wild control plants were germinated on half strength MS plates supplemented with 20 g/l sucrose. 14 days-old seedlings were transferred to pots containing mix of vermiculite; perlite and coco peat in the ratio of 1:1:1 and grown under long-day conditions comprising 16 hours of light period at 22° C. and 8 hours of dark period at 20° C. maintained in the Arabidopsis growth chamber. Different plant parts including rosette leaf; stem, cauline leaf and green pods were harvested from 65-days old plants and dried at 80° C. for 48 hrs. The quantitative determination of the C and N elements was conducted with Elementar CHNS analyzer using sulfanilamide as standard. The results are shown in FIG. 6 . The elementary analysis showed that the total C and N content in AspAT+GS+PEPCase transgenic plant leaves has significantly increased by co-overexpression of AspAT, GS and PEPCase compared to wild plants. Example 10 Investigation of Growth and Yield in Wild and AspAT+GS+PEPCase Transgenic Plants [0119] Wild and AspAT+GS+PEPCase transgenic plants were analyzed for different growth characteristics. Shoot, root fresh and dry weight was recorded for 60-days old plants. Across different parameters evaluated, AspAT+GS+PEPCase plants showed enhanced growth characteristics. In particular, the transgenic plants have more number of leaves per rosette having larger area. Transgenic plants exhibited about 70% increase in the shoot fresh weight with 60% increase in the shoot dry weight whereas the increase of about 40% and 30% was observed in the root fresh and dry weight respectively (shown in FIG. 3 ). [0120] Total number of pods from 72-days old AspAT+GS+PEPCase transgenic plants was calculated and compared to untransformed wild plants (shown in FIG. 7 a ). Furthermore total seed yield (total seed weight per plant) was also measured for transgenic and control plants. Across both the parameters, AspAT+GS+PEPCase transgenic Arabidopsis plant showed increase in yield compared to wild plants as shown in FIG. 7 b. ADVANTAGES OF THE INVENTION [0000] 1. There have been efforts to enhance carbon and nitrogen status of plants, a step towards food security. 2. The present invention provides an innovative approach wherein overexpression of PEPCase provides a carbon skeleton to capture nitrogen assimilated through over expression of AspAT and GS. 3. The improved capacity of plant for carbon and nitrogen capture was also reflected in improved plant productivity both in terms of plant seed and plant biomass production.
The assimilated C and N largely influence plant growth and crop yields. Previous attempts to alter the carbon and nitrogen status of the plants attempted with one or two genes The present invention involves simultaneous co-overexpression of three genes wherein one gene (PEPCase) efficiently capture CO2 whereas the other two encode for enzymes (Asp AT and GS) involved in nitrogen assimilation. The combined effect is the enhancement of carbon and nitrogen status of the plant and the productivity.
8
CLAIM OF PRIORITY This application claims priority under 35 U.S.C. 119(e)(1) to U.S. Provisional Application Nos. 61/033,592 filed Mar. 4, 2008, 61/035,502 filed Mar. 11, 2008 and 61/047,586 filed Mar. 24, 2008. TECHNICAL FIELD OF THE INVENTION The technical field of this invention is wireless communications. BACKGROUND OF THE INVENTION FIG. 1 shows an exemplary wireless telecommunications network 100 . The illustrative telecommunications network includes base stations 101 , 102 and 103 , though in operation, a telecommunications network necessarily includes many more base stations. Each of base stations 101 , 102 and 103 are operable over corresponding coverage areas 104 , 105 and 106 . Each base station's coverage area is further divided into cells. In the illustrated network, each base station's coverage area is divided into three cells. Handset or other user equipment (UE) 109 is shown in Cell A 108 . Cell A 108 is within coverage area 104 of base station 101 . Base station 101 transmits to and receives transmissions from UE 109 . As UE 109 moves out of Cell A 108 and into Cell B 107 , UE 109 may be handed over to base station 102 . Because UE 109 is synchronized with base station 101 , UE 109 can employ non-synchronized random access to initiate handover to base station 102 . Non-synchronized UE 109 also employs non-synchronous random access to request allocation of up-link 111 time or frequency or code resources. If UE 109 has data ready for transmission, which may be traffic data, measurements report, tracking area update, UE 109 can transmit a random access signal on up-link 111 . The random access signal notifies base station 101 that UE 109 requires up-link resources to transmit the UE's data. Base station 101 responds by transmitting to UE 109 via down-link 110 , a message containing the parameters of the resources allocated for UE 109 up-link transmission along with a possible timing error correction. After receiving the resource allocation and a possible timing advance message transmitted on down-link 110 by base station 101 , UE 109 optionally adjusts its transmit timing and transmits the data on up-link 111 employing the allotted resources during the prescribed time interval. FIG. 2 shows the Evolved Universal Terrestrial Radio Access (E-UTRA) time division duplex (TDD) Frame Structure. Different subframes are allocated for downlink (DL) or uplink (UL) transmissions. Table 1 shows applicable DL/UL subframe allocations. TABLE 1 Configu- Switch-point Subframe number ration periodicity 0 1 2 3 4 5 6 7 8 9 0  5 ms D S U U U D S U U U 1  5 ms D S U U D D S U U D 2  5 ms D S U D D D S U D D 3 10 ms D S U U U D D D D D 4 10 ms D S U U D D D D D D 5 10 ms D S U D D D D D D D 6 10 ms D S U U U D S U U D One interesting property of TDD is that the number of UL and DL subframes can be different. In the configurations where there are more DL subframes than UL subframes, multiple DL subframes are associated with one single UL subframe for transmission of corresponding control signal. For example, for each dynamically scheduled transmission in the DL subframes, acknowledge and non-acknowledge (ACK/NAK) bits need to be transmitted in an associated UL subframe to support proper hybrid automatic repeat request (HARQ) operation. If UE 109 is scheduled in a multiple of DL subframes all of which are associated with one single UL subframe, UE 109 needs to transmit multiple ACK/NAK bits in that single UL subframe. SUMMARY OF THE INVENTION This invention is a method of wireless communication having a communications protocol providing more downlink subframes than uplink subframes. The user equipment detects within a frame a plurality of downlink communications, producing either an acknowledge (ACK) response signal or a non-acknowledge (NAK) response signal for each detected downlink communication and transmits a combination of a plurality of ACK/NAK response signals and related data from the mobile user's equipment to a base station. The related data could be the number of bits N of the plurality of ACK/NAK response signals or the number of detected downlink communications S requiring ACK/NAK response signals. The plural ACK/NAK signals could be coded after production and before transmission. The coding could include block coding, convolutional coding and turbo coding. The user equipment could produce a cyclical redundancy check set of bits of the ACK/NAK signals for transmission. The cyclical redundancy check bits could be scrambled for transmission dependent upon the numbers N or S. As an example, an even number would use a first value for scrambling and an odd number would use a second value for scrambling. Similar selections are feasible with resource elements or an index of a modulation symbol or codeword. The N bits of the plurality of ACK/NAK response signals could be compressed into M bits where 0<M<N. In a preferred embodiment M is predetermined. BRIEF DESCRIPTION OF THE DRAWINGS These and other aspects of this invention are illustrated in the drawings, in which: FIG. 1 is a diagram of a communication system of the prior art related to this invention having three cells; FIG. 2 shows the Evolved Universal Terrestrial Radio Access (E-UTRA) TDD Frame Structure of the prior art; FIG. 3 is a flow chart of the basic response of this invention; FIG. 4 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 5 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 6 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 7 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 8 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 9 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 10 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 11 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 12 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 13 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 14 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 15 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 16 illustrates an alternate embodiment of block 304 of FIG. 3 ; FIG. 17 illustrates an alternate embodiment of block 304 of FIG. 3 ; and FIG. 18 illustrates an alternate embodiment of block 304 of FIG. 3 . DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS FIG. 3 illustrates a flow chart of the basic response of UE 109 . The process starts at start block 301 . In block 302 UE 109 detects plural down link transmissions requiring response. In block 303 UE 109 generates the ACK/NAK signal for the respective down link transmissions. In block 304 UE 109 transmits the ACK/NAK signals together with uplink payload data dependent upon the ACK/NAK signals. This basic response ends at end block 304 . This invention includes techniques for the transmission of multiple ACK/NAK bits with data. Typically, the transmission of multiple ACK/NAK bits and data occurs on a data channel such as physical uplink shared channel (PUSCH) in 3GPP long term evolution (LTE). The inventive techniques are mostly applicable to TDD systems where UE 109 may need to transmit multiple ACK/NAK bits with data in a subframe. It is also feasible to use the proposed techniques in frequency division duplex (FDD) systems where UE 109 needs to transmit multiple ACK/NAK bits with data in a subframe. Without loss of generality, assume N is the number of ACK/NAK bits UE 109 needs to transmit with data in a subframe. A straightforward approach is to encode the N ACK/NAK(s) with a coding scheme. These could be block codes, convolutional codes or turbo codes. Accordingly, block 304 includes this encoding. The encoded ACK/NAK bits are transmitted on the data channel preferably closely mapped to the reference signal to obtain better channel estimates. It is possible for UE 109 to miss one of the multiple DL grants. If this occurs less ACK/NAK bits are transmitted by UE 109 while base station 101 is expecting more ACK/NAK bits. This scenario is often called ACK/NAK DTX. In these cases UE 109 needs to provide additional information to base station 101 so that base station 101 can perform ACK/NAK DTX detection to enable proper HARQ operations. One solution is for UE 109 to explicitly transmit the information on the number of ACK/NAK bits it has in the data within a subframe. Thus UE 109 explicitly transmits N to base station 101 . It is preferable that the number N is separately coded from the actual information of the multiple ACK/NAK bits. Therefore, base station 101 can decode N first. This provides sufficient information to decode the N ACK/NAK bits subsequently. However, the number N and the actual ACK/NAK bits may be jointly coded. In this case, base station 101 may need to perform hypothesis testing since it has no prior information on the number of ACK/NAK bits UE 109 is transmitting. FIG. 4 illustrates an alternate block 304 according to this embodiment. In block 401 UE 109 determines the number of bits N of the plural ACK/NAK signals. In block 402 UE 109 transmits the plural ACK/NAK signals together with this number N. Without loss of generality, assume S is the number of DL grants UE 109 detects within the time frame where multiple DL subframes are associated with a common UL subframe. It is possible for UE 109 to explicitly convey the value S to base station 101 , to facilitate ACK/NAK DTX detection at base station 101 . FIG. 5 illustrates an alternate block 304 according to this embodiment. In block 501 UE 109 determines the number S of the plural ACK/NAK signals needed for response. In block 502 UE 109 transmits the plural ACK/NAK signals together with this number S. Cyclic redundancy check (CRC) bits can be appended to the coded or uncoded ACK/NAK bits. CRC provides additional information to the receiver or base station 101 on whether the ACK/NAK bits are decoded correctly. These CRC bits may be scrambled with the value N. Thus base station 101 can implicitly derive the number of ACK/NAK bits UE 109 is transmitting. In this case, there are N possible ways UE 109 can scramble the ACK/NAK CRC bits corresponding to the different values of N. Alternatively, assuming that UE 109 missing two or more DL grants within a certain time period is unlikely, it may be sufficient to scramble the CRC bits with mod(N, 2). Thus if UE 109 is transmitting an even number of ACK/NAK bits in a subframe, it scrambles the CRC bits with a value A. Otherwise, UE 109 scrambles the CRC bits with a value B. Base station 101 can check the CRC bits after descrambling with values of A and B to determine whether a correct number of ACK/NAK bits were transmitted by UE 109 to perform ACK/NAK DTX detection. FIG. 6 illustrates another embodiment of block 304 according to one of these options. In block 601 UE 109 determines the number of bits N of the plural ACK/NAK signals. In block 602 UE 109 calculates CRC bits corresponding to the ACK/NAK signals. In block 603 UE 109 scrambles the CRC bits and the number of bits N. In block 604 UE 109 transmits the ACK/NAK signals together with the scrambled CRC bits. FIG. 7 illustrates another embodiment of block 304 according to another of these options. In block 701 UE 109 determines the number of bits N of the plural ACK/NAK signals. In block 702 UE 109 calculates CRC bits corresponding to the ACK/NAK signals. In block 703 UE 109 determines if the number of bits N is even. If this number of bits is even (Yes at block 703 ), then in block 704 UE 109 scrambles the CRC bits with a first value A. If this number of bits is odd (No at block 703 ), then in block 705 UE 109 scrambles the CRC bits with a second value B. In block 706 UE 109 transmits the ACK/NAK signals together with the scrambled CRC bits. For single data stream transmission in all scheduled DL subframes N=S. For multiple data stream transmission: N = ∑ i = 1 S ⁢ d ⁡ ( i ) where: d(i) is the number of data streams in the ith scheduled DL subframe. It is possible to scramble the CRC bits with the value S. Thus base station 101 can implicitly determine the number of detected DL grants by UE 109 . In this case, there are S possible ways UE 109 can scramble the ACK/NAK CRC bits corresponding to different values of S. Alternatively, assuming that UE 109 missing two or more DL grants within a certain time period is unlikely, it may be sufficient to scramble the CRC bits with mod(S, 2). If UE 109 detects an even number of DL grants, it scrambles the CRC bits with value A. Otherwise, UE 109 scrambles the CRC bits with value B. Base station 101 can check the CRC bits after descrambling with value A and B to determine whether a correct number of DL grants are detected by UE 109 to perform ACK/NAK DTX detection. FIG. 8 illustrates another embodiment of block 304 according to one of these options. In block 801 UE 109 determines the number S of the plural ACK/NAK signals needed for response. In block 802 UE 109 calculates CRC bits corresponding to the ACK/NAK signals. In block 803 UE 109 scrambles the CRC bits and the number S. In block 804 UE 109 transmits the ACK/NAK signals together with the scrambled CRC bits. FIG. 9 illustrates another embodiment of block 304 according to another of these options. In block 901 UE 109 determines the number S of the plural ACK/NAK signals needed for response. In block 902 UE 109 calculates CRC bits corresponding to the ACK/NAK signals. In block 903 UE 109 determines if the number S is even. If S is even (Yes at block 903 ), then in block 904 UE 109 scrambles the CRC bits with a first value A. If S is odd (No at block 903 ), then in block 905 UE 109 scrambles the CRC bits with a second value B. In block 906 UE 109 transmits the ACK/NAK signals together with the scrambled CRC bits. ACK/NAK bundling or compression is commonly employed to reduce the resources needed for the transmission of ACK/NAK bits. Thus N ACK/NAK bits are compressed into M ACK/NAK bits, where 0<M<N. The compressed M ACK/NAK bits are transmitted on the data channel with proper a coding scheme such as block codes, convolutional codes or turbo codes with an optional CRC attachment as previously described. The value of M can be predetermined and thus known at base station 101 to avoid unnecessary hypothesis testing. Base station 101 will not know N a prior since UE 109 may miss one or multiple DL grants. Such misses control the number of ACK/NAK bits UE 109 transmits. UE 109 may explicitly or implicitly signal the value of N to base station 101 to enable ACK/NAK DTX detection. UE 109 may explicitly or implicitly signal S to base station 101 to enable ACK/NAK DTX detection at base station 101 . FIG. 10 illustrates an alternate block 304 according to this embodiment. In block 1001 UE 109 compresses the of the plural ACK/NAK signals to M bits. In block 1002 UE 109 transmits the compressed ACK/NAK signals. As a further alternative UE 109 may implicitly signal the number of ACK/NAK bits N or the number of detected DL grants S to base station 101 by the positions of resource elements (REs) used for ACK/NAK transmission. A resource element is a time-frequency resource. UE 109 can choose different REs for the transmission of ACK/NAK bits. Base station 101 needs to perform hypothesis testing on all possible RE locations where ACK/NAK bits can be transmitted to determine N or S. Suppose two RE regions are defined for ACK/NAK transmission. If the number of ACK/NAK bits or the number of detected DL grants is even, then a first RE region is used for ACK/NAK transmission. Otherwise a second RE region is used for ACK/NAK transmission. More than two RE regions can be defined to implicitly convey partial information on N or S. This RE region dependent ACK/NAK transmission can be applied in conjunction with ACK/NAK bundling or compression. The compressed M ACK/NAK bits are transmitted on the selected ACK/NAK RE region which is dependent on the value of N or S. FIG. 11 illustrates another embodiment of block 304 according to one of these options. In block 1101 UE 109 determines the number of bits N of the plural ACK/NAK signals. In block 1102 UE 109 selects one of a plurality of possible resource elements according to the number of bits N. In block 1103 UE 109 transmits the ACK/NAK signals using the selected resource element. FIG. 12 illustrates another embodiment of block 304 according to another of these options. In block 1201 UE 109 determines the number of bits N of the plural ACK/NAK signals. In block 1202 UE 109 determines if the number of bits N is even. If this number of bits is even (Yes at block 1202 ), then in block 1203 UE 109 selects a first resource element A. If this number of bits is odd (No at block 1202 ), then in block 1204 UE 109 selects a second resource element B. In block 1205 UE 109 transmits the ACK/NAK signals using the selected resource element. FIG. 13 illustrates another embodiment of block 304 according to another of these options. In block 1301 UE 109 determines the number S of the plural ACK/NAK signals needed for response. In block 1302 UE 109 selects one of a plurality of possible resource elements according to the number S. In block 1303 UE 109 transmits the ACK/NAK signals using the selected resource element. FIG. 14 illustrates another embodiment of block 304 according to another of these options. In block 1401 UE 109 determines the number S of the plural ACK/NAK signals needed for response. In block 1402 UE 109 determines if the number S is even. If S is even (Yes at block 1402 ), then in block 1403 UE 109 selects a first resource element A. If S is odd (No at block 1402 ), then in block 1404 UE 109 selects a second resource element B. In block 1405 UE 109 transmits the ACK/NAK signals using the selected resource element. In a yet further alternative UE 109 may implicitly signal the number of ACK/NAK bits N or the number of detected DL grants S to base station 101 by the index of the set of modulation symbols or codewords it is currently using for the transmission of ACK/NAK bits. The possible modulation symbols or codewords can be divided into two sets denoted S 1 and S 2 . If a modulation symbol or a codeword in set S 1 is used, base station 101 determines that an even number of ACK/NAK bits were transmitted by UE 109 or an even number of DL grants were detected by UE 109 . Otherwise base station 101 determines that an odd number of ACK/NAK were transmitted or an odd number of DL grants were detected. More than two sets of modulation symbols or codewords could be defined for implicit transmission of partial information of N or S values. This set dependent ACK/NAK transmission can be applied in conjunction with ACK/NAK bundling or compression. One modulation symbol or codeword within the selected set could be chosen and transmitted to convey the compressed M ACK/NAK bits. The proposed RE region dependent ACK/NAK transmission could be applied together with the modulation symbol or codeword set dependent ACK/NAK transmission and ACK/NAK bundling or compression. The transmission of multiple ACK/NAK bits could be applied for ACK/NAK transmission without any data transmission. The transmission of multiple ACK/NAK bits could be employed in either TDD or FDD systems. FIG. 15 illustrates another embodiment of block 304 according to one of these options. In block 1501 UE 109 determines the number of bits N of the plural ACK/NAK signals. In block 1502 UE 109 selects one of a plurality of possible indices according to the number of bits N. In block 1503 UE 109 transmits the ACK/NAK signals using the selected index. FIG. 16 illustrates another embodiment of block 304 according to another of these options. In block 1601 UE 109 determines the number of bits N of the plural ACK/NAK signals. In block 1602 UE 109 determines if the number of bits N is even. If this number of bits is even (Yes at block 1602 ), then in block 1603 UE 109 selects a first index S 1 . If this number of bits is odd (No at block 1602 ), then in block 1604 UE 109 selects a second index S 2 . In block 1505 UE 109 transmits the ACK/NAK signals using the selected index. FIG. 17 illustrates another embodiment of block 304 according to another of these options. In block 1701 UE 109 determines the number S of the plural ACK/NAK signals needed for response. In block 1702 UE 109 selects one of a plurality of possible indices according to the number S. In block 1703 UE 109 transmits the ACK/NAK signals using the selected index. FIG. 18 illustrates another embodiment of block 304 according to another of these options. In block 1801 UE 109 determines the number S of the plural ACK/NAK signals needed for response. In block 1802 UE 109 determines if the number S is even. If S is even (Yes at block 1802 ), then in block 1803 UE 109 selects a first index S 1 . If S is odd (No at block 1802 ), then in block 1804 UE 109 selects a second index S 2 . In block 1805 UE 109 transmits the ACK/NAK signals using the selected index. Assume for a certain bundling window of size there are T DL subframes associated with one UL subframe. The maximum number of ACK/NAK bits UE 109 may have within the bundling window is 2T. This is because there could be two DL data streams per DL subframe with multiple input multiple output (MIMO) operation. Alternatively UE 109 may be scheduled on a subset of the T DL subframes. For explicit transmission of multiple ACK/NAK bits on PUSCH, UE 109 needs to identify for which subset of DL subframes it detects DL grants. In one possible technique UE 109 always transmit 2T ACK/NAK bits on PUSCH with 2 bits reserved for each DL subframe in the bundling window. For the DL subframes that UE 109 does not detect any DL grant, then NAK or (NAK, NAK) is transmitted as the ACK/NAK bits for the corresponding DL subframes. UE 109 may reserve 1 bit per DL subframe. Thus UE 109 always transmits T ACK/NAK bits on PUSCH, one for each DL subframe. For the DL subframes in which UE 109 does not detect any DL subframe, then NAK is transmitted as the ACK/NAK bit for the corresponding DL subframes. When UE 109 has DL MIMO operation, then the multiple ACK/NAK bits are bundled or compressed into a single ACK/NAK bit per DL subframe by a logical AND operation. These multiple ACK/NAK bits such as 2T or T ACK/NAK bits can be jointly or separately coded, and transmitted on PUSCH.
This invention is a method of wireless communication having a communications protocol providing more downlink subframes than uplink subframes. The user equipment transmits a combination of a plurality of ACK/NAK response signals and related data. The related data could be the number of bits N of the plurality of ACK/NAK response signals or the number of detected downlink communications grants S requiring ACK/NAK response signals. This related data could be a cyclical redundancy check set of bits which may be scrambled upon the numbers N or S. Similar selections are feasible with resource elements or an index of a modulation symbol or codeword.
7
BACKGROUND OF THE INVENTION This invention relates generally to bedding, and more particularly, to a bedding foundation having a nestably stackable spring assembly. Bedding foundations or so-called box springs generally include a base and an upper grid including a generally rectangular border wire between which coil or bent wire spring modules are located. As thus manufactured, these box spring assemblies are bulky and shipping them to the manufacturer for application of padding and covering thereto is costly because of space requirements. To reduce the space requirements, it is customary to compress the assemblies to reduce their individual thicknesses and to tie them in their compressed state. This involves using presses and ties which are expensive, and the extra operations of pressing and tying the assemblies also adds to their manufacturing cost. At the delivery end, the manufacturer must cut and discard the ties before applying the covering. These additional material and handling expenses increase the end cost of box spring assemblies. Box spring assemblies by their very nature are intended to provide a stable support foundation for mattresses or other bedding placed on top thereof. Toward that end, the components used in the box spring assemblies should be securely and firmly mounted in the assembly to avoid any wobble or shifting during use. U.S. Pat. Nos. 5,052,064 and 7,237,282 disclose bedding foundations having nestably stackable spring assemblies which may reduce shipping costs. However, each of the foundations disclosed in these patents has an upper border wire having a round cross-sectional configuration. The border wire of these and other known bedding foundations is often three-gauge having a diameter of 0.243 inches. To make a border wire having the same beam strength, but made from a smaller diameter wire, say four-gauge wire having a diameter of 0.224 inches, would save material and therefore reduce the end cost of the foundation. In order to achieve the same beam strength, the four-gauge border wire must be changed or shaped from a circular cross-section to a rectangular cross-section in accordance with the present invention. Thus, the present invention enables one to use a four-gauge wire rather than a three-gauge wire in the border wire of the bedding foundation and therefore, reduce wire cost without giving up any beam strength. In order to achieve cost savings, it would be desirable to reduce the cross sectional area of the border wire of a bedding foundation (by creating the border wire from a smaller diameter wire) while maintaining the same beam strength or increasing it. Therefore, a bedding foundation having a nestable, stackable spring assembly including a border wire with a rectangular cross-section that can be stacked for shipping without having to compress and tie the spring assembly would be a significant improvement. SUMMARY OF THE INVENTION This invention provides the desirable cost savings in wire without compromising the integrity of known bedding foundations. In one embodiment, this invention is a bedding foundation having a nestably stackable spring assembly which may be shipped separately than the bases of the foundations. This bedding foundation comprises a rectangular base and a spring assembly fixedly attached atop the base. Padding overlies the spring assembly and a fabric covering surrounds the spring assembly, padding and base. The nestable stackable spring assembly includes a rectangular border wire having two parallel sides and two parallel ends. The border wire has a generally rectangular cross-sectional configuration with the height being greater than the width of the cross-section. The spring assembly further comprises a plurality of spaced and longitudinally extending support wires parallel to the border wire sides and extending between the border wire ends. Each support wire has ends connected to the border wire ends and is a continuous piece of wire. These support wires are generally corrugated along their lengths, having a plurality of peaks and a plurality of valleys. The flattened distal portions of the peaks are generally co-planar with the plane defined by the border wire, and the flattened distal portions of the valleys are displaced beneath and intermediate of the peaks. The spring assembly further comprises longitudinally spaced, parallel and transversely extending upper connector wires parallel to the border wire ends and connected along their lengths to the peaks of the support wires. In addition, the spring assembly may comprise a plurality of longitudinal wires welded to the upper connector wires and having ends crimped around the border wire ends and extending parallel the border wire sides. The longitudinal voids between the peaks of the support wires are of a greater dimension than the valleys of the support wires. This configuration enables one spring assembly to be nestably stacked atop a second spring assembly since the support wire valleys of the first assembly fit into the voids between the peaks of the support wires of the second assembly. Such a nested and stacked arrangement results in a total height dimension which is less than the sum of the individual assembly height dimensions. The border wire of the spring assembly of this invention has a unique cross-sectional configuration which enables the border wire to be made of a larger gauge, smaller diameter wire than heretofore known in art without comprising the beam strength of the border wire when compared to prior art border wires having a round cross-sectional configuration. The smaller diameter wire, when re-shaped from a circular cross-section into a rectangular cross-section, has the same cross-sectional area as when it had a circular cross-section. One advantage of this invention is that it enables a bedding foundation having a wire core to be made using less steel or material, thereby reducing the ultimate cost of the foundation to the foundation's assembler. In addition to reducing the quantity of wire necessary to manufacture a spring core for use in a bedding foundation, the unique shape of the border wire of the present invention provides a secure connection between the ends of the support wires and the border wire. Although one type of wire core has been described, the present border wire may be used in any bedding foundation. For example, individual coil springs may be used rather than generally corrugated support wires, the individual coil springs being clipped to the unique border wire of this invention. BRIEF DESCRIPTION OF THE DRAWINGS The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which: FIG. 1 is a perspective view, partially broken away, of a bedding foundation according to one embodiment of this invention; FIG. 2 is an enlarged perspective view illustrating a portion of the foundation of FIG. 1 ; FIG. 3A is a cross-sectional view taken along the line 3 A- 3 A of FIG. 2 ; FIG. 3B is a cross-sectional view taken along the line 3 B- 3 B of FIG. 2 ; FIG. 4 is a cross sectional view illustrating prior art; FIG. 5 is a cross sectional view illustrating the border wire of the present invention; FIG. 6 is a cross-sectional view taken along the line 6 - 6 of FIG. 1 without padding or a fabric covering; and FIG. 7 is a side elevational view of two stacked spring assemblies of the foundation of FIG. 1 without padding or a fabric covering. DETAILED DESCRIPTION OF THE INVENTION Referring first to FIG. 1 , a bedding foundation 10 according to one embodiment of this invention is illustrated. As shown in FIG. 1 , the foundation 10 has a longitudinal dimension or length L, a transverse dimension or width W and a height H. Although the length L is shown as being greater than the width W, they may be identical. The foundation 10 has a base 12 , including a rectangular base frame 13 on which transverse wooden slats 14 are attached. A nestably stackable spring assembly or wire core 16 is fixed atop the base 12 and, more particularly, secured to the transverse slats 14 of base 12 with staples 15 , as shown in FIG. 2 . Padding 18 overlies the nestably stackable spring assembly 16 , and a fabric covering 20 overlies the padding 18 and surrounds the nestably stackable spring assembly 16 and the base 12 . Although the base 12 is usually made of wood, it may be made of any other material, such as plastic, for example. The nestably stackable spring assembly 16 includes a rectangular steel border wire 22 having two parallel sides 24 , 24 and two parallel ends 26 , 26 . The parallel sides 24 , 24 are longer than the parallel ends 26 , 26 in the embodiment illustrated. Transversely spaced, parallel, and longitudinally extending steel support wires 28 are parallel to the border wire sides 24 , 24 and have ends 30 which are welded to and/or crimped around the ends 26 , 26 of the border wire 22 . These support wires 28 are formed so as to be generally corrugatedly-shaped along their lengths, having peaks 32 and valleys 34 . These peaks 32 and valleys 34 are flattened at their respective distal portions 36 and 38 , respectively. See FIG. 6 . The adjacent distal portions 36 , 38 are joined together by linear connecting portions 39 of the support wire 28 . Alternatively, the support wires may be resilient with non-linear arms or connecting portions joining adjacent flattened peaks and flattened valleys. Examples of such support wires are disclosed in U.S. patent application Ser. No. 12/352,208, which is fully incorporated herein. Longitudinally spaced, parallel and transversely extending steel upper connector wires 40 extend parallel to the border wire ends 26 , 26 and have ends 42 which are welded to and/or crimped around the border wire sides 24 , 24 . These upper connector wires 40 are welded intermediate of their ends 42 , 42 along their lengths at intersections 44 to the flattened peaks 36 of the support wires 28 . The support wires 28 have flattened distal peak portions 36 and flattened distal valley portions 38 , with the support wire ends 30 being welded to and/or crimped around the border wire 22 . In this embodiment, two upper connector wires 40 per flattened distal peak portion 36 are illustrated. However, any number of upper connector wires 40 may be secured, i.e., welded to each flattened distal peak portion 36 of each support wire 28 . The distal valley portions 38 of the support wires 28 may be stapled or otherwise attached to the transverse slats 14 which are in turn affixed to the base frame 13 . If desired, additional steel end wires (not shown) may be added either before or after the stackable spring assembly 16 has reached its final assembly destination. These end wires have spaced ends which are crimped around the border wire 22 and the endmost upper connector wire 40 , respectively. These end wires provide additional stiffness to the stackable assembly 16 in an edgemost location of the ends of the assembly 16 so as to prevent the end border wires from deflecting and being permanently distorted when a person sits on the end of a bed of which the foundation forms a part. Such steel end wires are shown in U.S. Pat. No. 5,361,434, which is hereby incorporated by reference in its entirety. Referring again to FIG. 1 , continuous longitudinal wires 46 may be included in the stackable spring assembly 16 . These longitudinal wires 46 have their ends 48 welded to and/or crimped around the border wire ends 26 , 26 . These longitudinal wires 46 may be welded along their lengths to the upper connector wires 40 as desired. In the illustrated embodiment, two longitudinal wires 46 per foundation 10 are illustrated. However, any number of longitudinal wires 46 may be incorporated into the foundation. The nestably stackable spring assembly 16 of bedding foundation 10 is generally manufactured by a supplier, who then ships it to an assembler. The assembler adds to the spring assembly 16 the wooden base 12 , incorporates padding 18 , and covers the components with upholstery 20 to make a completed product. This invention facilitates shipment of the metal core or stackable assembly 16 by a supplier to the assembler. With reference to FIG. 7 , a first stackable spring assembly 16 may be placed upon a surface with the flattened distal valley portions 38 of the support wires 28 oriented downwardly and the flattened distal peak portions 36 of the support wires 28 oriented upwardly. Next, a second like assembly 16 is placed atop the first assembly 16 , with its flattened distal valley portions 38 and flattened distal peak portions 36 likewise oriented downwardly and upwardly, respectively. The flattened distal valley portions 38 of the second assembly 16 are thereby allowed to enter into the voids between the flattened distal peak portions 36 of the first assembly 16 . The second assembly 16 nestles downwardly within the first assembly 16 until the outside dimension of the connecting portions 39 of the valleys 34 of the second assembly 16 is equal to the inside dimension of the connecting portions 39 of the valleys 34 of the first assembly 16 . At this point, the second assembly 16 comes to nest within the first assembly 16 , with the overall height of the nested assemblies 16 , 16 is substantially less than the sum of the individual heights of the assemblies 16 , 16 . Of course, any number of assemblies 16 may be nested and stacked together for storage or shipment. One advantage of the spring assembly 16 and associated bedding foundation 10 according to this invention is that the border wire 22 is uniquely configured to enable the border wire 22 to be made of a lesser gauge, smaller diameter wire than existing border wires without giving up any strength. In the embodiment of the bedding foundation 10 and associated spring assembly 16 shown in the drawings, the border wire 22 has a rectangular cross-sectional configuration with the height H 2 of border wire 22 being greater than the width W 2 of the border wire 22 . See FIG. 5 . FIG. 4 illustrates a cross-section of a prior art border wire 50 made of three-gauge wire. The cross-section is round and has a diameter of H 2 (0.243 inches in the case of three-gauge wire). FIG. 5 illustrates a rectangular cross-section of the border wire 22 of foundation 10 . The border wire 22 is re-shaped into a rectangular cross section from a four-gauge wire having a round cross section (shown in dashed lines in FIG. 5 ) having a diameter of H 1 , which is less than the diameter H 2 of the three-gauge wire shown in FIG. 4 . In the example, H 1 is 0.224 inches and H 2 is 0.243 inches. The cross-section of border wire 22 shown in FIG. 5 is rectangular and has a height of H 2 (0.243 inches, same as the diameter of the three-gauge wire shown in FIG. 4 ) and a width of 0.153 inches. Thus, in switching from a three-gauge wire having a round cross-section to a four-gauge wire having a rectangular cross-section, no height is lost. In changing the shape of the border wire 22 from a round cross-section to a rectangular cross-section, the cross-sectional area remains approximately identical. The generally rectangular cross-section of border wire has rounded corners 52 as shown in FIG. 5 . FIG. 3A shows one of the upper connector wires 40 passing underneath one of the sides 24 of border wire 22 and having its end 42 wrapped over and around the border wire 22 . FIG. 3B shows one of the longitudinal wires 46 passing over one of the ends 26 of border wire 22 and having its end 48 wrapped under and around border wire 22 . One of ordinary skill in the art will readily recognize that the alternative embodiments of the foundation unit 10 shown herein are exemplary only of a wide variety of alternative configurations that are readily possible within the scope of this invention. From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.
A bedding foundation having a nestably stackable spring assembly including a border wire having a generally rectangular cross-section. The foundation's spring assembly may be nestably stacked with numerous other such assemblies for transportation, thereby avoiding the need to compress and tie the assembly for shipping. Each foundation assembly includes a number of corrugated support wires having alternating peaks and valleys. The border wire is generally rectangular in cross-section to reduce wire costs without compromising beam strength of the border wire.
1
[0001] This application is a divisional of pending U.S. patent application Ser. No. 14/513,522 filed Oct. 14, 2014, entitled “Nitrile Rubbers Having Low Emission Values” which is entitled to the right of priority of European Patent Application 13290246.1, filed Oct. 14, 2013, the contents of which are hereby incorporated by reference in their entirety. FIELD OF THE INVENTION [0002] The invention relates to a nitrile rubber having low emission values, to a process for the production thereof, to vulcanizable mixtures comprising this nitrile rubber and, furthermore, to a process for producing vulcanizates from these mixtures and to the resultant vulcanizates. BACKGROUND OF THE INVENTION [0003] Nitrile rubbers, also abbreviated to “NBR”, are rubbers which are co- or terpolymers of at least one α,β-unsaturated nitrile monomer, at least one conjugated diene and optionally one or more additional copolymerizable monomers. Nitrile rubbers of this type and processes for producing such nitrile rubbers are known, see, for example, Ullmann's Encyclopedia of Industrial Chemistry, VCH Verlagsgesellschaft, Weinheim, 1993, p. 255-261. [0004] NBR is typically produced by emulsion polymerization to initially obtain an NBR latex. The NBR solid is isolated from this latex by coagulation, usually using salts or acids. The emulsion polymerization is typically carried out using molecular weight regulators. Commonly used molecular weight regulators are based on mercaptans. The use of dodecyl mercaptans is of particular importance for molecular weight regulation of emulsion rubbers based on monomers such as styrene, butadiene, acrylonitrile, (meth)acrylic acid, fumaric acid, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, chloroprene and others. [0005] U.S. Pat. No. 2,434,536 describes that synthetic rubbers based on diolefins, for example butadiene and optionally additional copolymerizable monomers, for example styrene, α-methylstyrene, vinylnaphthalene, acrylonitrile, methacrylonitrile, methyl methacrylate, ethyl fumarate or methyl vinyl ketone, are produced by emulsion polymerization in the presence of aliphatic mercaptans as molecular weight regulators. It is disclosed that these mercaptans comprise at least 7 and preferably 10 or more carbon atoms. It is preferable to use aliphatic mercaptans having a mean molecular weight of from 188 to 230 which comprise at least 50% dodecyl mercaptan and which comprise the balance to 100% in the form of mercaptans having 10 to 16 carbon atoms. [0006] Ullmanns Enzyklopädie der technischen Chemie [Ullmann's encyclopedia of industrial chemistry] 4th edition, volume 13, page 611-612 describes in general terms that the molecular weight of nitrile-butadiene rubbers can be controlled by using alkyl mercaptans, di- and polysulfides or xanthogen disulfides. tert-dodecyl mercaptan and diisopropylxanthogen disulfide are named as the regulators mainly used. [0007] Tertiary dodecyl mercaptans (also abbreviated to “TDM” or “TDDM”) are also often used in industrial practice. The TDM commercially available from Chevron Phillips is known, for example, and generally consists of a large mixture of a very wide range of isomers. [0008] Whether, or to what extent, volatile substances outgas from vulcanizates produced on the basis of nitrile rubber is relevant for a very wide range of applications, for example floor coverings of nitrile rubber. Applicant studies showed that nitrile rubbers produced using TDM comprise a high proportion of sulphur compounds and, furthermore, non-sulphur-containing impurities in the TDM in VOC tests (carried out by means of TDS GC-MS analyses according to VDA recommendation 278 September 2002). Depending on the mode and purpose of the application these can outgas in practical use and can lead to noticeable, unpleasant odour nuisances that may become unacceptable. [0009] While there is extensive literature in existence about the influence of the salts that can be used for latex coagulation on the properties of the NBR obtained, there are no indications or studies concerning the influence of the molecular weight regulators on the volatile constituents contents in nitrile rubbers. [0010] DD 154 702 discloses a process for free-radical copolymerization of butadiene and acrylonitrile in emulsion, which is controlled via a specific, advantageously computer-aided metered addition programme for the monomers and the molecular weight regulator, for example tert-dodecyl mercaptan, and in which the latices obtained are worked up by coagulation in an acidic medium to give the solid rubber. A significant advantage of the process is stated to be that, due to the use of acids in the coagulation, the resin soaps and/or fatty acid soaps used as emulsifiers remain in the rubber, i.e., are not washed out as in other processes. This is claimed not just to have the advantage of good properties of the NBR but particularly also to improve the economics of the process and to avoid wastewater pollution by washed-out emulsifier. It is stated that the butadiene-acrylonitrile copolymers comprising 10-30% by weight of acrylonitrile feature good elasticity properties and low-temperature properties combined with elevated swell resistance and advantageous processibility. Measures making it possible to influence the VOC values of the nitrile rubber or the profile of properties of the vulcanized NBR cannot be inferred from the teaching of this patent. [0011] EP-A-0 692 496, EP-A-0 779 301 and EP-A-0 779 300 each describe nitrile rubbers based on an unsaturated nitrile and a conjugated diene and said nitrile rubbers each comprise 10-60% by weight of unsaturated nitrile, have a Mooney viscosity in the range of 15-150 or, according to EP-A-0 692 496, of 15-65 and comprise at least 0.03 mol of a C 12 -C 16 -alkylthio group per 100 mol of monomer units, this alkylthio group comprising at least three tertiary carbon atoms and a sulphur atom bonded directly to at least one of the tertiary carbon atoms. Each of the nitrile rubbers is produced in the presence of a C 12 -C 16 -alkyl thiol of appropriate structure as molecular weight regulator which functions as a “chain transfer agent” and is thus incorporated into the polymer chains as an end group. [0012] It is stated that the nitrile rubbers according to EP-A-0 779 300 have an unsaturated nitrile composition distribution breadth “ΔAN” (AN stands for acrylonitrile) in the copolymer in the range of from 3 to 20. The process for their production differs from that of EP-A-0692496 in that only 30-80% by weight of the total monomer amount is employed on commencement of the polymerization and the remaining monomer amount is only metered in at a conversion of the polymerization of 20-70% by weight. [0013] It is stated that the nitrile rubbers according to EP-A-0 779 301 comprise 3-20% by weight of a fraction having a low molecular weight having a number-average molecular weight Mn of less than 35 000. The process for the production of said rubbers differs from that of EP-A-0 692 496 in that only 10-95% by weight of the alkythiol are mixed into the monomer mixture prior to the polymerization and the remaining amount of the alkylthiol is metered in only once a polymerization conversion of 20-70% by weight has been attained. [0014] According to EP-A-0 692 496, EP-A-0 779 300 and EP-A-0 779 301, it is in each case essential for the production of the nitrile rubbers to use alkylthiols in the form of the compounds 2,2,4,6,6-pentamethylheptane-4-thiol and 2,2,4,6,6,8,8-heptamethylnonanc-4-thiol as molecular weight regulator. In this connection it is pointed out that nitrile rubbers having poorer properties are obtained when the conventional, known tert-dodecyl mercaptan is used as regulator. [0000] [0015] It is asserted that the nitrile rubbers produced in EP-A-0 692 496, EP-A-0 779 300 and EP-A-0 779 301 have an advantageous profile of properties and that they facilitate good processability of the rubber mixtures and low mould soiling on processing. The vulcanizates obtained are said to have a good combination of low-temperature stability and oil resistance and good mechanical properties. Emphasis is furthermore placed on the high productivity of the production process due to high polymerization conversions of more than 75%, preferably more than 80%, the high vulcanization rate in the vulcanization with sulphur or peroxides, in particular for NBR-types for injection moulding, a short scorch time of the nitrile rubbers and a high crosslinking density. Neither EP-A-0 692 496 nor EP-A-0779 300 nor EP-A-0779 301 give indications as to the influence, if any, of the molecular weight regulators used on the properties of the NBR and the emission characteristics thereof. [0016] WO-A-2001/094432 discloses specific branched nitrile rubbers which, at a content of bound unsaturated nitrile of from 15% to 50% by weight and a Mooney viscosity (ML 1+4 at 100° C.) in the range of from 15 to 150 Mooney units, exhibit chain branching in the range of from 0° to 20° (determined by what is known as the Δδ B value) and a solubility measured in methyl ethyl ketone at 20° C. of ≧85% by weight. These nitrile rubbers are provided by effecting the polymerization using a molecular weight regulator, wherein the regulator is not added to the polymerization mixture in one charge, i.e., at once, but rather in at least two stages, preferably three or more stages, though continuous addition over the entire polymerization time is also possible. According to WO-A-2001/094432, various chain regulators can be used and these are mentioned in EP 0 799 300 BI on page 3, lines 51-58 and page 4, paragraph 3. Preference is given to alkyl thiols, such as 2,4,4-trimethylpentane-2-thiol, 2,2′,4,6,6′-pentamethylheptane-4-thiol, 2,2′,4,6,6′,8,8′-heptamethyl-nonane-4-thiol and mixtures thereof. [0017] WO-A-2008/142042. WO-A-2008/142035 and WO-A-2008/142039 each disclose processes used to produce specific NBR nitrile rubbers having particular ion contents and ion indices and specific properties associated therewith both in the rubber and in the corresponding vulcanizates. Specific dodecyl mercaptans, for example that described in WO-A-2008/42037, can be used for molecular weight regulation in these processes. Accordingly, fragments of the regulator substances used are found in the polymer chains. [0018] The production of butadiene/acrylonitrile copolymers in the presence of various primary, secondary and tertiary mercaptans was studied in J. Appl. Polym. Sci. 1968, Vol. 12, 1075-1095. A particular focus was the performance of the mercaptans in terms of their ability to control the molecular weight and the Mooney viscosity of the polymers. The poorest results were attained with n-alkyl mercaptans. By contrast, secondary mercaptans such as 2-nonyl mercaptan, 2-decyl mercaptan and mixtures proved to be more efficient regulators at low temperatures (5° C.). Tertiary C 7 to C 13 mercaptans showed the best results. Optimal transfer constants for a 70/30 butadiene/acetonitrile copolymer and an 80/20 butadiene/acetonitrile copolymer were obtained in a polymerization at 5° C. When using tert-nonyl mercaptan the polymerization was carried out up to a conversion of no more than 59%. No indication whatsoever is given as to the influence, if any, of the regulator substances analysed on the volatile substances content in the butadiene/acrylonitrile rubbers produced and the extent to which the other properties of the rubbers and vulcanizates based thereon are influenced. [0019] In summary it can be stated that, to date, there are still no known measures by which mercaptans can be used as molecular weight regulators to obtain nitrile rubbers having a distinctly reduced volatile substances content and simultaneously a profile of properties which remains unchanged and good, particularly in terms of the vulcanizate properties. SUMMARY OF THE INVENTION [0020] It is an object of the present invention to provide nitrile rubbers which on subsequent processing give vulcanizates having a good profile of properties and which simultaneously have distinctly improved emission characteristics compared to nitrile rubbers produced exclusively using the molecular weight regulator TDM typically used in industry. [0021] It was found that, surprisingly, nitrile rubbers having very good vulcanization characteristics and improved emission characteristics, and also vulcanizates based thereon having excellent vulcanizate properties, are obtained when the emulsion polymerization is carried out using specific molecular weight regulators and simultaneously the polymerization is conducted up to a conversion of 60% or more. [0022] Consequently, the present invention provides a nitrile rubber comprising repeating units of at least one α,β-unsaturated nitrile monomer and at least one conjugated diene monomer and having an emission quotient E according to general formula (I) of less than or equal to 0.25 mg/(kg*Mooney units) [0000] E = [ volatile   constituents ] [ Mooney   viscosity ] × [ nitrile   content ] 100 ( I ) [0000] where [volatile constituents] is the volatile constituents concentration in mg/kg of nitrile rubber determined by TDS GC-MS analysis according to VDA recommendation 278 (version September 2002) between 28.4 min and 34.0 min, [Mooney viscosity] is the Mooney viscosity ML 1+4 at 100° C. of the nitrile rubber in Mooney units determined according to ASTM D 1646 and [nitrile content] is the α,β-unsaturated nitrile content in the nitrile rubber in % by weight determined pursuant to DIN 53 625 according to Kjeldahl. [0026] The nitrile content is given dimensionless in general formula (I) (or in alternative expression “normalized”), this means the unit “% by weight” is not considered in general formula (I). [0027] For the sake of clarity this means: Consequently, the present invention provides a nitrile rubber comprising repeating units of at least one α,β-unsaturated nitrile monomer and at least one conjugated diene monomer and having an emission quotient E according to general formula (I) of less than or equal to 0.25 mg/(kg*Mooney units) [0000] E = [ volatile   constituents ] [ Mooney   viscosity ] × [ nitrile   content ] 100 ( I ) [0000] where [volatile constituents] is the volatile constituents concentration in mg/kg of nitrile rubber determined by TDS GC-MS analysis according to VDA recommendation 278 (version September 2002) between 28.4 min and 34.0 min, [Mooney viscosity] is the Mooney viscosity ML 1+4 at 100° C. of the nitrile rubber in Mooney units determined according to ASTM D 1646 and [nitrile content] is the dimensionless α,β-unsaturated nitrile content in the nitrile rubber, wherein such content is determined in % by weight pursuant to DIN 53 625 according to Kjeldahl. [0031] Furthermore, the present invention provides a process for producing nitrile rubbers by emulsion polymerization of at least one α,β-unsaturated nitrile monomer and at least one conjugated diene monomer, characterized in that the emulsion polymerization is carried out in the presence of tertiary nonyl mercaptan up to a conversion of at least 60% by weight based on the sum of the monomers employed. [0032] The present invention further provides a vulcanizable mixture comprising the nitrile rubber according to the invention, a process for producing this vulcanizable mixture, vulcanizates based on this vulcanizable mixture and a process for producing such vulcanizates. DETAILED DESCRIPTION OF THE INVENTION Nitrile Rubber: [0033] The nitrile rubber according to the invention has an emission quotient E according to general formula (I) of less than or equal to 0.25 mg/(kg*Mooney units), preferably less than or equal to 0.22 mg/(kg*Mooney units) and more preferably less than or equal to 0.20 mg/(kg*Mooney units) [0000] E = [ volatile   constituents ] [ Mooney   viscosity ] × [ nitrile   content ] 100 ( I ) [0000] where [volatile constituents] is the volatile constituents concentration in mg/kg of nitrile rubber determined by TDS GC-MS analysis according to VDA recommendation 278 (version September 2002) between 28.4 min and 34.0 min, [Mooney viscosity] is the Mooney viscosity ML 1+4 at 100° C. of the nitrile rubber in Mooney units determined according to ASTM D 1646 and [nitrile content] is the α,β-unsaturated nitrile content in the nitrile rubber in % by weight determined to DIN 53 625 according to Kjeldahl. [0037] The nitrile content is given dimensionless in general formula (I) (or in alternative expression “normalized”), this means the unit “% by weight” is not considered in general formula (I). [0038] For the sake of clarity this means: Consequently, the present invention provides a nitrile rubber comprising repeating units of at least one α,β-unsaturated nitrile monomer and at least one conjugated diene monomer and having an emission quotient E according to general formula (I) of less than or equal to 0.25 mg/(kg*Mooney units) [0000] E = [ volatile   constituents ] [ Mooney   viscosity ] × [ nitrile   content ] 100 ( I ) [0000] where [volatile constituents] is the volatile constituents concentration in mg/kg of nitrile rubber determined by TDS GC-MS analysis according to VDA recommendation 278 (version September 2002) between 28.4 min and 34.0 min, [Mooney viscosity] is the Mooney viscosity ML 1+4 at 100° C. of the nitrile rubber in Mooney units determined according to ASTM D 1646 and [nitrile content] is the dimensionless α,β-unsaturated nitrite content in the nitrile rubber, wherein such content is determined in % by weight pursuant to DIN 53 625 according to Kjeldahl. [0042] The volatile constituents which have their concentration determined by TDS GC-MS analysis according to VDA recommendation 278 (version September 2002) between 28.4 min and 34.0 min are typically volatile constituents of the molecular weight regulator used. [0043] The determination of the Mooney viscosity of the nitrile rubber (ML 1+4 at 100° C.) according to ASTM D 1646 is typically effected using noncalendered nitrile rubbers according to the invention. [0044] Nitrile rubbers which were not polymerized using the specific molecular weight regulator and which were not polymerized up to conversions of at least 60% based on the sum of the monomers employed have distinctly poorer emission characteristics. Vulcanizates produced using the nitrile rubbers according to the invention no longer exhibit any odour nuisances whatsoever in the relevant applications, for example in floor coverings. The nitrile rubbers according to the invention simultaneously feature excellent vulcanization characteristics. [0045] The nitrile rubbers according to the invention comprise repeating units of at least one α,β-unsaturated nitrile monomer and at least one conjugated diene monomer. The nitrile rubbers according to the invention can further comprise repeating units of one or more additional copolymerizable monomers. [0046] The repeating units of the at least one conjugated diene preferably derive from (C 4 -C 6 ) conjugated dienes or mixtures thereof. Particular preference is given to 1,2-butadiene, 1,3-butadiene, isoprene, 2,3-dimethylbutadiene, piperylene and mixtures thereof. Especially preferred are 1,3-butadiene, isoprene and mixtures thereof. Very particular preference is given to 1,3-butadiene. [0047] The α,β-unsaturated nitrile used for production of the inventive nitrile rubbers can be any known α,β-unsaturated nitrile, preference being given to (C 3 -C 5 ) α,β-unsaturated nitriles such as acrylonitrile, methacrylonitrile, ethacrylonitrile or mixtures thereof. Acrylonitrile is particularly preferred. [0048] When one or more additional copolymerizable monomers are used, these can be, for example, aromatic vinyl monomers, preferably styrene, α-methylstyrene and vinylpyridine, fluorinated vinyl monomers, preferably fluoroethyl vinyl ether, fluoropropyl vinyl ether, o-fluoromethylstyrene, vinyl pentafluorobenzoate, difluoroethylene and tetrafluoroethylene, or else copolymerizable antiaging monomers, preferably N-(4-anilinophenyl)acrylamide, N-(4-anilinophenyl)methacrylamide, N-(4-anilinophenyl)cinnamides, N-(4-anilinophenyl)crotonamide, N-phenyl-4-(3-vinylbenzyloxy)aniline and N-phenyl-4-(4-vinylbenzyloxy)aniline, and also nonconjugated dienes, such as 4-cyanocyclohexene and 4-vinylcyclohexene, or else alkynes such as 1- or 2-butyne. [0049] Furthermore, copolymerizable termonomers used can be monomers comprising hydroxyl groups, preferably hydroxyalkyl(meth)acrylates. However, it is also possible to use correspondingly substituted (meth)acrylamines. [0050] Examples of useful hydroxyalkyl acrylate monomers include 2-hydroxyethyl(meth)acrylate, 2-hydroxypropyl(meth)acrylate, 3-hydroxypropyl(meth)acrylate, 3-chloro-2-hydroxypropyl(meth)acrylate, 3-phenoxy-2-hydroxypropyl(meth)acrylate, glyceryl mono(meth)acrylate, hydroxybutyl(meth)acrylate, 3-chloro-2-hydroxypropyl(meth)acrylate, hydroxyhexyl(meth)acrylate, hydroxyoctyl(meth)acrylate, hydroxymethyl(meth)acrylamide, 2-hydroxypropyl(meth)acrylate, 3-hydroxypropyl(meth)acrylamide, di(ethylene glycol)itaconate, di(propylene glycol)itaconate, bis(2-hydroxypropyl)itaconate, bis(2-hydroxyethyl)itaconate, bis(2-hydroxyethyl)fumarate, bis(2-hydroxyethyl)maleate and hydroxymethyl vinyl ketone. [0051] Furthermore, copolymerizable termonomers used can be monomers comprising epoxy groups, preferably glycidyl(meth)acrylates. [0052] Examples of monomers comprising epoxy groups include diglycidyl itaconate, glycidyl p-styrenecarboxylate, 2-ethylglycidyl acrylate, 2-ethylglycidyl methacrylate, 2-(n-propyl)glycidyl acrylate, 2-(n-propyl)glycidyl methacrylate, 2-(n-butyl)glycidyl acrylate, 2-(n-butyl)glycidyl methacrylate, glycidylmethyl acrylate, glycidylmethyl methacrylate, glycidyl acrylate, (3′,4′-epoxyheptyl)-2-ethyl acrylate, (3′,4′-epoxyheptyl)-2-ethyl methacrylate, 6′,7′-epoxyheptyl acrylate, 6′,7′-epoxyheptyl methacrylate, allyl glycidyl ether, allyl 3,4-epoxyheptyl ether, 6,7-epoxyheptyl allyl ether, vinyl glycidyl ether, vinyl 3,4-epoxyheptyl ether, 3,4-epoxyheptyl vinyl ether, 6,7-epoxyheptyl vinyl ether, o-vinylbenzyl glycidyl ether, m-vinylbenzyl glycidyl ether, p-vinylbenzyl glycidyl ether, 3-vinylcyclohexene oxide. [0053] Alternatively, additional copolymerizable monomers used can be copolymerizable termonomers comprising carboxyl groups, for example α,β-unsaturated monocarboxylic acids, esters thereof, α,β-unsaturated dicarboxylic acids, mono- or diesters thereof or the corresponding anhydrides or amides thereof. [0054] The α,β-unsaturated monocarboxylic acids used can preferably be acrylic acid and methacrylic acid. [0055] It is also possible to use esters of the α,β-unsaturated monocarboxylic acids, preferably the alkyl esters and alkoxyalkyl esters thereof. Preference is given to the alkyl esters, in particular C 1 -C 18 alkyl esters, of the α,β-unsaturated monocarboxylic acids, particular preference being given to alkyl esters, in particular C 1 -C 18 alkyl esters, of acrylic acid or of methacrylic acid, in particular methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, tert-butyl acrylate, 2-ethylhexyl acrylate, n-dodecyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate and 2-ethylhexyl methacrylate. Preference is also given to alkoxyalkyl esters of the α,β-unsaturated monocarboxylic acids, particular preference being given to alkoxyalkyl esters of acrylic acid or of methacrylic acid, in particular C 2 -C 12 -alkoxyalkyl esters of acrylic acid or of methacrylic acid, very particular preference being given to methoxymethyl acrylate, methoxyethyl(meth)acrylate, ethoxyethyl(meth)acrylate and methoxyethyl(meth)acrylate. It is also possible to use mixtures of alkyl esters, for example those mentioned hereinabove with alkoxyalkyl esters, for example in the form of those mentioned hereinabove. It is also possible to use cyanoalkyl acrylate and cyanoalkyl methacrylates in which the number of carbon atoms in the cyanoalkyl group is 2-12, preferably α-cyanoethyl acrylate, β-cyanoethyl acrylate and cyanobutyl methacrylate. It is also possible to use hydroxyalkyl acrylates and hydroxyalkyl methacrylates in which the number of carbon atoms of the hydroxyalkyl groups is 1-12, preferably 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate and 3-hydroxypropyl acrylate; it is also possible to use acrylates or methacrylates comprising fluorine-substituted benzyl groups, preferably fluorobenzyl acrylate and fluorobenzyl methacrylate. It is also possible to use acrylates and methacrylates comprising fluoroalkyl groups, preferably trifluoroethyl acrylate and tetrafluoropropyl methacrylate. It is also possible to use amino-groups-containing α,β-unsaturated carboxylic esters such as dimethylaminomethyl acrylate and diethylaminoethyl acrylate. [0056] It is further possible to use α,β-unusaturated dicarboxylic adds, preferably maleic acid, fumaric acid, crotonic acid, itaconic acid, citraconic acid and mesaconic acid as additional copolymerizable monomers. [0057] It is further possible to use α,β-unsaturated dicarboxylic anhydrides, preferably maleic anhydride, itaconic anhydride, citraconic anhydride and mesaconic anhydride. [0058] It is further possible to use mono- or diesters of α,β-unsaturated dicarboxylic acids. [0059] These α,β-unsaturated dicarboxylic mono- or diesters can be, for example, alkyl, preferably C 5 -C 10 -alkyl, in particular ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, n-pentyl or n-hexyl, alkoxyalkyl, preferably C 2 -C 12 -alkoxyalkyl, more preferably C 3 -C 5 -alkoxyalkyl, hydroxyalkyl, preferably C 1 -C 12 -hydroxyalkyl, more preferably C 2 -C 8 -hydroxyalkyl, cycloalkyl, preferably C 5 -C 12 -cycloalkyl, more preferably C 6 -C 12 -cycloalkyl, alkylcycloalkyl, preferably C 6 -C 12 -alkylcycloalkyl, more preferably C 7 -C 10 -alkylcycloalkyl, aryl, preferably C 6 -C 14 -aryl, mono- or diesters, wherein any diesters can also be mixed esters. [0060] Particularly preferred alkyl esters of α,β-unsaturated monocarboxylic adds are methyl(meth)acrylate, ethyl(meth)acrylate, propyl(meth)acrylate, n-butyl(meth)acrylate, t-butyl(meth)acrylate, hexyl(meth)acrylate, 2-ethylhexyl(meth)acrylate, octyl(meth)acrylate, 2-propylheptyl acrylate and lauryl(meth)acrylate. In particular, n-butyl acrylate is used. [0061] Particularly preferred alkoxyalkyl esters of the α,β-unsaturated monocarboxylic adds are methoxyethyl(meth)acrylate, ethoxyethyl(meth)acrylate and methoxyethyl(meth)acrylate. In particular, methoxyethyl acrylate is used. [0062] Other α,β-unsaturated monocarboxylic acid esters used further include, for example, polyethylene glycol(meth)acrylate, polypropylene glycol(meth)acrylate, N-(2-hydroxyethyl)acrylamides, N-(2-hydroxymethyl)acrylamides and urethane(meth)acrylate. [0063] Examples of α,β-unsaturated dicarboxylic monoesters include monoalkyl maleates, preferably monomethyl maleate, monoethyl maleate, monopropyl maleate and mono-n-butyl maleate; monocycloalkyl maleates, preferably monocyclopentyl maleate, monocyclohexyl maleate and monocycloheptyl maleate; monoalkylcycloalkyl maleates, preferably monomethylcyclopentyl maleate and monoethylcyclohexyl maleate; monoaryl maleates, preferably monophenyl maleate; monobenzyl maleates, preferably monobenzyl maleate; monoalkyl fumarates, preferably monomethyl fumarate, monoethyl fumarate, monopropyl fumarate and mono-n-butyl fumarate; monocycloalkyl fumarates, preferably monocyclopentyl fumarate, monocyclohexyl fumarate and monocycloheptyl fumarate; monoalkylcycloalkyl fumarates, preferably monomethylcyclopentyl fumarate and monoethylcyclohexyl fumarate; monoaryl fumarates, preferably monophenyl fumarate; a monobenzyl fumarates, preferably monobenzyl fumarate; monoalkyl citraconates, preferably monomethyl citraconate, monoethyl citraconate, monopropyl citraconate and mono-n-butyl citraconate; monocycloalkyl citraconates, preferably monocyclopentyl citraconate, monocyclohexyl citraconate and monocycloheptyl citraconate; monoalkylcycloalkyl citraconates, preferably monomethylcyclopentyl citraconate and monoethylcyclohexyl citraconate; monoaryl citraconates, preferably monophenyl citraconate; monobenzyl citraconates, preferably monobenzyl citraconate; monoalkyl itaconates, preferably monomethyl itaconate, monoethyl itaconate, monopropyl itaconate and mono-n-butyl itaconate; monocycloalkyl itaconates, preferably monocyclopentyl itaconate, monocyclohexyl itaconate and monocycloheptyl itaconate; monoalkylcycloalkyl itaconates, preferably monomethylcyclopentyl itaconate and monoethylcyclohexyl itaconate; monoaryl itaconates, preferably monophenyl itaconate; monobenzyl itaconates, preferably monobenzyl itaconate; monoalkyl mesaconates, preferably monoethyl mesaconate. [0086] The α,β-unsaturated dicarboxylic diesters used can be the analogous diesters based on the monoester groups mentioned hereinabove and the ester groups can also be chemically different groups. [0087] Useful additional copolymerizable monomers further include free-radically polymerizable compounds comprising at least two olefinic double bonds per molecule. Examples of polyunsaturated compounds include acrylates, methacrylates and itaconates of polyols, for example ethylene glycol diacrylate, diethylene glycol dimethacrylate, triethylene glycol diacrylate, butane-1,4-diol diacrylate, propane-1,2-diol diacrylate, butane-1,3-diol dimethacrylate, neopentyl glycol diacrylate, trimethylolpropane di(meth)acrylate, trimethylolethane di(meth)acrylate, glyceryl di- and triacrylate, pentaerythrityl di-, tri- and tetraacrylate and -methacrylate, dipentaerythrityl tetra-, penta- and hexaacrylate and -methacrylate and -itaconate, sorbityl tetraacrylate, sorbityl hexamethacrylate, diacrylates and dimethacrylates of 1,4-cyclohexanediol 1,4-dimethylolcyclohexane, 2,2-bis(4-hydroxyphenyl)propane, of polyethylene glycols and of oligoesters and oligourethanes having terminal hydroxyl groups. The polyunsaturated monomers used can also be acrylamides, for example methylenebisacrylamide, hexamethylene-1,6-bisacrylamide, diethylenetriaminetrismethacrylamide, bis(methacrylamidopropoxy)ethane or 2-acrylamidoethyl acrylate. Examples of polyunsaturated vinyl and allyl compounds include divinylbenzene, ethylene glycol divinyl ether, diallyl phthalate, allyl methacrylate, diallyl maleate, triallyl isocyanurate and triallyl phosphate. [0088] The proportions of conjugated diene and α,β-unsaturated nitrile in the nitrile rubbers according to the invention can vary within wide limits. The proportion of or the proportion of the sum of the conjugated diene(s) is typically in the range of from 20% to 95% by weight, preferably in the range of from 45% to 90% by weight, more preferably in the range of from 50% to 85% by weight, based on the overall polymer. The proportion of or the proportion of the sum of the α,β-unsaturated nitrile(s) is typically 5% to 80% by weight, preferably 10% to 55% by weight, more preferably 15% to 50% by weight, based on the overall polymer. The proportions of the repeating units of conjugated diene and α,β-unsaturated nitrile in the nitrile rubbers according to the invention sum to 100% by weight in each case. [0089] The additional monomers can be present in amounts of from 0% to 40% by weight, preferably 0% to 30% by weight, more preferably 0% to 26% by weight, based on the overall polymer. In this case, corresponding proportions of the repeating units of the conjugated diene(s) and/or of the repeating units of the α,β-unsaturated nitrile(s) are replaced by the proportions of these additional monomers and the proportions of all of the repeating units of the monomers must still add up to 100% by weight in each case. [0090] When esters of (meth)acrylic acid are used as additional monomers, they are typically used in amounts of from 1% to 25% by weight. When α,β-unsaturated mono- or dicarboxylic acids are used as additional monomers, they are typically used in amounts of less than 10% by weight. [0091] The nitrogen content in the nitrile rubbers of the invention is determined to DIN 53 625 according to Kjeldahl. Due to the polar comonomers content, the nitrile rubbers are typically ≧85% by weight soluble in methyl ethyl ketone at 20° C. [0092] The nitrile rubbers have Mooney viscosities ML 1+4 at 100° C. of from 10 to 150 Mooney units (MU), preferably of from 20 to 100 MU. [0093] The glass transition temperatures of the nitrile rubbers are in the range −70° C. to +10° C., preferably in the range −60° C. to 0° C. [0094] Preference is given to nitrile rubbers according to the invention comprising repeating units of acrylonitrile, and 1,3-butadiene. Preference is further given to nitrile rubbers comprising repeating units of acrylonitrile, 1,3-butadiene and one or more additional copolymerizable monomers. Preference is likewise given to nitrile rubbers comprising repeating units of acrylonitrile, 1,3-butadiene and one or more α,β-unsaturated mono- or dicarboxylic acids or esters or amides thereof and, in particular, repeating units of an alkyl ester of an α,β-unsaturated carboxylic acid, most preferably of methyl(meth)acrylate, ethyl(meth)acrylate, propyl(meth)acrylate, n-butyl(meth)acrylate, t-butyl(meth)acrylate, hexyl(meth)acrylate, 2-ethylhexyl(meth)acrylate, octyl(meth)acrylate or lauryl(meth)acrylate. Process for Producing the Nitrile Rubbers: [0095] The nitrile rubbers are produced by emulsion polymerization in the process according to the invention. Molecular Weight Regulator: [0096] It is essential that the process for producing the nitrile rubbers according to the invention is carried out in the presence of tert-nonyl mercaptan as molecular weight regulator. This can be, for example, a) tert-nonyl mercaptan at a purity of at least 95% by weight, preferably at least 97% by weight, or b) a mixture comprising (i) at least 50% by weight but less than 95% by weight of tert-nonyl mercaptan and (ii) the remainder being one or more further isomeric nonyl mercaptans and/or one or more further C 10 -C 16 alkylthiols. [0099] The tert-nonyl mercaptan a) is commercially available, for example from Sigma Aldrich (CAS No. 25360-10-5) at a purity of at least 97% by weight or from Chevron Phillips as the product Sulfol® 90 at a purity of at least 97% by weight or from various chemicals producers. [0100] Mixtures b) comprising at least 50% by weight but less than 95% by weight of tert-nonyl mercaptan and further on one or more further isomeric nonyl mercaptans and/or one or more further C 12 -C 16 alkylthiols are likewise commercially available, for example as mercaptans 175 from Atofina having a tert-nonyl mercaptan content of 65% by weight and a dodecyl mercaptans content of 35% by weight or Sulfol® 100 from Chevron Phillips. [0101] The molecular weight regulator used is typically used in the polymerization in an amount of from 0.05 to 3 parts by weight, preferably of from 0.1 to 1.5 parts by weight, based on 100 parts by weight of the monomer mixture. Suitable amounts can be determined in simple hand experiments by a person skilled in the art. [0102] The metered addition of the molecular weight regulator or the molecular weight regulator mixture is effected either exclusively on commencement of the polymerization or on commencement and additionally portionwise over the course of the polymerization. In batch processes the total amount of the molecular weight regulator or the molecular weight regulator mixture is typically added at the beginning and when the process is carried out continuously incremental addition has proven advantageous. The molecular weight regulator or the regulator mixture is then typically added in at least two stages and addition in two, three or even more stages is possible. Even continuous addition over the total polymerization time is possible. It is particularly preferable to add the molecular weight regulator or the molecular weight regulator mixture in two stages. For a two-stage metered addition, it has proven advantageous to initially add the regulator/the regulator mixture, prior to commencement of the polymerization, in an amount of from 5% to 65% by weight, preferably 10% to 65% by weight, based on the total amount of regulator/regulator mixture, and the remaining amount of regulator/regulator mixture in a subsequent metered addition at a conversion of from 5% to 80%, preferably 10% to 55%, based on the total amount of monomers employed. For three-stage and multistage metered addition, it is advisable to determine the most favourable amount of molecular weight regulator and the most favourable time for addition by suitable preliminary experiments. [0103] On account of its function, the molecular weight regulator is found to a certain extent in the form of end groups in the nitrile rubber, i.e., the nitrile rubber comprises the corresponding alkylthio end groups to a certain extent. Emulsifiers: [0104] Emulsifiers used can be water-soluble salts of anionic emulsifiers or else uncharged emulsifiers. It is preferable to use anionic emulsifiers. [0105] Anionic emulsifiers used can be modified resin acids obtained by dimerization, disproportionation, hydrogenation and modification of resin acid mixtures comprising abietic acid, neoabietic acid, palustric acid, levopimaric acid. A particularly preferred modified resin acid is disproportionated resin acid (Ullmann's Encyclopedia of Industrial Chemistry, 6th edition, volume 31, p. 345-355). [0106] Anionic emulsifiers used can also be fatty acids. These comprise 6 to 22 carbon atoms per molecule. They can be fully saturated or can comprise one or more double bonds in the molecule. Examples of fatty acids include caproic acid, lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid, linoleic acid, linolenic acid. The carboxylic acids are typically based on origin-specific oils or fats, for example castor oil, cottonseed, peanut oil, linseed oil, coconut fat, palm kernel oil, olive oil, rapeseed oil, soya oil, fish oil and bovine tallow etc. (Ullmann's Encyclopedia of Industrial Chemistry, 6th edition, volume 13, p. 75-108). Preferred carboxylic acids derive from coconut fatty acid and from bovine tallow and are partly or fully hydrogenated. [0107] Such carboxylic acids based on modified resin acids or fatty acids are used in the form of water-soluble salts of lithium, sodium, potassium and ammonium. The sodium and potassium salts are preferred. [0108] Anionic emulsifiers are, furthermore, sulphonates, sulphates and phosphates bonded to an organic radical. Useful organic radicals are aliphatic, aromatic, alkylated aromatic systems, fused aromatic systems and methylene-bridged aromatic systems and the methylene-bridged and fused aromatic systems may additionally be alkylated. The length of the alkyl chains is 6 to 25 carbon atoms. The length of the alkyl chains bonded to the aromatic systems is between 3 and 12 carbon atoms. [0109] The sulphates, sulphonates and phosphates are used in the form of salts of lithium, sodium, potassium and ammonium. The salts of sodium, potassium and ammonium are preferred. [0110] Examples of sulphonates, sulphates and phosphates of this type include sodium laurylsulphate, sodium alkylsulphonate, sodium alkylarylsulphonate, sodium salts of methylene-bridged arylsulphonates, sodium salts of alkylated naphthalenesulphonates, and the sodium salts of methylene-bridged naphthalenesulphonates, which may also be oligomerized, the oligomerization level being between 2 and 10. Typically, the alkylated naphthalenesulphonic acids and the methylene-bridged (and optionally alkylated) naphthalenesulphonic acids are in the form of isomer mixtures which can also comprise more than 1 sulphonic acid group (2 to 3 sulphonic acid groups) in the molecule. Particular preference is given to sodium laurylsulphate, sodium alkylsulphonate mixtures having 12 to 18 carbon atoms, sodium alkylarylsulphonates, sodium diisobutylenenaphthalenesulphonate, methylene-bridged polynaphthalenesulphonate mixtures and methylene-bridged arylsulphonate mixtures. [0111] Uncharged emulsifiers derive from addition products of ethylene oxide and propylene oxide onto compounds having sufficiently acidic hydrogen. These include, for example, phenol, alkylated phenol and alkylated amines. The mean polymerization levels of the epoxides are between 2 and 20. Examples of uncharged emulsifiers are ethoxylated nonylphenols having 8, 10 and 12 ethylene oxide units. The uncharged emulsifiers are typically not used alone, but rather in combination with anionic emulsifiers. [0112] Preference is given to the sodium and potassium salts of disproportionated abietic acid and of partly hydrogenated tallow fatty acid and mixtures thereof, sodium laurylsulphate, sodium alkylsulphonates, sodium alkylbenzenesulphonate, and alkylated and methylene-bridged naphthalenesulphonic acids. [0113] The emulsifiers are used in an amount of from 0.2 to 15 parts by weight, preferably 0.5 to 12.5 parts by weight, more preferably 1.0 to 10 parts by weight, based on 100 parts by weight of the monomer mixture. [0114] The emulsion polymerization is carried out using the emulsifiers mentioned. When, on completion of the polymerization, lattices having a tendency to self-coagulate prematurely on account of a certain instability are obtained, said emulsifiers can also be used for post-stabilization of the lattices. This may become necessary particularly prior to the removal of unconverted monomers by treatment with steam and prior to latex storage. Polymerization Initiators: [0115] The emulsion polymerization is typically initiated using polymerization initiators which break down to free radicals. These include compounds comprising an —O—O— unit (peroxo compounds) or an —N═N— unit (azo compound). [0116] Peroxo compounds include hydrogen peroxide, peroxodisulphates, peroxodiphosphates, hydroperoxides, peracids, peresters, peracid anhydrides and peroxides having two organic radicals. Useful salts of peroxodisulphuric acid and peroxodiphosphoric acid are the sodium, potassium and ammonium salts. Useful hydroperoxides are, for example, t-butyl hydroperoxide, cumene hydroperoxide and p-menthane hydroperoxide. Useful peroxides having two organic radicals are dibenzoyl peroxide, 2,4-dichlorobenzoyl peroxide, di-t-butyl peroxide, dicumyl peroxide, t-butyl perbenzoate, t-butyl peracetate etc. Useful azo compounds are azobisisobutyronitrile, azobisvaleronitrile and azobiscyclohexanenitrile. [0117] Hydrogen peroxide, hydroperoxides, peracids, peresters, peroxodisulphate and peroxodiphosphate are also used in combination with reducing agents. Useful reducing agents are sulphenates, sulphinates, sulphoxylates, dithionite, sulphite, metabisulphite, disulphite, sugar, urea, thiourea, xanthates, thioxanthates, hydrazinium salts, amines and amine derivatives such as aniline, dimethylaniline, monoethanolamine, diethanolamine or triethanolamine. Initiator systems consisting of an oxidizing agent and a reducing agent are known as redox systems. When redox systems are used, salts of transition metal compounds such as iron, cobalt or nickel are often additionally used in combination with suitable complexing agents such as sodium ethylenediaminetetraacetate, sodium nitrilotriacetate and trisodium phosphate or tetrapotassium diphosphate. [0118] Preferred redox systems are, for example: 1) potassium peroxydisulphate in combination with triethanolamine, 2) ammonium peroxydiphosphate in combination with sodium metabisulphite (Na 2 S 2 O 5 ), 3) p-menthane hydroperoxide/sodium formaldehydesulphoxylate in combination with iron-II-sulphate (FeSO 4 *7H 2 O), sodium ethylenediaminoacetate and trisodium phosphate; 4) cumene hydroperoxide/sodium formaldehydesulphoxylate in combination with iron-II-sulphate (FeSO 4 *7H 2 O), sodium ethylenediaminoacetate and tetrapotassium diphosphate, 5) pinane hydroperoxide/sodium formaldehydesulphoxylate in combination with iron-II-sulphate (FeSO 4 *7H 2 O), sodium ethylenediaminoacetate and trisodium phosphate. [0124] The amount of oxidizing agents is 0.001 to 1 part by weight based on 100 parts by weight of monomer. The molar amount of reducing agent is between 50% and 500% based on the molar amount of the oxidizing agent employed. [0125] The molar amount of complexing agent is based on the amount of transition metal employed and is typically equimolar therewith. [0126] To carry out the polymerization, all or individual components of the initiator system are metered on commencement of the polymerization or during the polymerization. [0127] Portionwise addition of all and individual components of the activator system during the polymerization is preferred. Sequential addition can be used to control the reaction rate. [0128] The polymerization time is in the range of from 5 h to 15 h and depends substantially on the acrylonitrile content of the monomer mixture and on the polymerization temperature. [0129] The polymerization temperature is in the range of from 0 to 30° C., preferably of from 5 to 25° C. [0130] It is essential for obtaining the nitrile rubbers according to the invention that the polymerization is carried out up to a conversion of at least 60% based on the monomer mixture employed. The polymerization is preferably carried out up to a conversion in the range of from 60% to 98%, more preferably 62% to 95%, in particular 65% to 95%. On attainment of this conversion the polymerization is stopped. [0131] A stopper is added to the reaction mixture for this purpose. Useful for this purpose are, for example, dimethyl dithiocarbamate, sodium nitrite, mixtures of dimethyl dithiocarbamate and sodium nitrite, hydrazine and hydroxylamine and salts derived therefrom, such as hydrazinium sulphate and hydroxylammonium sulphate, diethylhydroxylamine, diisopropylhydroxylamine, water-soluble salts of hydroquinone, sodium dithionite, phenyl-α-naphthylamine and aromatic phenols such as tert-butylcatechol, or phenothiazine. [0132] The amount of water employed in the emulsion polymerization is in the range of from 100 to 900 parts by weight, preferably in the range of from 120 to 500 parts by weight, more preferably in the range of from 150 to 400 parts by weight of water, based on 100 parts by weight of the monomer mixture. [0133] Salts can be added to the aqueous phase during the emulsion polymerization to reduce the viscosity during the polymerization, for pH adjustment and as a pH buffer. Typical salts are salts of monovalent metals in the form of potassium hydroxide and sodium hydroxide, sodium sulphate, sodium carbonate, sodium hydrogencarbonate, sodium chloride and potassium chloride. Sodium hydroxide and potassium hydroxide, sodium hydrogencarbonate and potassium chloride are preferred. The amounts of these electrolytes are in the range 0 to 1 part by weight, preferably 0 to 0.5 part by weight, based on 100 parts by weight of the monomer mixture. [0134] The polymerization can be performed either batchwise or else continuously in a stirred tank cascade. [0135] To achieve smooth progress of the polymerization, only some of the initiator system is employed for the start of the polymerization and the remainder is metered in subsequently during the polymerization. The polymerization is typically commenced with 10% to 80% by weight, preferably 30-50% by weight, of the total amount of initiator. Subsequent metered addition of individual constituents of the initiator system is also possible. [0136] If the intention is to produce chemically homogeneous products, acrylonitrile or butadiene is subsequently metered in when the composition is intended to be outside the azeotropic butadiene/acrylonitrile ratio. Subsequent metered addition is preferred for NBR types having acrylonitrile contents of from 10% to 34% by weight and for the types having 40% to 50% by weight of acrylonitrile (W. Hofmann, “Nitilkautschuk” [“Nitrile rubber”], Berliner Union, Stuttgart, 1965, page 58-66). The subsequent metered addition is preferably effected—as specified in DD 154 702 for example—under computer control on the basis of a computer program. [0137] To remove unconverted monomers, the “stopped” latex can be subjected to a steam distillation. In this case, temperatures in the range of from 70° C. to 150° C. are used, the pressure being reduced for temperatures of <100° C. Post-stabilization of the latex with emulsifier can be effected prior to the steam distillation. To this end, it is advantageous to use the emulsifiers mentioned hereinabove in amounts of from 0.1% to 2.5% by weight, preferably 0.5% to 2.0% by weight, based on 100 parts by weight of nitrile rubber. Latex Coagulation: [0138] Prior to or during latex coagulation, one or more ageing stabilizers can be added to the latex. Phenolic, aminic and also other ageing stabilizers are suitable for this purpose. [0139] Useful phenolic ageing stabilizers are alkylated phenols, styrenated phenol, sterically hindered phenols such as 2,6-di-tert-butylphenol, 2,6-di-tert-butyl-p-cresol (BHT), 2,6-di-tert-butyl-4-ethylphenol, sterically hindered phenols comprising ester groups, sterically hindered phenols containing thioether groups, 2,2′-methylenebis(4-methyl-6-tert-butylphenol) (BPH) and sterically hindered thiobisphenols. [0140] When discolouration of the rubber is unimportant, aminic ageing stabilizers, for example mixtures of diaryl-p-pheylenediamines (DTPD), octylated diphenylamine (ODPA), phenyl-α-naphthylamine (PAN), phenyl-β-naphthylamine (PBN), preferably those based on phenylenediamine are also used. Examples of phenylendiamines include N-isopropyl-N′-phenyl-p-phenylenediamine, N-1,3-dimethylbutyl-N′-phenyl-p-phenylenediamine (6PPD), N-1,4-dimethylpentyl-N′-phenyl-p-phenylenediamine (7PPD), N,N′-bis-1,4-(1,4-dimethylpentyl)-p-phenylenediamine (77PD) etc. [0141] Other ageing stabilizers include phosphites such as tris(nonylphenyl) phosphite, polymerized 2,2,4-trimethyl-1,2-dihydroquinoline (TMQ), 2-mercaptobenzimidazole (MBI), methyl-2-mercaptobenzimidazole (MMBI), zinc methylmercaptobenzimidazole (ZMMBI). The phosphites are often used in combination with phenolic ageing stabilizers. TMQ, MBI and MMBI are mostly used for NBR types which are vulcanized using peroxides. [0142] For coagulation, the latex is adjusted to a pH known to a person skilled in the art, namely by addition of a base, preferably ammonia or sodium hydroxide or potassium hydroxide, or an acid, preferably sulphuric acid or acetic acid. [0143] In one embodiment of the process, the coagulation is carried out using at least one salt selected from the group consisting of the salts of aluminium, calcium, magnesium, sodium, potassium and lithium. Mono- or divalent anions are typically used as anions of these salts. Halides are preferred and chloride, nitrate, sulphate, hydrogencarbonate, carbonate, formate and acetate are particularly preferred. [0144] Useful are, for example, sodium chloride, potassium chloride, calcium chloride, magnesium chloride, sodium nitrate, potassium nitrate, sodium sulphate, potassium sulphate, sodium hydrogencarbonate, potassium hydrogencarbonate, sodium carbonate, potassium carbonate, aluminium sulphate, potassium aluminium sulphate (potassium alum), sodium aluminium sulphate (sodium alum), sodium acetate, calcium acetate and calcium formate. When a water-soluble calcium salt is used for the latex coagulation, calcium chloride is preferred. [0145] The salts are added in an amount of from 0.05% to 10% by weight, preferably 0.5% to 8% by weight, more preferably 1% to 5% by weight, based on the solids content of the latex dispersion. [0146] In addition to at least one salt from the group defined hereinabove, precipitants may also be used in the coagulation. Useful precipitants are water-soluble polymers for example. These are nonionic, anionic or cationic. [0147] Examples of nonionic polymeric precipitants include modified cellulose such as hydroxyalkylcellulose or methylcellulose and adducts of ethylene oxide and propylene oxide onto compounds comprising acidic hydrogen. Examples of compounds comprising acidic hydrogen include: fatty acids, sugars such as sorbitol, mono- and diglycerides of fatty acids, phenol, alkylated phenols, (alkyl)phenol-formaldehyde condensates etc. The addition products of ethylene oxide and propylene oxide onto these compounds can have a random and block structure. Of these products, those which become less soluble with increasing temperature are preferred. Characteristic cloud points are in the range 0 to 100° C., preferably in the range of from 20 to 70° C. [0148] Examples of anionic polymeric precipitants are the homo- and co-polymers of methacrylic acid, maleic acid, maleic anhydride etc. The sodium salt of polyacrylic acid is preferred. [0149] Cationic polymeric precipitants are typically based on polyamines and on homo- and co-polymers of (meth)acrylamide. Preference is given to polymethacrylamides and polyamines, particularly those based on epichlorohydrin and dimethylamine. The amounts of polymeric precipitants are 0.01 to 5 parts by weight, preferably 0.05 to 2.5 parts by weight, to 100 parts by weight of nitrile rubber. [0150] It is also conceivable to use other precipitants. However, it is possible to carry out the process according to the invention in the absence of additional precipitants without problems. [0151] The latex used for coagulation advantageously has a solids concentration in the range of from 1% to 40%, preferably in the range of from 5% to 35% and more preferably in the range of from 15% to 30% by weight. [0152] The latex coagulation is carried out in the temperature range of from 10 to 110° C., preferably of from 20 to 100° C., more preferably of from 50 to 98° C. The latex coagulation can be effected continuously or batchwise, preferably continuously. [0153] In an alternative embodiment, the latex, which has typically been separated off from unconverted monomers, can also be treated with acids at a pH in the range of ≦6, preferably ≦4, more preferably 2, which causes the polymer to precipitate out. All mineral and organic acids allowing the selected pH ranges to be established can be used for the precipitation. It is preferable to use mineral acids to adjust the pH. The polymer is subsequently separated off from the suspension in the manner customary to a person skilled in the art. This too can be effected continuously or batchwise, preferably continuously. Washing and Drying the Coagulated Nitrile Rubber: [0154] Following coagulation, the nitrile rubber is typically in the form of what is known as crumb. Washing the coagulated NBR is therefore also described as crumb washing. This washing can use either deionized water or non-deionized water. Washing is carried out at a temperature in the range of from 15° C. to 90° C., preferably at a temperature in the range of from 20° C. to 80° C. The amount of washing water is 0.5 to 20 parts by weight, preferably 1 to 10 parts by weight and more preferably 1 to 5 parts by weight, based on 100 parts by weight of nitrile rubber. The rubber crumb is preferably subjected to multistage washing and the rubber crumb is partially dewatered between the individual washing stages. The residual moistures of the crumb between the individual washing stages are in the range of from 5% to 50% by weight, preferably in the range of from 7% to 25% weight. The number of washing stages is typically 1 to 7, preferably 1 to 3. Washing is carried out batchwise or continuously. It is preferable to use a multistage continuous process and countercurrent washing is preferred for the sparing use of water. It has proven advantageous to dewater the nitrile rubber crumb once washing has been completed. Drying of the predewatered nitrile rubber is effected in a dryer and useful dryers include moving-bed dryers and plate dryers for example. The temperatures on drying are 80° C. to 150° C. Preference is given to drying with a temperature programme, wherein the temperature is reduced towards the end of the drying process. [0155] The invention further provides vulcanizable mixtures comprising at least one nitrile rubber according to the invention and at least one crosslinker. It is preferable for these vulcanizable mixtures to further comprise at least one filler. Furthermore, one or more additional typical rubber additives can be added to the mixtures. [0156] The production of these vulcanizable mixtures is effected by mixing at least one nitrile rubber according to the invention and at least one crosslinker. When one or more fillers and/or one or more further additives are used, these are also admixed. [0157] Useful crosslinkers are, for example, peroxidic crosslinkers such as bis(2,4-dichlorobenzyl) peroxide, dibenzoyl peroxide, bis(4-chlorobenzoyl) peroxide, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, tert-butyl perbenzoate, 2,2-bis(t-butylperoxy)butene, 4,4-di-tert-butyl peroxynonylvalerate, dicumyl peroxide, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, tert-butyl cumyl peroxide, 1,3-bis(t-butylperoxyisopropyl)benzene, di-t-butyl peroxide and 2,5-dimethyl-25-di(t-butylperoxy)-3-hexyne. [0158] It can be advantageous also to use, in addition to these peroxidic crosslinkers, further additions which can help to increase the crosslinking yield: Useful for this purpose are, for example, triallyl isocyanurate, triallyl cyanurate, trimethylolpropane tri(meth)acrylate, triallyltrimellitate, ethylene glycol dimethacrylate, butanediol dimethacrylate, trimethylolpropane trimethacrylate, zinc diacrylate, zinc dimethacrylate, 1,2-polybutadiene or N,N′-m-phenylenedimaleimide. [0159] The total amount of crosslinker(s) is typically in the range of from 1 to 20 phr, preferably in the range of from 1.5 to 15 phr and more preferably in the range of from 2 to 10 phr, based on the nitrile rubber. [0160] The crosslinkers used can also be sulphur in elemental soluble or insoluble form, or sulphur donors. [0161] Useful sulphur donors include, for example, dimorpholyl disulphide (DTDM), 2-morpholinodithiobenzothiazole (MBSS), caprolactam disulphide, dipentamethylenethiuram tetrasulphide (DPTT) and tetramethylthiuram disulphide (TMTD). [0162] Also in the sulphur vulcanization of the nitrile rubbers according to the invention, it is possible to use yet further additions which can help to increase the crosslinking yield. In principle however, the crosslinking can also be effected with sulphur or sulphur donors alone. [0163] Conversely, crosslinking of the nitrile rubbers according to the invention can, however, also be effected only in the presence of the additions mentioned hereinabove, i.e. without addition of elemental sulphur or sulphur donors. [0164] Useful additions which can help to increase the crosslinking yield are, for example, dithiocarbamates, thiurams, thiazoles, sulphenamides, xanthates, guanidine derivatives, caprolactams and thiourea derivatives. [0165] Dithiocarbamates used can be, for example: ammonium dimethyldithiocarbamate, sodium diethyldithiocarbamate (SDEC), sodium dibutyldithiocarbamate (SDBC), zinc dimethyldithiocarbamate (ZDMC), zinc diethyldithiocarbamate (ZDEC), zinc dibutyldithiocarbamate (ZDBC), zinc ethylphenyldithiocarbamate (ZEPC), zinc dibenzyldithiocarbamate (ZBEC), zinc pentamethylenedithiocarbamate (Z5MC), tellurium diethyldithiocarbamate, nickel dibutyldithiocarbamate, nickel dimethyldithiocarbamate and zinc diisononyldithiocarbamate. [0166] Thiurams used can be, for example, tetramethylthiuram disulphide (TMTD), tetramethylthiuram monosulphide (TMTM), dimethyldiphenylthiuram disulphide, tetrabenzylthiuram disulphide, dipentamethylenethiuram tetrasulphide or tetraethylthiuram disulphide (TETD). [0167] Thiazoles used can be, for example, 2-mercaptobenzothiazole (MBT), dibenzothiazyl disulphide (MBTS), zinc mercaptobenzothiazole (ZMBT) or copper 2-mercaptobenzothiazole. [0168] Sulphenamide derivatives used can be, for example, N-cyclohexyl-2-benzothiazylsulphenamide (CBS), N-tert-butyl-2-benzothiazylsulphenamide (TBBS), N,N′-dicyclohexyl-2-benzothiazylsulphenamide (DCBS), 2-morpholinothiobenzothiazole (MBS), N-oxydiethylenethiocarbamyl-N-tert-butylsulphenamide or oxydiethylenethiocarbamyl-N-oxyethylenesulphenamide. [0169] Xanthates used can be, for example, sodium dibutylxanthate, zinc isopropyldibutylxanthate or zinc dibutylxanthate. [0170] Guanidine derivatives used can be, for example, diphenylguanidine (DPG), di-o-tolylguanidine (DOTG) or o-tolylbiguanide (OTBG). [0171] Dithiophosphates used can be, for example, zinc dialkyldithiophosphates (chain length of the alkyl radicals of C 2 to C 16 ), copper dialkyldithiophosphates (chain length of the alkyl radicals of C 2 to C 16 ) or dithiophosphorylpolysulfide. [0172] A caprolactam used can be, for example, dithiobiscaprolactam. [0173] Thiourea derivatives used can be, for example, N,N′-diphenylthiourea (DPTU), diethylthiourea (DETU) and ethylenethiourea (ETU). [0174] Equally useful as additions are, for example, zinc diaminodiisocyanate, hexamethylenetetramine, 1,3-bis(citraconimidomethyl)benzene and cyclic disulphanes. [0175] The additions and crosslinking agents mentioned can be used either individually or in mixtures. It is preferable to use the following substances for crosslinking the nitrile rubbers: sulphur, 2-mercaptobenzothiazole, tetramethylthiuram disulphide, tetramethylthiuram monosulphide, zinc dibenzyldithiocarbamate, dipentamethylenethiuram tetrasulphide, zinc dialkyldithiophosphate, dimorpholyl disulphide, tellurium diethyldithiocarbamate, nickel dibutyldithiocarbamate, zinc dibutyldithiocarbamate, zinc dimethyldithiocarbamate and dithiobiscaprolactam. [0176] The crosslinking agents and aforementioned additions can each be used in amounts of from about 0.05 to 10 phr, preferably 0.1 to 8 phr, in particular 0.5 to 5 phr (single dose, based in each case on the active substance). [0177] In the sulphur crosslinking according to the invention, it may also be useful, in addition to the crosslinking agents and additions mentioned hereinabove, to use further inorganic or organic substances as well, such as zinc oxide, zinc carbonate, lead oxide, magnesium oxide, saturated or unsaturated organic fatty acids and zinc salts thereof, polyalcohols, amino alcohols, for example triethanolamine, and amines, for example dibutylamine, dicyclohexylamine, cyclohexylethylamine and polyether amines. [0178] In addition, it is also possible to use scorch retardants. These include cyclohexylthiophthalimide (CTP), N,N′-dinitrosopentamethylenetetramine (DNPT), phthalic anhydride (PTA) and diphenylnitrosamine. Preference is given to cyclohexylthiophthalimide (CTP). [0179] In addition to the addition of the crosslinker(s), the nitrile rubber according to the invention can also be mixed with other typical rubber additives. [0180] These include, for example, the typical substances known to a person skilled in the art, such as fillers, filler activators, antiozonants, ageing stabilizers, antioxidants, processing aids, extender oils, plasticizers, reinforcing materials and mould release agents. [0181] Fillers used can be, for example, carbon black, silica, barium sulphate, titanium dioxide, zinc oxide, calcium oxide, calcium carbonate, magnesium oxide, aluminium oxide, iron oxide, aluminium hydroxide, magnesium hydroxide, aluminium silicates, diatomaceous earth, talc, kaolins, bentonites, carbon nanotubes, Teflon (the latter preferably in powder form) or silicates. [0182] Useful filler activators are, in particular, organic silanes for example vinyltrimethyloxysilane, vinyldimethoxymethylsilane, vinyltriethoxysilane, vinyltris(2-methoxyethoxy)silane, N-cyclohexyl-3-aminopropyltrimethoxysilane, 3-aminopropyltrimethoxysilane, methyltrimethoxysilane, methyltriethoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, trimethylethoxysilane, isooctyltrimethoxysilane, isooctyltriethoxysilane, hexadecyltrimethoxysilane or (octadecyl)methyldimethoxysilane. Further filler activators are, for example, surface-active substances such as triethanolamine and ethylene glycols having molecular weights of 74 to 10 000 g/mol. The amount of filler activators is typically 0 to 10 phr, based on 100 phr of the nitrile rubber. [0183] Ageing stabilizers which can be added to the vulcanizable mixtures are those already described in this application in connection with latex coagulation. They are typically used in amounts of about 0 to 5 phr, preferably 0.5 to 3 phr, based on 100 phr of the nitrile rubber. [0184] Useful mould release agents are, for example, saturated or partly unsaturated fatty acids and oleic acids and derivatives thereof (fatty acid esters, fatty acid salts, fatty alcohols, fatty acid amides), which are preferably used as a mixture constituent, and furthermore products applicable to the mould surface, for example products based on low molecular weight silicone compounds, products based on fluoropolymers and products based on phenol resins. [0185] The mould release agents are used as a mixture constituent in amounts of from about 0 to 10 phr, preferably 0.5 to 5 phr, based on 100 phr of the nitrile rubber. [0186] Also possible is reinforcement with strengthening agents (fibres) of glass, according to the teaching of U.S. Pat. No. 4,826,721, and reinforcement by cords, woven fabrics, fibres made of aliphatic and aromatic polyamides (Nylon®, Aramid®), polyesters and natural fibre products. [0187] The mixing of the components for the purpose of producing the vulcanizable mixtures is typically effected either in an internal mixer or on a roll. Internal mixers used are typically those having what is known as an “intermeshing” rotor geometry. At the starting time, the internal mixer is charged with the nitrile rubber according to the invention. Said rubber is typically in bale form and is then initially comminuted. After a suitable period, which can be determined by a person skilled in the art without difficulty, the crosslinker, the filler(s) and additives are added. The mixing is effected under temperature control with the proviso that the mixture remains at a temperature in the range of from 100° C. to 150° C. for a suitable time. After a further suitable mixing period, further mixture constituents are added, for example antioxidants, plasticizers, white pigments (e.g. titanium dioxide), colourants and other processing aids. After a further suitable mixing period, the internal mixer is vented and the shaft is cleaned. After a further period, the internal mixer is emptied to obtain the vulcanizable mixture. All the aforementioned periods are typically in the region of a few minutes and can be determined by the person skilled in the art without difficulty depending on the mixture to be produced. If rolls are used as mixing units, it is possible to proceed in an analogous manner and sequence for the metered addition. [0188] The invention further provides a process for producing vulcanizates based on the nitrile rubbers according to the invention, characterized in that the vulcanizable mixtures comprising the nitrile rubber according to the invention are subjected to vulcanization. The vulcanization is typically effected at temperatures in the range of from 100° C. to 200° C., preferably at temperatures of from 120° C. to 190° C. and most preferably of from 130° C. to 180° C. [0189] To this end, the vulcanizable mixture is subjected to further processing by means of extruders, injection moulding systems, rolls or calenders. The preformed mass thus obtainable is then typically vulcanized to completion in presses, autoclaves, hot air systems, or in what are known as automatic mat vulcanization systems, temperatures in the range of from 120° C. to 200° C., preferably 140° C. to 190° C., having proven advantageous. The vulcanization time is typically 1 minute to 24 hours and preferably 2 minutes to 1 hour. Depending on the shape and size of the vulcanizates, a second vulcanization by reheating may be necessary to attain complete vulcanization. [0190] The invention accordingly provides the vulcanizates thus obtainable, based on the nitrile rubbers according to the invention. These vulcanizates may take the form of a drive belt, of roll coverings, of a seal, of a cap, of a stopper, of a hose, of floor covering, of sealing mats or sheets, of profiles or of membranes. Specifically, the vulcanizates can be an O-ring seal, a flat seal, a shaft sealing ring, a gasket sleeve, a sealing cap, a dust protection cap, a connector seal, a thermal insulation hose (with or without added PVC), an oil cooler hose, an air suction hose, a power steering hose, a shoe sole or parts thereof, or a pomp membrane. The nitrile rubbers according to the invention having a low emission quotient are very particularly suitable for producing floor coverings. EXAMPLES I Determining the Volatile Constituents Content [0191] The volatile constituents emissions within the meaning of formula (I) are detected in a TDS GC-MS analysis according to VDA recommendation 278 (version September 2002) between 28.4 and 34.0 min and related to an emission of “mg/kg of nitrile rubber”. A separating column DB-5MS of 60 m×0.25 mm, 1.00 μm (5% phenyl)-methylsiloxane was used; oven temperature 40° C. 1 min to 280° C., 5° C./min. II Production of Nitrile Rubbers A to J Inventive Examples and Comparative Examples [0192] Nitrile rubbers A to J used in the examples which follow were produced with the formulations and polymerization conditions specified in Table 1 and all starting materials are specified in parts by weight based on 100 parts by weight of the monomer mixture. [0193] The polymerization was effected batchwise in a 5 l autoclave with stirrer. For each of the autoclave batches, 1.25 kg of the monomer mixture, a total amount of water of 2.1 kg and EDTA in an equimolar amount based on the Fe(II) were employed. 1.9 kg of the amount of water were initially charged into the autoclave with the emulsifier and purged with a nitrogen stream. Thereafter, the destabilized monomers and the amount specified in Table 1 of the inventive molecular weight regulator or the noninventive molecular weight regulator were added and the reactor was sealed. Following thermostating of the reactor contents, the polymerizations were commenced by adding aqueous solutions of iron (II) salts (in the form of premixed solutions) and of para-menthanehydroperoxide (Trigonox® NT50). The premixed solution comprised 0.986 g of Fe(II)SO 4 *7H 2 O and 2.0 g of Rongalite C to 400 g of water. [0194] The course of the polymerization was monitored by gravimetric determinations of conversion. On attainment of the conversions specified in Table 1, the polymerization was stopped by adding an aqueous solution of diethylhydroxylamine. Unconverted monomers were removed by means of steam distillation. [0195] Prior to coagulation of the respective NBR latex, said latex was in each case admixed with a 50% strength dispersion of Vulkanox® BKF (0.3% by weight of Vulkanox® BKF based on NBR solids). The latex was subsequently coagulated, washed and the crumb obtained was dried. [0196] The dried NBR rubbers were characterized by Mooney viscosity ML 1+4@ 100° C. according to ASTM D 1646 and by the ACN content. Furthermore, the volatile constituents content required for the calculation of the emission quotient E according to formula (I) was determined as specified hereinabove under point I. [0000] TABLE 1 A B C D F H Com- Com- Com- Com- Com- Com- Nitrile rubber parison parison parison parison E parison G parison I J Butadiene 65 65 65 65 65 73 73 36/10 36/10 36/10 [% by weight based on sum of monomers] (total/increment 1) ) Acrylonitrile 35/9 35/9 35/9 35/9 35/9 27/9 27/9 64 64 64 [% by weight based on sum of monomers] (total/increment 2) ) Total amount of water 200 200 200 200 200 170 170 170 170 170 Oleic acid 1.5 1.5 1.5 1.5 1.5 1.4 1.4 1.4 1.4 1.4 Resin acid 3) 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 AOS 4) 0.2 0.2 0.2 0.2 0.2 0.4 0.4 0.4 0.4 0.4 Sulfole ® 120 0.650/ 0.650/ 0.420 0.600 (TDM) 5) 0.228 0.230 (total/increment 2) ) Sulfole ® 100 6) 0.400/ 0.450/ 0.420 (total/increment 2) ) 0.140 0.158 Sulfole ® 90 7) 0.350/ 0.250 0.385 (total/increment 2) ) 0.123 p-Menthane 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 hydroperoxide Premixed FeSO 4 8) 0.05 0.05 0.05 0.05 0.05 0.015 0.015 0.090 0.075 0.075 Diethylhydroxylamine 0.4 0.4 0.4 0.4 0.4 0.15 0.15 0.15 0.15 0.15 Vulkanox ® BKF 9) 0.3 0.3 0.3 0.3 0.3 0.1 0.1 0.1 0.1 0.1 pH 10) 11.0 ± 1.0 11.0 ± 1.0 11.0 ± 1.0 11.0 ± 1.0 11.0 ± 1.0 11.0 ± 1.0 11.0 ± 1.0 11.0 ± 1.0 11.0 ± 1.0 11.0 ± 1.0 Polymerization 11.5 ± 1.5 11.5 ± 1.5 11.5 ± 1.5 11.5 ± 1.5 11.5 ± 1.5 11.5 ± 1.5 11.5 ± 1.5 11.5 ± 1.5 11.5 ± 1.5 11.5 ± 1.5 temperature [° C.] Polymerization 56 58 56 79 78 80 78 71 68 69 conversion [%] Polymerization 5.5 7.25 7.5 6 6.25 5.75 6.0 3.5 3.75 5.0 time [h] 1) The increment was added at a monomer conversion of 52% 2) The increment was added at a monomer conversion of 36% 3) Sodium salt of disproportionated resin acid, CAS 61790-51-0 4) AOS: Sodium α-olefin sulphonate 5) Sulfole ® 120: t-DDM (tertiary dodecyl mercaptan); Chevron Phillips Chemicals 6) Sulfole ® 100: (Mixture of tertiary dodecyl mercaptan and tertiary nonyl mercaptan); Chevron Phillips Chemicals 7) Sulfole ® 90: (tertiary nonyl mercaptan); Chevron Phillips Chemicals 8) comprising the reducing agent Rongalit ® C (sodium salt of a sulphinic acid derivative) and the Fe(II)SO 4 . 9) 2-[(2-hydroxy-5-methyl-3-tert-butylphenyl)methyl]-4-methyl-6-tert-butylphenol; Lanxess Deutschland GmbH 10) measured on commencement of polymerization [0000] TABLE 2 Com- Com- Com- Com- Com- Com- Nitrile parison parison parison parison parison parison rubber A B C D E F G H I J ACN content (% by 35.0 35.3 34.7 34.1 34.1 28.0 28.5 49.6 50.5 49.6 weight) Mooney viscosity 57 50 38 36 48 65 63 76 80 83 (ML 1 + 4@100° C.) Volatile constituents 464 70 31 177 26 134 31 40 27 6 (mg/kg) 2) Emission quotient E 2.85 0.49 0.28 1.68 0.18 0.58 0.14 0.26 0.17 0.04 (mg/(kg Mu)) 3) 1) Mean value from duplicate TDS GC-MS analysis according to VDA recommendation 278 (September 2000) 2) Regulator constituents emissions for TDS GC-MS analysis according to VDA recommendation 278 (Version September 2000) between 28.4 und 34.0 min 3) Emission quotient E determined according to general formula (I) [0197] Table 2 clearly shows that the process according to the invention, using the specific molecular weight regulators while simultaneously fulfilling the condition that the polymerization conversion must be 60% or more, gives polymers clearly differing from the nitrile rubbers obtained using a conventional tert-dodecyl mercaptan and/or lower conversions in that they exhibit considerably reduced VOC values and regulator emissions in TDS GC-MS analyses. III Production of Vulcanizates of the Nitrile Rubbers A to F Inventive Examples and Comparative Examples [0198] The vulcanizates V1 to V7 were produced from the nitrile rubbers D to J by the method described hereinbelow. The amounts of the mixture constituents are based on 100 parts by weight of rubber and specified in Table 3. [0000] TABLE 3 Rubber mixtures V1 V3 V5 Com- Com- Com- Mixture parison V2 parison V4 parison V6 V7 Polymer D 100 Polymer E 100 Polymer F 100 Polymer G 100 Polymer H 100 Polymer I 100 Polymer J 100 Further mixture constituents Carbon black IRB 7 1) 40 40 40 40 40 40 40 Edenor ® C 18 98-100 2) 1 1 1 1 1 1 1 SULFUR SPIDER 3) 1.54 1.54 1.54 1.54 1.54 1.54 1.54 VULKACIT ® 0.7 0.7 0.7 0.7 0.7 0.7 0.7 NZ/EGC 4) IRM 91 5) 3 3 3 3 3 3 3 1) IRB 7: carbon black (Sid Richardson Carbon Co.) 2) Edenor ® C 18 98-100: stearic acid (Caldic) 3) SULFUR SPIDER: sulphur (S 8 ) (Krahn Chemie GmbH) 4) VULKACIT ® NZ/EGC: N-tert-butyl-2-benzothiazolesulphenamide (TBBS) (Lanxess Deutschland GmbH) 5) IRM 91: zinc(II) oxide: (Midwest Zinc) [0199] The mixtures were produced in a Banbury Mixer. To this end, the nitrile rubber and all additives named in Table 3 were mixed at a maximum temperature or up to 120° C. for a total of 4 minutes. To this end, the rubber was initially charged in the mixer, all further additives were added after 1 minute, and after 2 further minutes a reversal step was conducted. After a total of 4 minutes, the rubber was discharged from the mixer. The vulcanizates obtained had the properties specified in Table 4. [0200] The vulcanization characteristics of the mixtures were analysed according to ASTM D 5289-95 at 160° C. with the aid of a MDR2000 Moving Die Rheometer from Alpha Technology. The characteristic vulcameter values which follow were determined in this way. [0201] In this context: Min. torque: is the vulcameter reading at the minimum of the crosslinking isotherm Max. torque: is the maximum on the vulcameter display TS01: is the time in minutes in which the Mooney viscosity of the mixture increases by one Mooney unit compared to the starting value t 10 : time at which 10% of the final conversion/degree of vulcanization has been attained t 50 : time at which 50% of the final conversion/degree of vulcanization has been attained t 90 : time at which 90% of the final conversion/degree of vulcanization has been attained [0000] TABLE 4 Vulcanization characteristics V1 V3 V5 Com- Com- Com- Mixture parison V2 parison V4 parison V6 V7 MDR (160° C./30 min) Min. torque 1.3 1.8 2.8 2.9 2.1 2.2 2.5 (dNm) Max. torque 15.9 18.8 18.3 19.2 21.7 22.2 24.4 (dNm) TS01 2.7 2.6 2.5 2.3 1.9 1.8 1.5 (min) t 10 (min) 2.8 2.9 2.8 2.6 2.2 2.0 1.8 t 50 (min) 3.8 3.6 3.5 3.1 4.3 4.3 3.6 t 90 (min) 10.8 9.5 6.1 5.7 18.5 18.5 18.3 [0208] Compared to the respective comparative examples V1, V3 and V5, the mixtures V2, V4, V6 and V7, which are based on nitrile rubbers according to the invention, feature a higher maximum torque in the vulcanization which is an important parameter for the vulcanization characteristics. The resultant higher crosslinking density makes it possible for the user to reduce the amount of the starting materials for crosslinking in order to arrive at a crosslinking density equivalent to that of the comparative examples.
An improved polymerization process using a specific molecular weight regulator makes it possible to produce new nitrile rubbers featuring particularly low emission values and giving vulcanizates which have an advantageous profile of properties and which are of outstanding quality, in particular in odour-sensitive applications.
2
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part application of U.S. patent application Ser. No. 09/952,940, entitled “Concentrated Formulations and Methods for Neutralizing Chemical and Biological Toxants”, filed on Sep. 14, 2001 now U.S. Pat. No. 6,723,890, which is a continuation-in-part application of U.S. patent application Ser. No. 09/607,586, entitled “Formulations for Neutralization of Chemical and Biological Toxants”, filed on Jun. 29, 2000, now U.S. Pat. No. 6,566,574, and the specifications thereof are incorporated herein by reference. This application is also a continuation-in-part application of U.S. patent application Ser. No. 10/251,569, entitled “Enhanced Formulations for Neutralization of Chemical, Biological and Industrial Toxants”, filed on Sep. 20, 2002 now pending, which claimed the benefit of the filing of U.S. Provisional Patent Application Ser. No. 60/326,508, entitled “DF-200—An Enhanced Formulation for Decontamination and Mitigation of CBW Agents and Biological Pathogens”, filed on Oct. 1, 2001, and of U.S. Provisional Patent Application Ser. No. 60/334,271, entitled “Configurations for the Rapid Deployment of DF-200”, filed on Nov. 30, 2001, and of U.S. Provisional Patent Application Ser. No. 60/387,104, entitled “Decontamination Formulations”, filed on Jun. 7, 2002, and the specifications thereof are incorporated herein by reference. This application is also a continuation-in-part application of U.S. patent application Ser. No. 10/623,370, entitled “Decontamination Formulation with Sorbent Additive”, filed on Jul. 18, 2003 now pending, which claimed the benefit of the filing of U.S. Provisional Patent Application Ser. No. 60/397,424 entitled “Powdered Additive for DF-200,” filed on Jul. 19, 2002, and the specifications thereof are incorporated herein by reference. This application is also a continuation-in-part application of U.S. patent application Ser. No. 10/740,317, entitled “Granulated Decontamination Formulations,” filed on Dec. 18, 2003 now allowed, by M. D. Tucker, which claimed the benefit of the filing of U.S. Provisional Patent Application Ser. No. 60/446,642 entitled “DF-200 Configurations for Special Applications”, filed on Feb. 10, 2003, and the specifications thereof are incorporated herein by reference. GOVERNMENT RIGHTS The Government has rights to this invention pursuant to Contract No. DE-AC04-94AL85000 awarded by the U.S. Department of Energy. BACKGROUND OF THE INVENTION The present invention relates to decontamination formulations for disinfection and sterilization applications. In particular, the present invention is directed to aqueous formulations that include at least one reactive compound, bleaching activator, and inorganic base; and that allow the formulation to be pre-mixed and packaged as a two-part kit system. The aqueous decontamination formulations can be delivered in a wide variety of embodiments, including, but not limited to: foams, sprays, liquids, gels, fogs and aerosols. Much of the background of decontamination formulations has been previously discussed in the related patent applications and patent listed above. Briefly, the formulations of the present invention fall generally into two families, designated “DF-100” and “DF-200.” DF-100 formulations comprise, for example, a cationic surfactant (e.g., benzalkonium chloride) and a reactive compound (e.g., hydrogen peroxide mixed with potassium bicarbonate, which forms the highly reactive, negatively-charged nucleophillic species, hydroperoxycarbonate (HCO 4 − ), which is a strong oxidant), that when mixed with water (e.g., tap water, well water, seawater, etc.) and exposed to a toxant, neutralizes that toxant. The solubilizing agent serves to effectively render the toxant susceptible to attack, while the reactive compound serves to attack and neutralize the toxant. The second family of decontamination formulations, DF-200, are enhanced versions of DF-100. In DF-200, a bleaching activator (e.g., propylene glycol diacetate or glycerol diacetate) has been added to speed up reaction kinetics, improve performance, and eliminate the need for pH adjustment. In both DF-100 and DF-200 decontamination formulations some of the ingredients must be stored separately in order to prevent premature chemical reaction before use. For example, hydrogen peroxide must be stored separately from the other ingredients prior to use, due to its high reactivity. This can be accomplished by packaging the formulation as a multi-part kit system (e.g., 2-part, 3-part or 4-part kits). For example, a two-part kit system can be used, comprising a relatively inert component (Part A), and an active component (Part B) that comprises the reactive compound. The bulk of the make-up water may be “pre-packaged” in one of the two containers, which allows for rapid deployment of the decontamination solution, without the need for providing extra water in the field. Alternatively, the make-up water (including seawater) can be separately provided in the field, which greatly reduces the weight of the pre-packaged kit components, making the kit easier to ship and store. An example of a non-foaming DF-200 decontamination formulation is: DF-200NF (Enhanced Formulation for No Foam Applications) 2% Benzalkonium Chloride (Cationic Surfactant) 2% Glycerol Diacetate [Diacetin] (Bleaching Activator) 3% Hydrogen Peroxide (Oxidant) 5% Potassium Carbonate (Base, pH Buffer, and Peroxide Activator) 88% Water Note: The formulation should have a pH value between 9.6 and 9.85 after mixing. Although DF-100 and DF-200 decontamination formulations have been found to be highly effective in a number of applications for decontamination of chemical warfare agents (e.g., Sarin, Soman, VX, and Mustard), biological warfare agents (e.g., anthrax and plague), and toxic industrial chemicals (e.g., cyanide and phosgene), there is considerable interest in expanding this technology for use in more routine disinfection and sterilization applications. Examples of these applications include disinfection of food processing equipment, disinfection of areas containing livestock, mold remediation, sterilization of medical instruments, and direct disinfection of food surfaces, such as beef carcasses. DF-100 or DF-200 decontamination formulations are perfectly applicable for some of these proposed uses, such as for mold remediation or disinfection of livestock areas. However, DF-100 and DF-200 are less than desirable for the other proposed applications for two reasons. First, the application of DF-100 or DF-200 to a surface leaves a residue upon drying which needs to be rinsed before further use of certain items, such as food processing equipment or medical instruments. This residue is primarily caused by the cationic surfactant (e.g., benzalkonium chloride) that is used in some embodiments of the formulations. A second problem is that benzalkonium chloride is not approved for use on surfaces that will contact food unless it is used at very low concentrations (less than 400 mg/l), or unless it is thoroughly rinsed from the surface after use. The concentration of benzalkonium chloride in some embodiments of DF-100 or DF-200 decontamination formulations is approximately 20,000 mg/l in DF-200 and approximately 52,500 mg/l in DF-100. Both of these levels are well above the allowed concentration of 400 mg/l. Other ingredients in DF-200 (e.g., glycerol diacetate, hydrogen peroxide, potassium carbonate, water, etc.) are considered safe to be applied to food contact surfaces or directly to food surfaces. As noted above, previous versions of DF-200 decontamination formulations generally have a pH in the range of 9.6-9.85 after mixing. The higher pH, while useful for neutralization of chemical toxants, is not necessary for kill of biological pathogens. For disinfection and sterilization applications, it would be generally desirable to have a lower pH value (i.e., less than 9, and preferably in the range of 7-8). Some embodiments of DF-200 decontamination formulations are required to be packaged in three separate parts, which are mixed immediately before use. One reason that DF-200 is packaged as a three-component kit system is that it contains a novel bleaching activator (e.g., glycerol diacetate). Bleaching activators include compounds with O- or N-bounded acetyl groups, which react with strongly nucleophilic hydroperoxy anions (OOH − ) to yield peroxygenated species. The peroxygenated species is a more efficient oxidizer than hydrogen peroxide alone. However, a fundamental problem with the use of a bleaching activator is that it must be stored separately from water (since it will hydrolyze over time in an aqueous solution); and it must be stored separately from hydrogen peroxide (to prevent the peroxygenation reaction) until just prior to use. Therefore, because Part A contains water and Part B contains hydrogen peroxide, the bleaching activator is packaged as a separate component, Part C. An example of a three-part kit configuration for DF-200 is shown below: DF-200 (All-Liquid Three Part Kit Configuration) Part A: 2.0 g Variquat 80MC (cationic surfactant) 1.0 g Adogen 477 (cationic hydrotrope) 9.0 g Propylene Glycol (solvent and anti-freeze) 0.4 g 1-Dodecanol (foam stabilizer) 0.8 g Diethylene Glycol Monobutyl Ether (solvent) 0.5 g Isobutanol (solvent) 0.2 g Celquat SC-240C (water soluble polymer for viscosity boosting) 5.0 g Potassium Carbonate (base and pH buffer) 0.2 g Potassium Bicarbonate (pH buffer) 30.9 g De-ionized Water Part B: 43.3 g of 8% Hydrogen Peroxide Solution (oxidizer) Part C: 2.0 g Glycerol Diacetate [Diacetin] (bleaching activator) Note: Mix Part B into Part A. Then mix Part C into Part A/B. The final pH (after mixing) should be between 9.6 and 9.8. Total=100 grams of activated solution. Although the three parts of DF-200 in this example can be mixed together in a very short time, this three-part packaging requirement limits deployment options for the formulation. For example, it would be desirable to have the capability to deploy DF-200 in small hand-held spray bottles for personal use. Such a spray bottle could draw liquid formulation out of two separate chambers and conveniently mix the two liquids as they are sprayed. However, three-part kit configurations of DF-200 cannot be deployed using a two-component spray bottle. Previous formulations of DF-100/DF-200 used a high pH (e.g., 9.6) to provide effective decontamination of certain chemical agents (e.g., VX). However, a high pH is not necessary for effective kill of biological pathogens. A more neutral, lower pH (e.g., 7.5-8.0) would be preferred for disinfection and sterilization applications that don't involve chemical agent decontamination. Optionally, some or all of the various components/parts of a multi-part (e.g., 2-part or 3-part) kit system may be in the form of a dry, granulated, freely flowing powder that can be easily mixed with water that has been provided in the field. Such a dry powder material could be packaged with a desiccant for providing superior moisture protection, thereby extending the shelf life. Fortunately, one of the preferred reactive compounds, hydrogen peroxide, is available in a variety solid, granulated, water-soluble forms, including: urea hydrogen peroxide, sodium perborate, and sodium percarbonate. Most of the other ingredients that are used in DF-100/200 formulations (e.g., cationic surfactants, cationic hydrotropes, solvents, peroxide activators, freeze point depressants, etc.) are typically available only in liquid form. Sorbent materials can be used to “dry-out” these liquid ingredients and convert them into a dry, granulated, freely-flowing powder that is more easily handled and mixed in the field, without affecting the neutralization performance of the made-up (i.e., “activated”) decontamination solution. An all-granulated (all-dry) decontamination formulation would have the following advantages over an all-liquid or part-liquid plus part-granulated formulations: 1. Significant reduction in the weight of the formulation required to be shipped and stored. 2. Saltwater or other low quality water can be used as the make-up water. 3. The formulation can be stored in low temperature locations. 4. Increased shelf life due to removal of water from the formulation. Against this background, the present invention was developed. SUMMARY OF THE INVENTION The present invention relates to aqueous decontamination formulations that neutralize biological pathogens for disinfection and sterilization applications. Examples of suitable applications include disinfection of food processing equipment, disinfection of areas containing livestock, mold remediation, sterilization of medical instruments and direct disinfection of food surfaces, such as beef carcasses. The formulations include at least one reactive compound, bleaching activator, inorganic base, and water. The formulations can be packaged as a two-part kit system, and can have a pH value in the range of 7-8. DETAILED DESCRIPTION OF THE INVENTION The present invention addresses the need for decontamination formulations that neutralize the adverse effects of biological pathogens. Neutralization, disinfection, and sterilization are used interchangeably herein, and are defined as the mitigation, detoxification, decontamination, or otherwise destruction of biological pathogens to the extent that the biological pathogens no longer cause adverse effects to humans or animals. The formulation and described variations of the present invention can neutralize, and does not itself contain or produce, infection, significant adverse health effects, or even fatality in animals. The word “formulation” is defined herein as the made-up, activated product or solution (i.e., aqueous decontamination solution) that is applied to a surface or body, dispersed into the air, etc. for the purpose of neutralization, with or without the addition of a gas (e.g., air) to create foam. Unless otherwise specifically stated, the concentrations, constituents, or components listed herein are relative to the weight percentage of the made-up aqueous decontamination solution. The word “water” is defined herein to broadly include: pure water, tap water, well water, waste water, deionized water, demineralized water, saltwater, or any other liquid consisting primarily of H 2 O. A minimum set of ingredients for an aqueous decontamination solution for disinfection and sterilization applications, according to the present invention, comprises: a reactive compound selected from the group consisting of nucleophilic compounds and oxidizing compounds; a bleaching activator; an inorganic base; and water. Additional ingredients may optionally be added to the present invention, depending on the application and form of deployment. Some of the optional ingredients include: solubilizing compounds, cationic surfactants, cationic hydrotropes, solvents, fatty alcohols, freeze-point depressants, water-soluble polymers, foam stabilizers, pH buffers, corrosion inhibitors, sorbent additives for drying out liquid components, and combinations thereof. Examples of suitable reactive compounds include: peroxide compounds, activated peroxide compounds (e.g., hydrogen peroxide+bicarbonate), hydrogen peroxide, urea hydrogen peroxide, hydroperoxycarbonate, sodium perborate, sodium percarbonate, sodium carbonate perhydrate, sodium peroxysilicate, sodium peroxypyrophosphate, sodium peroxysilicate, sodium peroxysilicatehydrogen, peroxide adducts of pyrophosphates, citrates, sodium sulfate, urea, sodium silicate, peracetic acid, oximates (e.g., butane-2,3-dione, monooximate ion, and benzohydroxamate), alkoxides (e.g., methoxide and ethoxide), aryloxides (e.g., aryl substituted benzenesulfonates), aldehydes (e.g., glutaraldehyde), peroxymonosulfate, Fenton's reagent (a mixture of iron and peroxide), sodium hypochlorite, and combinations thereof. Use of these reactive compounds in the present invention can produce a variety of negatively-charged nucleophiles, e.g., hydroxyl ions (OH − ) and hydroperoxide ions (OOH − ) produced when using hydrogen peroxide; and/or hydroperoxycarbonate ions (HCO 4 − ) produced when hydrogen peroxide is combined with a carbonate salt. Hydroperoxycarbonate ions (HCO 4 − ) are much stronger oxidants than hydroxyl ions (OH − ) or hydroperoxide ions (OOH − ), and are especially effective in reacting with biological toxants. As mentioned above, the reactive compound may comprise hydroperoxycarbonate ions (HCO 4 − ), which are produced when hydrogen peroxide is combined with a carbonate salt in an aqueous solution. Examples of suitable carbonate salts include: potassium carbonate, potassium bicarbonate, sodium carbonate, sodium bicarbonate, sodium percarbonate ammonium bicarbonate, ammonium hydrogen bicarbonate, lithium bicarbonate, ammonium carbonate, and calcium carbonate. Addition of carbonate salts can also buffer the formulation to optimize the pH value. Examples of suitable inorganic bases include: potassium carbonate, potassium bicarbonate, potassium hydroxide, potassium sulfate, potassium phosphate (dibasic or tribasic), potassium borate, potassium tetraborate, potassium acetate, sodium carbonate, sodium bicarbonate, sodium hydroxide, sodium sulfate, sodium phosphate (dibasic or tribasic), sodium borate, sodium acetate, ammonium carbonate, ammonium bicarbonate, ammonium hydroxide, ammonium sulfate, ammonium phosphate (dibasic or tribasic), ammonium borate, ammonium acetate, calcium carbonate, calcium bicarbonate, calcium hydroxide, calcium sulfate, calcium phosphate (dibasic or tribasic), calcium borate, calcium acetate, magnesium carbonate, magnesium bicarbonate, magnesium hydroxide, magnesium sulfate, magnesium phosphate (dibasic or tribasic), magnesium borate, magnesium acetate, sodium percarbonate, ammonium hydrogen bicarbonate and lithium bicarbonate, and combinations thereof. Some of these inorganic bases, such as potassium acetate, potassium carbonate, potassium bicarbonate and potassium phosphate (dibasic or tribasic), can also serve as a buffer for controlling and optimizing the pH value of the made-up decontamination solution. Bleaching activators include compounds with O- or N-bounded acetyl groups or with nitrile groups that react with the strongly nucleophilic hydroperoxy anion (OOH − ) to yield peroxygenated species, which are more efficient oxidizers than hydrogen peroxide alone. Since the 1950's, a number of different bleaching activators have been used in commercial laundry detergents, as well as other commercial products. The most common activators are tetraacetyl ethylenediamine (TAED), which is primarily used in Europe and Asia; and n-nonanoyloxybenzenesulfonate (NOBS), which is primarily used in the United States; and N-acetyl pentaacetate. NOBS is a proprietary chemical of the Proctor and Gamble Company. In a laundry detergent, hydrogen peroxide is provided in a solid form (usually as sodium perborate, which reacts in water to form the hydroperoxy anion). The addition of a bleaching activator greatly enhances the ability of a laundry detergent to remove stains from clothing. It should be noted that TAED and NOBS bleaching activators are extremely insoluble in water (e.g., TAED is only 0.1% soluble at 25° C.). To get around this problem in a laundry detergent, the solid TAED or NOBS particles are kept in suspension by the agitating action of the washing machine, where they slowly react with the hydrogen peroxide in the detergent. However, agitating DF-200 solutions in the field presents practical problems; hence, water-soluble bleaching activators are preferred. Examples of suitable water-soluble bleaching activators, according to the present invention, include: short-chained organic compounds that contain an ester bond (e.g., ethylene glycol diacetate), propylene glycol monomethyl ether acetate, methyl acetate, dimethyl glutarate, diethylene glycol monoethyl ether acetate, glycerol acetate (monoacetin), glycerol diacetate (diacetin), glycerol triacetate (triacetin), acetylcholine chloride, 4-cyanobenzoic acid, propylene glycol diacetate, and combinations thereof. A preferred activator is diacetin (glycerol diacetate). Another preferred water-soluble bleaching activator is propylene glycol diacetate (PGDA), which is shown below. This molecule reacts with hydroperoxy anions (OOH − ), giving up the ester bonds to form two peroxygenated molecules. Propylene glycol diacetate (PGDA) also acts as an organic solvent that is highly effective in solubilizing insoluble organic molecules (e.g., chemical warfare agents, as well as foam stabilizers/boosters, such as 1-dodecanol and Lauramide DEA. Therefore, an added function of this compound is that it can be used to supplement the diethylene glycol monobutyl ether (DEGMBE) solvent that may be used in DF-100 and DF-100A formulations, or to supplement the di(propylene glycol) methyl ether solvent that may be used in some DF-200 formulations, thereby allowing the propylene glycol diacetate to serve a dual purpose (i.e., solvent and bleaching activator). Bleaching activators are generally not stable in water for long periods of time. This is especially true when the aqueous solution is at a high pH (>10). Therefore, for long shelf life, the propylene glycol diacetate (or other bleaching activator) is preferably stored separate from the aqueous solution until use: This is not unlike other products that utilize bleach activators (e.g., laundry detergents), where all the components of the formulation are kept dry and separated until use (note: in the case of laundry detergent, the bleaching activator is encapsulated to prevent it from prematurely reacting with the peroxide component until both components are mixed in water). Another example of a water-soluble bleaching activator is ethylene glycol diacetate, which also works well in DF-200 formulations. However, when ethylene glycol diacetate reacts with hydrogen peroxide it forms ethylene glycol (i.e., anti-freeze), which is a relatively toxic byproduct. Propylene glycol diacetate, on the other hand, does not form this relatively toxic byproduct. Solid O-acetyl bleaching activators (e.g., acetylcholine chloride, which is often used in eye drop solutions),may be used in place of (liquid) propylene glycol diacetate. The chemical structure of this O-acetyl bleaching activator is shown below. As can be seen, the molecule contains an O-acetyl group that can activate peroxide, and it is a quaternary compound, which is very compatible with DF-100/200 formulations. Acetylcholine chloride is also soluble in water, and is very hygroscopic. Three other O-acetyl bleaching activators, monoacetin (glycerol monoacetate) diacetin (glycerol diacetate), and triacetin (glycerol triacetate) have also been tested for their effectiveness in DF-200 formulations. All of these compounds have also proven to be extremely effective bleaching activators. These compounds are water-soluble liquids. Experiments have also shown that the peroxide in some DF-200 formulations is also effectively activated by a nitrile-containing compound, such as 4-cyanobenzoic acid (which is water-soluble), at a concentration of, for example, 2%, for the neutralization of both chemical agent and biological agent simulants. The present invention may additionally comprise one or more solubilizing compounds. Examples of suitable solubilizing compounds include: cationic surfactants, cationic hydrotropes, ethanol, and combinations thereof. Examples of suitable cationic surfactants include: quaternary ammonium salts and polymeric quaternary salts. Examples of suitable quaternary ammonium salts include: cetyltrimethyl ammonium bromide, benzalkonium chloride, benzethonium chloride, cetylpyridinium chloride, alkyldimethylbenzylammonium salt, tetrabutyl ammonium bromide, and combinations thereof. A preferred cationic surfactant is VARIQUAT 80MC™ (which used to be supplied by WITCO, Inc., but now is supplied by Degussa Goldschmidt). VARIQUAT 80MC™ comprises a mixture of benzyl (C12-C16) alkyldimethylammonium chlorides. A preferred concentration of quaternary ammonium salt used in these decontamination formulations is greater than about 0.1%, but less than about 10%, because at higher concentrations the quaternary ammonium salt becomes significantly toxic to humans and the environment. Examples of suitable cationic hydrotropes include: tetrapentyl ammonium bromide, triacetyl methyl ammonium bromide, tetrabutyl ammonium bromide, and combinations thereof. A preferred cationic hydrotrope is ADOGEN 477™ (which used to be supplied by WITCO, Inc., but now is supplied by Degussa Goldschmidt). ADOGEN 477™ comprises pentamethyltallow alkyltrimethylenediammonium dichloride. Ethanol may also be used as a solubilizing compound in the present invention because it is reported to have the capability to penetrate spore coats (Mechanisms of Killing Spores of Bacillus subtilis by Acid, Alkali and Ethanol, Setlow, B; Loshon, C A; Genest, P C; Cowan, A E; Setlow, C; Setlow, P, Journal of Applied Microbiology ; 2002; v. 92, no. 2, p. 362-375). Ethanol is also safe for application to food contact surfaces. Additionally, some low molecular weight alcohols are not only solubilizers, but are also antimicrobial. Examples of suitable fatty alcohols include alcohols having 8-20 carbon atoms per molecule, such as: 1-dodecanol, 1-tridecanol, hexadecanol, 1-tetradecanol, and combinations thereof. Examples of suitable freeze point depressants include proplyene glycol, or inorganic salts, such as potassium acetate. In foaming decontamination formulations, a cationic water-soluble polymer (e.g., Jaguar 8000™), may be used to increase the bulk viscosity of the solution and to produce a more stable foam. Some examples of suitable non-anionic water-soluble polymers include: polyvinyl alcohol, guar gum, (cationic or non-ionic) polydiallyl dimethyl ammonium chloride, polyacrylamide, glycerol, poly(ethylene oxide), poly(ethylene glycol), polyethylene glycol 8000 (e.g., PEG 8000), Jaguar 8000™ (Guar Gum 2-hydroxypropyl ether), polyquaternium compounds, and combinations thereof. A cationic polymer is preferred over a non-ionic polymer because anionic polymers do not work as well. Fatty alcohols, i.e., 1-dodecanol, serve to increase the surface viscosity of the foam lamellae and to increase foam stability against drainage and bubble collapse. Other foaming agents may also be included in high-foaming formulations, namely Celquat SD 240c (at about 0.15%) and/or Lumulse Poly-Ethoxylated Glycerine (POE 12), at about 4%). POE-12 is a preferred additive because it allows for a broader range of workable temperature; it is liquid at room temperature, while others in this class are not. Polyethylene glycol polymer (PEG 8000) may be used for viscosity enhancement. This polymer is used in many cosmetics and is extremely soluble and stable in water. In addition, it is easier to mix into solution than Jaguar 8000 or a high molecular weight poly(ethylene oxide), since it does not have the tendency to clump. In general, for any embodiments of the present invention, an acid or base may be added to the made-up decontamination solution, or to one of the Part A or Part B components, in order to adjust or buffer the final pH of the solution. Acid or base compounds may include, for example: KOH, citric acid, and HCL. Alternatively, sodium bisulfate (a common pool conditioning chemical), or other acid, can be used in place of citric acid to adjust the pH. Corrosion inhibitors may be added to certain embodiments of the present invention to reduce their corrosivity. A preferred corrosion inhibitor is N,N-dimethyl ethanolamine. Other corrosion inhibitors, such as triethanolamine, ethanolamine salts of C9, C10, and C12 diacid mixtures, dicyclohexyl amine nitrite, and N,N-dibenzylamine, may also be used. The corrosion inhibitors added to DF-100/200 formulations can serve multiple purposes, including: 1. a corrosion inhibitor, 2. a pH buffer, 3. a solvent to keep 1-dodecanol in solution, and 4. a co-solvent to solubilize insoluble chemical agents, such as sarin or mustard. Glycerol (glycerine) may be added to certain embodiments of the present invention as a viscosity builder (e.g., to replace Jaguar 8000, poly (ethylene oxide), or polyethylene glycol). Glycerol is a common ingredient in cosmetics, where it is used a viscosity builder, humectant, and emollient. Thus, the use of glycerol can serve multiple purposes: 1. viscosity builder, 2. a humectant (i.e., a substance which moisturizes the skin), 3. a solvent to keep 1-dedecanol in solution, and 4. a co-solvent to solubilize insoluble chemical agents, such as sarin or mustard. A drawback to the use of glycerol is that it is solid at a fairly high temperature (below about 10° C.). Therefore, it would preferably be used in controlled temperature conditions (i.e., warm temperature conditions). Alternatively, ethoxylated forms of glycerol [e.g., poly(ethoxylated glycerol)] can be used. These forms of glycerol have a lower freezing point. Sorbent additives optionally may be used to “dry out” one or more liquid ingredients of the aqueous decontamination formulation when pre-packaged in a multi-part kit system. A goal of “drying out” as many liquid ingredients as possible is to produce a dry, free-flowing, granulated powder or powders that can be placed in protective packaging (e.g., with a desiccant), have an extended shelf life, be more convenient to handle and mix in the field (as compared to handling and mixing a liquid), preferably not leave a residue, and have a reduced storage weight. In this way, the sorbent material acts as a drying agent to produce a granulated form. The process of “drying out” liquid ingredients is not really an evaporation process as it is commonly understood. Rather, the sorbent additive absorbs and/or adsorbs the liquid to produce a powdered, free-flowing, granulated product that is easier to handle. Preferably, the sorbent additive should not contain any water, since some of the liquid ingredients will hydrolyze or degrade in the presence of moisture. Preferably, the sorbent additive is water-soluble so that it can be rapidly dissolved and mixed, and leave no residue. Alternatively, a water-insoluble sorbent additive may be used (e.g., amorphous silica), if the presence of insoluble particles in the formulation is acceptable or desirable. For example, insoluble sorbent particles may be used to thicken and increase the viscosity of the made-up decontamination solution, effectively creating a gel that has increased “hang-time” on vertical surfaces. Alternatively, insoluble sorbent additives may be used as a cleaning solution and/or where an abrasive effect is desired. For some methods of application the presence of a sludge at the bottom of a container may not be a problem. However, the presence of insoluble sorbent particles in the made-up decontamination formulation may damage a pump mechanism, clog a spray nozzle, or leave an undesirable residue. The sorbent additive is preferably finely ground to a small particle size so that a large effective surface area can be provided for adsorbing/absorbing the liquid ingredient(s). The sorbent additive preferably is chemically compatible with the entire family of DF-100/200 formulations, and should not cause degradation of the decontamination solution's effectiveness, or degrade the foaming properties (if a foaming version is being used). The sorbent additive may be selected from elements/ingredients already found in the decontamination formulation. The sorbent additive may comprise a single compound, or a blend of different compounds. For example, in some foaming embodiments of DF-200, polyethlyene glycol (e.g., PEG 8000 or Carbowax 8000) is used as a viscosity builder for the foam. Since PEG 8000 is typically provided as a fine powder and is essentially anhydrous, then it can also serve as some (or all) of the sorbent additive for “drying out” liquid ingredients. Some examples of suitable compounds that may be used as the sorbent additive, either alone or in various combinations, according to the present invention, are listed in Table 1. TABLE 1 Sorbent Additives Sodium carbonate Sodium bicarbonate Potassium carbonate Potassium bicarbonate Calcium carbonate Potassium silicate Precipitated silicates Percarbonates Amorphous silica (fumed silica) Sodium Citrate Dendritic Salt (e.g., sea salt) Citric Acid Polyethylene Glycols, (e.g., PEG 8000) Urea Polyols (e.g., Sorbitol, Mannitol) Some examples of suitable polyols that may be used as a sorbent additive are listed in Table 2. TABLE 2 Polyol Sorbent Additives Sorbitol, Mannitol, Hydrogenated Starch Hydrolysates (HSH), Maltitol, Zylitol, Lactitol Monohydrate, Anhydrous Isomalt, Erythritol, and Polydextrose. The polyols listed above are sugar-free sweeteners. They are carbohydrates, but they are not sugars. Chemically, polyols are considered polyhydric alcohols or “sugar alcohols” because part of the structure resembles sugar and part is similar to alcohols. However, these sugar-free sweeteners are neither sugars nor alcohols, as those words are commonly used. They are derived from carbohydrates whose carbonyl group (e.g., aldehyde or ketone, reducing sugar) has been reduced to a primary or secondary hydroxyl group. The most widely used polyols in the food industry are sorbitol, mannitol, and malitol. Sorbitol is derived from glucose; mannitol from fructose; and malitol from high maltose corn syrup. Sorbogem™ and Mannogem™ are product names for sorbitol and mannitol sold by SPI Polyols, Inc., which are available in a wide range of particle size, down to fine sizes (i.e., Sorbogem Fines™). Sorbitol is a hexahydric alcohol (C 6 H 14 O 6 ) corresponding to glucose, and has a molecular weight of 182.2. It occurs naturally, and can be produced by the hydrogenation of glucose syrup in the presence of Raney Nickel Catalyst. Some synonyms for sorbitol include: cholaxine, clucitol, diakarmon, gulitol, 1-gulitol, karion, nivitin, sionit, sorbicolan, sorbite, d-sorbitol, sorbo, sorbol, sorbostyl, sorvilande. Sorbitol has a CAS No. 50-70-4 and an EC No. 200-061-5. Alternatively, the sorbent additive may be selected to be a “G.R.A.S.” material, meaning that it is Generally Accepted As Safe to be used in this and other applications. Alternatively, the sorbent additive may comprise amorphous silica (i.e., fumed silica). Amorphous silica, which is water-insoluble, is commercially available from the Cabot Corporation under the trade name CAB-O-SIL® in a wide variety of particle sizes, surface areas, bulk densities, and pour densities. CAB-O-SIL® powders are untreated, high-purity, amorphous fumed silicas manufactured by high temperature hydrolysis of chlorosilanes in a hydrogen/oxygen flame. They have extremely small particle sizes, enormous surface areas (from 130-380 m 2 /g), and can form three-dimensional branched chain aggregates with a length of approximately 0.2-0.3 microns. Further agglomeration takes place during manufacturing to yield a fine, white fluffy powder with an agglomerate size of less than about 44 microns (325 US Mesh). When amorphous silica is used as an optional sorbent additive in the present invention, the dispersed amorphous silica can create a gel, which helps to increase the contact time. Amorphous silica is chemically un-reactive in DF-100/200 formulations, and, thus, does not change its performance against chemical and biological agents when used at relatively low concentrations. A first example of an aqueous decontamination formulation for disinfection and sterilization applications, according to the present invention, is shown below: Formulation #1 50 g of 8% Hydrogen Peroxide Solution 8 g Diacetin 6 g Ethanol 7 g Potassium Carbonate 29 g Deionized Water The pH of this formulation is 9.60. The total amount is 100 grams. The hydrogen peroxide concentration in this formulation is 4%. Spore kill tests were performed on Formulation #1 using Bacillus globigii spores. Spores (initial concentration of 3.4×10 7 CFU/ml) were exposed to the formulation for contact times of 15 minutes and 60 minutes. No spore growth was observed on any culture plates after either of the contact times. This corresponds to 7-log kill in this formulation. A second example, according to the present invention, is shown below: Formulation #2 50 g of 8% Hydrogen Peroxide Solution 8 g Diacetin 7 g Potassium Carbonate 35 g Deionized Water The initial pH of this formulation was 9.23. Potassium Hydroxide was added to bring the pH to 9.53. The total amount is 100 grams. The hydrogen peroxide concentration in this formulation is 4%. Spore kill tests were performed on Formulation #2 using Bacillus globigii spores. Spores (initial concentration of 4.4×10 7 CFU/ml) were exposed to the formulation for contact times of 15 minutes and 60 minutes. No spore growth was observed on any culture plates after either of these contact times. This corresponds to 7-log kill of the spores in this formulation. To investigate the beneficial effects of using a bleaching activator, spore kill tests were performed on a simplified formulation without a bleaching activator containing 4% hydrogen peroxide, 5% potassium bicarbonate, and 91% water. These tests showed only 3-log kill in this formulation after a 60 minute contact time, clearly demonstrating the increased efficacy obtained when a bleaching activator (e.g., diacetin) is used. In Formulations #1 and #2, the cationic surfactant, benzalkonium chloride, was eliminated because of the previously mentioned problems with leaving a residue upon drying, and also because it is not approved for use on surfaces that contact food (unless at very low concentrations, less than 400 mg/l). Next, we present two examples of the present invention that do use a cationic surfactant (i.e., benzalkonium chloride), and that replaces the potassium carbonate base/buffer with an alternative bass/buffer (i.e., potassium acetate). Two advantages of potassium acetate over potassium carbonate are that (1) acetates tend to be even less corrosive than carbonate (which is only slightly corrosive itself), and (2) it serves as an antifreeze agent and crystal de-icer in aqueous solutions. However, potassium acetate is a much weaker base, so the final pH of the made-up formulation is around 8.0 (which is preferred over the higher pH of ˜9.5). The two examples that utilize potassium acetate are shown below: Formulation #3 50 g of 8% Hydrogen Peroxide Solution 8 g Diacetin 20 g Potassium Acetate 4 g Benzalkonium Chloride 18 g Propylene Glycol The initial pH of this formulation was 7.82. The total amount is 100 grams. No pH adjustment was made. The hydrogen peroxide concentration in this formulation is 4%. Spore kill tests were performed on Formulation #3 using Bacillus globigii spores. Spores with initial concentrations of 1.08×10 8 CFU/ml and 9.6×10 7 CFU/ml were exposed to the formulation for contact times of 15 minutes and 60 minutes, respectively. No spore growth was observed on any culture plates after either of these contact times. This corresponds to 7 to 8-log kill of the spores in this formulation. Formulation #4 50 g of 8% Hydrogen Peroxide Solution 6 g Deionized Water 4 g Diacetin 20 g Potassium Acetate 2 g Benzalkonium Chloride 18 g Propylene Glycol The initial pH of this formulation was 7.54. No pH adjustment was made. The total amount is 100 grams. The hydrogen peroxide concentration in this formulation is 4%. Spore kill tests were performed on Formulation #4 using Bacillus globigii spores. Spores with initial concentrations of 1.19×10 8 CFU/ml and 1.56×10 8 CFU/ml were exposed to the formulation for contact times of 15 minutes and 60 minutes, respectively. No significant spore growth was observed on any culture plates after either of these contact times. This corresponds to 8-log kill of the spores in this formulation. A fifth example, according to the present invention, is shown below: Formulation #5 0.5-60% reactive compound 1-10% bleaching activator 3-30% inorganic base 0-5% cationic surfactant 0-10% ethanol 0-20% freeze-point depressant water (remainder) In formulation #5, the reactive compound may comprise hydrogen peroxide; the bleaching activator may comprise glycerol diacetate or propylene glycol diacetate; the inorganic base may comprise potassium acetate or potassium carbonate; the cationic surfactant may comprise benzalkonium chloride; and the freeze-point depressant may comprise propylene glycol. A sixth example, according to the present invention, is shown below: Formulation #6 0.5-60% hydrogen peroxide 1-10% glycerol diacetate or propylene glycol diacetate 3-10% potassium carbonate 0-10% ethanol water (remainder) Optionally, Formulation #6 may comprise no amount of a cationic surfactant (i.e., benzalkonium chloride). A seventh example, according to the present invention, is shown below: Formulation #7 0.5-60% hydrogen peroxide 1-10% glycerol diacetate or propylene glycol diacetate 5-30% potassium acetate 0-20% proplyene glycol water (remainder) Optionally, Formulation #7 may comprise no amount of a carbonate salt (i.e., potassium carbonate). Two-Part Kit System The decontamination formulations of the present invention may be packaged as a two-part kit system (i.e., Part A and Part B) kit system. When all of the water is “pre-packaged” in either of Part A or Part B, the mixing of the formulation for use can be accomplished in a very short time since it only consists of two parts. Therefore, it could be deployed very easily and rapidly at the scene of an incident involving biological pathogens or agents. This configuration is ideal for use the civilian first responder (firefighter, HazMat units, police officers, and others who would be the first to arrive at the location of a CBW attack). However, it is heavier to store and carry than other kit configurations that must add water in the field. Although it is not required, all of the organic ingredients may be placed in Part A, and all of the inorganic ingredients may be placed in Part B. A first example of a two-part kit system is shown below: Two-Part Kit System, Example #1 Part A (organic components) bleaching activator Part B (inorganic components) reactive compound inorganic base water Optionally, Part A may additionally comprise: solubilizing compounds, cationic surfactants, cationic hydrotropes, solvents, fatty alcohols, freeze-point depressants, water-soluble polymers, foam stabilizers, pH buffers, corrosion inhibitors, sorbent additives for drying out liquid components, and combinations thereof. Optionally, Part B may comprise pH buffers and sorbent additives. The inorganic base may comprise potassium acetate or potassium tetraborate. A second example of a two-part kit system is shown below (wherein the total amount of solution when Parts A and B are mixed together equals 100 grams): Two-Part Kit System, Example #2 Part A (organic components) 1-10 grams of a bleaching activator 0-4 grams of a cationic surfactant 0-2 grams of a cationic hydrotrope 0-20 grams of a freeze-point depressant 0-0.6 grams of a fatty alcohol 0-2 grams of a solvent 0-6 grams of a water-soluble polymer 0-6 grams of an organic base Part B (inorganic components) 3-70 grams of 8% hydrogen peroxide solution 5-20 grams of an inorganic base sufficient water to make up 100 grams of made-up solution. In this second example of a two-part kit system, the bleaching activator may comprise glycerol diacetate or propylene glycol diacetate; the cationic surfactant may comprise benzalkonium chloride; the inorganic base may comprise potassium acetate (which serves as a base/buffer and antifreeze agent); the freeze-point depressant may comprise propylene glycol; the fatty alcohol may comprise 1-dodecanol; the solvent may comprise diethylene glycol monobutyl ether and isobutanol; the water-soluble polymer may comprise poly-ethoxylated glycerine; the organic base may comprise triethanolamine; and the inorganic base may comprise potassium acetate. A third example of a two-part kit system is shown below (wherein the total amount of solution when Parts A and B are mixed together equals 100 grams): Two-Part Kit System, Example #3 Part A (organic components) 2 g Variquat 80MC 1 g Adogen 477 10 g Propylene Glycol 0.4 g 1-Dodecanol 0.8 g Diethylene Glycol Monobutyl Ether 0.5 g Isobutanol 4 g Poly-Ethoxylated Glycerine [POE (12)] 4 g Glycerol Diacetate (Diacetin) Part B (inorganic components) 50 g 8% Hydrogen Peroxide Solution 15 g Potassium Acetate 12.3 g De-ionized Water Mix Part A into Part B. The final pH (after mixing) should be between 7.5 and 8.0. In Example #3, Part A contains all organic components and Part B contains all inorganic components and water. The peroxide activator (glycerol diacetate in Part A) is protected from water and hydrogen peroxide, both of which are packaged in Part B. In order to configure DF-200 as a two-part (or binary) system, three fundamental changes were made to standard three-part DF-200 formulations. 1. Elimination of Potassium Carbonate and Bicarbonate—these serve as a base and pH buffer in the three-part DF-200 configuration. In the two-part configuration, these constituents were replaced by potassium acetate. Potassium acetate is also a base and a pH buffer. Carbonate and bicarbonate were eliminated because it would be necessary to place them in Part B (since they are inorganic) but this is not possible because they react with hydrogen peroxide. Testing of this two-part configuration demonstrated that a mixture of peroxide and acetate is stable, as will be described below. Potassium acetate also allows for additional effects that carbonates, etc. cannot provide. 2. Elimination of Celquat SC-240C—The water soluble polymer Celquat SC-240C was replaced by an organic viscosity- booster, poly-ethoxylated glycerine. Since it is water soluble, Celquat SC-240C would have to be placed in Part B where it would react with and degrade the hydrogen peroxide over time. Poly-ethoxylated glycerol (e.g., POE-12) is placed in Part A with the other organic constituents. POE-12 also maintains its working function over a larger range of environments (e.g., pH, Temp, etc.) than do others in this family. 3. Higher Glycerol Diacetate (peroxide activator) Concentration—It should be noted that the pH of this configuration (Example #3) is lower (˜7.5) than the three-part DF-200 configuration (˜9.6). The higher pH in the original three-part configuration is necessary to decontaminate certain chemical agents (e.g., VX); and to produce a high concentration of the peracetate molecule (the pH for the deprotonation reaction of hydrogen peroxide is 9.6—therefore, formation of the OOH − species, which reacts with glycerol diacetate to form peracetate, is optimal at pH values near 10). The higher pH is not necessary for kill of biological pathogens. A pH between 7.5-8.0 will achieve a very high level kill of microorganisms (including bacterial spores), as shown below. The lower concentration of the peracetate molecule (at this lower pH) is compensated for by adding a higher concentration of glycerol diacetate, which drives the peracetate production reaction to the right, thereby producing more peracetate. A fourth example of a two-part kit system is shown below (wherein the total amount of solution when Parts A and B are mixed together equals 100 grams): Two-Part Kit System, Example #4 Part A Part B  2 g Variquat 80MC 50 g 8% Hydrogen Peroxide Solution  4 g Glycerol Diacetate 20 g Potassium Acetate 18 g Propylene Glycol  6 g De-ionized Water The pH (after mixing) was ˜7.5. Spore kill tests were performed on the two-part DF-200 formulation of Example #4 using Bacillus globigii spores. Spores (initial concentration of 1.2×10 8 CFU/ml) were exposed to the formulation for contact times of 15 minutes and 60 minutes. No significant spore growth was observed on any culture plates after either of these contact times. This corresponds to 7-log kill of the spores in this formulation. In order to assess the stability of the individual parts in these two-part kit systems, the solution containing hydrogen peroxide and potassium acetate (i.e., Part B in the two-part DF-200 formulation) was tested for the presence of hydrolysis by-products, peracetate formation, and peroxide stability. The tests were conducted at both room temperature (˜23° C.) and at an elevated temperature (˜80° C.). There were no hydrolysis by-products detected in the solution, which was verified by several testing methodologies. No peracetate formation or degradation of the peroxide was detected, either. The addition of the potassium acetate to the peroxide/water blend has no apparent effect in destabilizing the H 2 O 2 solution (Part B) above what is seen in a solution of commercially-available stabilized H 2 O 2 +H 2 O. In fact, potassium acetate is used by some companies as a stabilizer of peroxide (albeit at much lower concentrations). Note that an organic base, such as triethanolamine (TEA), can also be added to any of the 2-part kit configurations to increase the pH, and to provide corrosion protection. TEA is a common ingredient in many cosmetics including some shampoos. Because TEA is an organic, it is placed in Part A. Another example of a two-part configuration for DF-200, Example #5, is shown below: Two-Part Kit System, Example #5 Part A: Part B:   2 g Variquat 80MC   50 g 8% Hydrogen Peroxide Solution   1 g Adogen 477 24.3 g De-Ionized Water  10 g Propylene Glycol 0.4 g 1-Dodecanol 0.8 g Diethylene Glycol      Monobutyl Ether 0.5 g Isobutanol   4 g Poly-Ethoxylated      Glycerine [POE (12)]   4 g Glycerol Diacetate      (Diacetin)   3 g Triethanolamine (TEA) In this example, potassium acetate was removed and replaced with the organic base, triethanolamine (TEA). Note that this configuration contains only one inorganic constituent (i.e., H 2 O 2 ). The only base is the organic constituent, TEA. Another example of a two-part configuration for DF-200, Example #6, is shown below: Two-Part Kit System, Example #6 Part A: Part B:  2 g Variquat 80MC   50 g 8% Hydrogen Peroxide Solution  4 g Glycerol Diacetate 24.3 g Deionized Water 18 g Propylene Glycol  3 g Triethanolamine The pH (after mixing) was ˜8.5. Spore kill tests were performed using Bacillus globigii spores. Spores (initial concentration of ˜1.0×10 8 CFU/ml) were exposed to the formulation for contact times of 15 minutes and 60 minutes. Interestingly, no significant spore kill was achieved after either of these contact times. These results suggest that the presence of an inorganic base and/or buffer (e.g., potassium, sodium, ammonium, calcium, or magnesium salts of carbonate, bicarbonate, hydroxide, sulfate, phosphate, borate, and/or acetate) helps to achieve high rates of spore kill in DF-200. Optionally, the two-part kit systems may comprise no amount of a cationic surfactant. Alternatively, the two-part kit systems may comprise no amount of benzalkonium chloride. Alternatively, the two-part kit systems may comprise no amount of a cationic surfactant. Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents.
Aqueous decontamination formulations that neutralize biological pathogens for disinfection and sterilization applications. Examples of suitable applications include disinfection of food processing equipment, disinfection of areas containing livestock, mold remediation, sterilization of medical instruments and direct disinfection of food surfaces, such as beef carcasses. The formulations include at least one reactive compound, bleaching activator, inorganic base, and water. The formulations can be packaged as a two-part kit system, and can have a pH value in the range of 7-8.
8
BACKGROUND OF THE INVENTION The present invention relates generally to cleaning implements, and more particularly to such implements which additionally serve as disposable receptacles for waste matter. Removal of waste matter such as dog litter from sidewalks and yards is often accomplished using implements which become soiled and present a sanitary problem around the house. Cleaning up after pets also presents the problem of the proper disposal of the waste matter collected. Nevertheless, concerns over health and aesthetics and new laws in many communities have prompted increasing numbers of pet owners to clean up the litter created by their pets. The need for cleaning and storage of reusable implements for removing pet litter and the waste disposal problem both contribute significantly to the onerousness of the task. OBJECTS AND SUMMARY OF THE INVENTION It is a general object of the invention to provide a waste matter removal implement which is fully self-contained and is disposable. It is another object of the invention to provide such an implement which also serves as a receptacle for waste matter. It is another object of the invention to provide such an implement and receptacle which serves as an envelope prior to use for holding additional items to form a waste matter removal kit. Accordingly, a waste matter removal implement and receptacle is provided which includes an envelope formed of sheet material folded along predetermined fold lines. The envelope has a receiving portion forming an enclosure with an opening, and a flap portion joined to the received portion along a first fold line which also forms a line of weakness. The flap portion tucks into the opening of the receiving portion to close the envelope. The flap portion is readily detachable from the receiving portion along the first fold line to form a cooperating member for pushing waste matter into the opening of the receiving portion. Additional objects and features of the invention will be evident from the following description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of a foldable blank sheet for use in forming the implement and receptacle of the present invention. FIG. 2 is a perspective view of a disposal bag and glove for use in a kit according to the present invention. FIG. 3 is an elevational perspective view showing the assembly of the sheet material of FIG. 1 and the invention therein in accordance with the present invention. FIG. 4 is an elevational perspective view of a waste matter removal kit according to the invention in fully assembled merchandisable condition. FIG. 5 is an elevational perspective view as in FIG. 3, on a reduced scale, illustrating the use of the invention. FIG. 6 is a view as in FIG. 5 illustrating the disposal procedure when using the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIG. 1, the waste matter removal implement and receptacle of the invention includes an envelope which can be fabricated from a unitary blank of sheet material 10 such as cardboard. Blank 10 is provided with a plurality of predetermined fold lines which permit the blank to be folded into the shape of an envelope. The fold lines define separate panels of the sheet material which are folded together to form the envelope. A flap portion 12 of the envelope is joined to a receiving portion, as generally represented at 14, along a first fold line 16. Line 16 is perforated to form a line of weakness along which flap 12 is readily detachable from the remainder of the envelope. A pair of side panels 18 and 20 are joined to opposing edges of a bottom panel 22 along a pair of fold lines 23 and 24, respectively. An end panel 26 is joined to bottom panel 22 along a fourth fold line 27. The bottom panel 22, as defined by the four fold lines 16, 23, 24 and 27, can be substantially rectangular. To facilitate the forming of the envelope, the end panel 26 is provided with oppositely extending tabs 28 and 30, each having a diagonal fold line 32. Cooperating fold lines 32a are similarly provided in the side panels 18 and 20. An envelope is formed by folding the end panel 26 upwardly along the line 27 and the tabs 28 and 30 inwardly about tab fold lines 33. Side panels 18 and 20 are now folded upwardly about fold lines 23 and 24, respectively, to bring the cooperating fold lines 32 and 32a into register. In such position the end tabs can be secured inwardly of the side panels by gluing, stapling, or in another convenient fashion, joining the end and side panels. As best illustrated in FIG. 3, the tab and side panel fold lines 32, 32a and 33, cooperate with one another such that the end panel 26 is collapsible over the side panels 18 and 20 to form an envelope. The initial conversion of the envelope described above to a merchandisable kit is generally represented by FIGS. 3 and 4. Thus, the side panels 18 and 20 and end panel 26 are movable relative to back panel 22 between the open position of FIG. 3, in which the side and end panels are substantially perpendicular to the bottom panel, and a collapsed position as shown in FIG. 4, in which the side and end panels overlie the back panel. Due to the cooperating folds between the side and end panels, all of the panels raise up together with the envelope is opened. The receiving portion 14 of the envelope is thus an enclosure having three sides (panels 18, 20, and 26) and a bottom (panel 22), with an opening 38 overlying the bottom and extending between the sides. To close the envelope, flap portion 12 tucks into opening 38 under the end panel 26 to achieve the collapsed position shown in FIG. 4. The envelope is opened by sliding flap 12 from beneath end panel 26 and then raising the end and side panels. Referring to FIG. 2, the invention additionally includes a disposal bag 40 and glove 42. Bag 40 is any suitable bag formed of a disposable material such as paper and preferably foldable to a size slightly smaller than bottom panel 22 of the envelope. Glove 42 is preferably a disposable clear plastic glove of the type which can be worn on either hand. To assemble a complete kit according to the invention, bag 40 and glove 42 are inserted in a completed envelope, as shown in FIG. 3. The envelope is then closed and the completed waste matter removal kit assumes a compact and convenient shape, as shown in FIG. 4. Use of the present invention is shown in FIG. 5. The kit is carried in the closed position until needed. To collect waste matter, the kit is opened and the bag and glove removed. After putting on the glove, the user detaches flap 12 from receiving portion 14 along the perforated line of weakness 16. The sides and end panels are raised to the open position to form receiving portion 14 into a scoop. With the user holding both receiver 14 and flap 12, as shown in FIG. 5, flap 12 is used to push waste matter 44 into opening 38 of the receiver 14. The receiver 14 can then be collapsed to form a retentive envelope. Following use, the receiver 14, flap 12 and glove 42 are all deposited in bag 40, as shown in FIG. 6, for convenient disposal. The present invention provides a convenient and inexpensive kit which can be easily carried, for example in a coat pocket or purse. The kit is fully self-contained and affords maximum convenience and sanitation for the user. When formed as a scoop, the receiver 14 functions as a receptacle as well as a cleaning implement. Because of the low cost, the entire kit is simply thrown away, eliminating any need for subsequent cleaning or storage of the implement. Alternative constructions are possible within the scope of the invention. For example, the envelope portion could assume other shapes. Also, the flap portion could have a different shape or be attached to a different portion of the envelope. In general, a waste matter removal implement is provided which is fully self-contained and disposable. The implement serves as a receptacle for waste matter. The invention further provides an envelope which serves to hold additional items forming a waste matter removal kit.
An implement is provided for removing waste matter such as dog litter. The implement also forms a receptacle for convenient disposal. An envelope formed of sheet material such as cardboard opens to form a scoop with a detachable flap. When collapsed, the envelope holds a disposal bag and sanitary glove and the flap tucks into the scoop portion to form a convenient package.
4
FIELD OF THE INVENTION [0001] The present invention relates to improvements in or relating to downhole tools, and is more particularly, although not exclusively, concerned with reamer tools. BACKGROUND TO THE INVENTION [0002] Earth formation drilling utilises a long string of drilling pipes and tools coupled together. All elements of the drilling string are rotated together in order to rotate a cutting bit at the end of the drilling sting. The cutting bit creates a hole in a formation through which the rest of the drilling string moves in a drilling direction. An under-reamer, coupled between two other elements of the drilling string, is used to widen the walls of the hole created by the drill bit. The under-reamer, also known as a reamer, normally has an overall diameter in its retracted position which is the same as or less than the diameter of the hole being drilled. When in its deployed position, cutting elements are moved away from the body of the under-reamer to define a diameter which is larger than the diameter of the hole being drilled. As the under-reamer moves downhole rotating with the drilling string, it widens the hole in the formation behind the drill bit. In addition, an under-reamer may be used to open a collapsed formation on its way back up to the surface. [0003] WO-A-2005/124094 describes one such under-reamer or reamer tool. The reamer tool comprises a tubular body having an axial cavity and housings arranged around its periphery to define external openings. In each of these openings, a cutter element is housed which comprises two cutter arms that can be moved between a retracted position where each cutter element is fully retained within its associated housing, and an expanded position where each cutting element extends outside its opening so that more material can be cut away the walls of the hole in a formation thereby enlarging its diameter. A drive mechanism is provided within the tubular body to move the cutter elements between their retracted and expanded positions. [0004] In the reamer tool described in WO-A-2005/124094, one cutter arm is pivotally connected to the tubular body at one end and to the other cutter arm at the other end, the other cutter arm being connected to the drive mechanism so that both cutter arms can be retracted and expanded. The arrangement formed by the two cutter arms when deployed is a ‘V’-shape where the vertex of the V is outside the opening. [0005] Typically, such reamer tools are operated by the pressure of fluid passing through the drill string, and in particular, through the tool section itself. The pressure of fluid is controlled by the operation of a pump associated with the drill string. In US-A-2010/0006339, the pressure of fluid passing through the tool is used to operate the reamer so that it is expanded or retracted in accordance therewith. Here, the reamer assembly comprises cutter elements and stabiliser pads mounted for sliding movement on grooves. In the retracted position, the reamer assembly is housed within a recess, the reamer assembly being moved to the expanded position by movement along the grooves so that it is outside the recess. Fluid pressure is sensed to activate the expansion and retraction of the reamer. [0006] US-A-2010/0096191 discloses an under-reaming and stabilisation tool in which a blade element is moved from a retracted position to an expanded position by wedge elements coupled to a drive tube, the wedge elements interact with an inclined face of the blade element to effect the raising (expansion) and lowering (retraction) of the blade element relative to a guide channel. As the drive tube moves along the length of the tool body, the wedge elements are drawn along therewith and they slide under the inclined face of the blade element causing radial movement of the blade element to raise out (expand) out of its guide channel. Movement of the drive tube in the opposite direction along the length of the tool body withdraws the wedge elements from under the inclined face of the blade element allowing radial movement of the blade element to lower (retract) into its guide channel. The expansion of the blade element is limited by the actuation mechanism, that is, the drive tube and wedge elements coupled thereto. SUMMARY OF THE INVENTION [0007] It is therefore an object of the present invention to provide an improved reamer tool in which the cutter arms or blades are maintained parallel to the axis of the reamer tool in both its retracted and deployed positions as well as during expansion and retraction whilst providing a higher opening range. [0008] It is a further object of the present invention to provide a reamer tool in which the opening can be adjusted at the surface in accordance with a value within the opening range whilst providing a more efficient reamer tool. [0009] In accordance with a first aspect of the present invention, there is provided a reamer tool comprising: [0010] a substantially hollow body having a longitudinal axis and including an external wall having a first outer diameter; [0011] at least one arm bay formed in a portion of the external wall around the periphery of the body; [0012] at least one expandable arm located in an associated arm bay and mounted for expansion between a retracted position within the body and an expanded position in which each expandable arm describes a second outer diameter which is greater than the first outer diameter; and [0013] at least one expansion mechanism for expanding an associated expandable arm between the retracted and expanded positions; [0014] characterised in that each expansion mechanism comprises two elongate links pivotally connected to the associated expandable arm at one end position and to its associated arm bay at another end position, each expandable arm being pivotally mounted at the two end positions with respect to its associated arm bay so that each expandable arm is maintained substantially parallel to the longitudinal axis of the body in both the retracted and expanded positions and during its expansion and retraction between the retracted and expanded positions. [0015] By having links connecting each expandable arm to its associated arm bay, the expandable arm can be maintained substantially parallel to the longitudinal axis of the reamer tool thereby providing an opening range which is greater than that possible with expansion mechanisms comprising wedge elements or the like. [0016] In the case where the downhole tool comprises a reamer tool, the advantage of maintaining the expandable arm parallel to the longitudinal axis of the body is that the attack point for each cutting blade is reliable, the attack point being the point at which a leading cutting element engages with the material or formation to be cut. [0017] Naturally, an actuation mechanism is also provided for activating the expansion mechanism, each expandable arm being pivotally connected at another end position to the actuation mechanism. [0018] Advantageously, the expansion mechanism further comprises a third elongate link pivotally connected to each expandable arm and to the actuation mechanism. [0019] In this way, the actuation mechanism directly moves the expandable arm and the other elongate links serve to maintain the substantial parallelism with the longitudinal axis. In a preferred embodiment, the actuation mechanism comprises a piston. [0020] The downhole tool may further comprise at least one return member for deactivating each deployment mechanism. In one embodiment, each return member comprises a spring biased against the action of the actuation mechanism. [0021] A shoulder block may be provided which is locatable in each arm bay to limit the expansion of the expandable arm. By selecting a suitably sized shoulder block, the expansion of the expandable arm can be determined to provide a desired outer diameter for engagement with a formation. [0022] In a preferred embodiment, the second outer diameter may be up to 1.3 times the first outer diameter. For example, if the outer diameter of the downhole tool is 100 cm, the expandable arms may be expanded to describe an outer diameter of up to 130 cm. [0023] Preferably, the downhole tool comprises a reamer tool and each expandable arm comprises a cutter arm. [0024] In accordance with another aspect of the present invention, there is provided an expandable cutter arm for a downhole tool, the expandable cutter arm comprising at least a front cutting blade and a back cutting blade, each cutting blade comprising a plurality of cutting elements, one cutting element on each of the front cutting blade and the back cutting blade providing an attack point for the associated cutting blade. [0025] Such an expandable cutter arm may further comprise a first side and a second side located either side of a plane, each side being spaced at respective predetermined distances from a plane so that the attack point for the front blade and the attack point for the back blade are equi-spaced from the plane. [0026] By having the attack point for each cutter arm equi-spaced from the plane, efficiency of the reamer tool is improved. In addition, a more flexible reamer tool is provided in which a range of opening sizes can be accommodated. [0027] The predetermined distance for the first side may be different to the predetermined distance for the second side. [0028] In one embodiment, the cutting elements may comprise polycrystalline diamond cutting elements. [0029] In accordance with a further aspect of the present invention, there is provided a reamer tool having at least one expandable cutter arm as described above. [0030] In accordance with another aspect of the present invention, there is provided a reamer tool having a longitudinal axis, the reamer tool comprising at least one expandable cutter arm having a plurality of cutting elements arranged to form at least a front cutting blade and a back cutting blade, one of the cutting elements on the front cutting blade and one of the cutting elements on the back cutting blade providing respective attack points for their associated cutting blades, characterised in that the attack point for the front cutting blade and the attack point for the back cutting blade are equi-spaced from a plane extending through the longitudinal axis. [0031] The reamer tool preferably further comprises at least one expansion mechanism for expanding an associated expandable cutter arm between a retracted position and an expanded position, and an actuation mechanism for activating each expansion mechanism. [0032] In a preferred embodiment, each expansion mechanism comprises at least two elongate links pivotally connected to the associated expandable cutter arm at one end position and to its associated arm bay at another end position, each expandable cutter arm being pivotally mounted at the two end positions with respect to its associated arm bas so that each expandable cutter arm is maintained substantially parallel to the longitudinal axis in both the retracted and expanded positions, and, during expansion and retraction between the retracted and expanded positions. [0033] The expansion mechanism advantageously further comprises a third elongate link pivotally connected to each expandable cutter arm and to the actuation mechanism, each expandable cutter arm being pivotally connected at another end position to the actuation mechanism. [0034] The actuation mechanism preferably comprises a piston. The reamer tool may further comprise at least one return member for deactivating each expansion mechanism. [0035] A shoulder block may be provided which is locatable in each arm bay to limit the expansion of the expandable cutter arm. The cutter arm may have an opening range up to 1.3 times the outer diameter of the reamer tool, the shoulder block limiting the opening in accordance with it size. [0036] In accordance with another aspect of the present invention, there is provided a control module for a downhole tool, the downhole tool including a substantially hollow body having a longitudinal axis, at least one arm bay formed around the periphery of the substantially hollow body, at least one expandable arm located in an associated arm bay and mounted for expansion between a retracted position within the substantially hollow body and an expanded position in which the expandable arm describes a second outer diameter which is greater than the first outer diameter, at least one expansion mechanism for expanding an associated expandable arm between the retracted and expanded positions, and a piston for operating each expandable arm, the control module comprising: [0037] an element mounted within the body which is moveable between a first position and second position; [0038] a motor controlling the movement of the element; and [0039] a gearing mechanism associated with the motor for transferring drive from the motor to the element; [0040] characterised in that the control module further comprises a chamber and a port, the chamber being associated with the piston and the port having an open position and a closed position, the open and closed position being determined by the second and first positions respectively of the element; [0041] and in that the port, in its open position, allows fluid to flow into the chamber and to increase the pressure therein for operation of the piston to expand each expandable arm. [0042] In a preferred embodiment, the motor and gearing mechanism are mounted between the element and the external wall of the body. A power source is preferably located within the body of the reamer tool. This has the advantage of protecting the control module, that is, the motor, gearing mechanism and power source from the environment in which the reamer tool operates. [0043] In one embodiment, the power source comprises a battery. In another embodiment, the power source comprises a turbine arranged to generate power for the motor. [0044] The control module may further comprise at least one positional sensor for sensing the position of the element within the body. In addition, at least one pressure sensor may also be provided for sensing the pressure within the chamber. [0045] In addition, at least one sensor may be provided for sensing at least a change in pressure in fluid flowing through the downhole tool, each sensor providing a control signal for the motor. Moreover, at least one sensor may be provided for sensing a change in rotational speed of the downhole tool, each sensor providing a control signal for the motor. [0046] Additionally, a communications system may be provided through which control signals are provided for the motor. In one embodiment, the communications system includes a wired link over which control signals are transmitted. BRIEF DESCRIPTION OF THE DRAWINGS [0047] For a better understanding of the present invention, reference will now be made, by way of example only, to the accompanying drawings in which: [0048] FIG. 1 illustrates a schematic sectioned view of a reamer tool in accordance with the present invention, the reamer tool being shown in a retracted position; [0049] FIG. 2 is similar to FIG. 1 but illustrates the reamer tool in an expanded position; [0050] FIG. 3 illustrates cutters mounted on an arm of the reamer tool shown in FIGS. 1 and 2 ; [0051] FIG. 4 illustrates a sectioned view of a control system for the reamer tool shown FIGS. 1 and 2 with the reamer tool in the stowed position; [0052] FIG. 5 is similar to FIG. 4 but illustrates the control system with the reamer tool in the expanded position. DESCRIPTION OF THE INVENTION [0053] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. [0054] It will be understood that the terms “vertical” and “horizontal” are used herein refer to particular orientations of the Figures and these terms are not limitations to the specific embodiments described herein. In addition, the terms “top” and “bottom” are used to refer to parts of a drill string that face towards the surface, or top of the drill string, and away from the surface, or bottom of the drill string, respectively. [0055] The present invention relates to an improved reamer tool and a control system for operating such a reamer tool or other downhole tool. The reamer tool is described below with reference to FIGS. 1 to 3 and the control system is described with reference to FIGS. 4 and 5 . [0056] Although the present invention is described below with respect to a reamer tool having cutter arms, it is equally applicable to a downhole tool that may also be used for stabilisation. In this case, the cutter arms are replaced by stabilising pad arms which, when expanded, contact the walls of a formation to stabilise the drill string of which the tool forms a part. In addition, although the control system is described with reference to use with a reamer tool, it is not limited to use with a reamer tool and can be used with any other downhole tool. [0057] Reamer tools, as well as other downhole tools, are operated, that is, expanded and retracted by changes in the pressure of fluid flowing through the associated drill string. The fluid flow is controlled by a pump associated with the drill string. Changes in fluid pressure are detected by sensors located at appropriate positions in the drill string. [0058] Referring initially to FIGS. 1 and 2 , a longitudinal sectioned view of reamer tool 100 is shown. The reamer tool 100 comprises a reamer body 105 having three cutter arms 110 mounted within respective housings or arm bays 115 formed in the reamer body 105 . The three cutter arms 110 are equi-spaced around the periphery of the reamer body 105 but only one such cutter arm is shown in FIGS. 1 and 2 . [0059] Each cutter arm 110 comprises a cutting element or cutting blade 120 which is pivotally mounted on each of three elongate links 125 , 130 , 135 at respective pivot points 140 , 145 , 150 as shown. Two of the elongate links 125 , 130 are also pivotally attached to the housing or arm bay 115 at respective pivot points 155 , 160 . The third elongate link 135 is also pivotally mounted, by means of a pivot point 165 , on a piston 170 . [0060] The piston 170 comprises an actuation mechanism and is operated to move from a first position as shown in FIG. 1 to a second position as shown in FIG. 2 to expand the cutter arms 110 , and more particularly, the cutting elements or cutting blades 120 , from a retracted position to an expanded position where the cutting elements or cutting blades 120 extend outside the reamer body 105 and define an outer diameter which is up to 1.3 times that of the normal outer diameter of the reamer body 105 . [0061] It will be appreciated that, in other embodiments of the reamer tool 100 in accordance with the present invention, the outer diameter defined by the three cutter arms 110 and their cutting elements or cutting blades 120 may have other ratios compared to the outer diameter of the reamer body 105 as required, and, is therefore not limited to up to 1.3 times the outer diameter of the reamer body 105 . The outer diameter is limited by a shoulder block 175 and the size of the shoulder block 175 is chosen at the surface before introduction of the drill string of which the reamer tool 100 forms a part into a wellbore in a formation in accordance with the outer diameter of the reamer tool 100 required to from the wellbore in the formation. [0062] It will be appreciated that shoulder blocks of different sizes can be provided with the reamer tool 100 and an appropriately sized shoulder block is chosen to limit the expansion of the cutter arms 110 to control the outer diameter defined by the expanded cutter arms 110 and cutting elements or cutting blades 120 within an opening range from the same outer diameter of the reamer body 105 to 1.3 times that outer diameter. [0063] In the deployment of the cutter arms 110 from inside their respective housings or arm bays 115 formed in the reamer body 105 , the cutting structure (not shown) of each cutter arm 110 always remains parallel to a longitudinal axis 180 of the reamer body 105 . The pivot points 140 , 145 , 150 , 155 , 160 , 165 formed on respective ones of the links 125 , 130 , 135 , as described above, effectively provide pivoting axes about which rotation can occur to expand and retract the cutter arms 110 and cutting elements or cutting blades 120 out of and into their respective housings or arm bays 115 . However, pivot points 140 , 145 provided on respective links 125 , 130 ensure that the cutter arms 110 remain parallel to the reamer body 105 as they are expanded, used for cutting and retracted into their respective housings or arm bays 115 . Pivot point 150 provided on elongate link 135 is used to expand and retract the associated cutter arm 110 in accordance with the movement of the piston 170 or other actuation mechanism as will be described in more detail below. [0064] By using an expansion mechanism which utilises elongate links pivotally connected to both the cutter arm 110 and the housing or arm bay 115 as well as to the piston 170 or other actuation mechanism, the effective outer diameter of the cutter arm 110 and cutting element or cutting blade 120 can extend up to 1.3 times the outer diameter of the reamer body 105 . In addition, the amount of expansion can easily be limited by a suitable shoulder block 175 . [0065] The force for expanding the cutter arms 110 is provided by pressure applied to the piston 170 , and, the force for retracting the cutter arms is provided by a spring 185 (described below with reference to FIGS. 4 and 5 ). The applied pressure is provided by fluid flow through the reamer body 105 as will be described in more detail below. [0066] As shown in FIGS. 1 and 2 , the reamer body 105 is substantially tubular with a hollow central portion 190 which defines a fluid flow path. The piston 170 is mounted within the reamer body 105 and is operated by fluid flowing therethrough as will described in more detail with reference to FIGS. 4 and 5 below. [0067] In the embodiment of the reamer tool 100 described above, it is essential to ensure that the cutting elements, for example, polycrystalline diamond cutters known as PDC cutters, function adequately during the expansion stages to make contact with the formation in which the reamer tool is to be used. This is described in more detail with respect to FIG. 3 . [0068] In FIG. 3 , a portion 200 of a cutter arm 110 of the reamer tool 100 shown in FIGS. 1 and 2 is shown in more detail. The positioning of the cutting elements with respect to the cutter arm 110 is shown. The portion 200 shows a single cutter arm 110 ( FIG. 1 ) having two cutting blades 205 , 210 , a front cutting blade 205 and a back cutting blade 210 . [The terms “front” and “back” refer to the order in which the cutting blades make contact with the walls of a wellbore formed in a formation and is determined by the direction of rotation of the drill string (not shown) of which the reamer tool 100 ( FIG. 1 ) forms a part.] [0069] In the embodiment shown in FIG. 3 , five cutting elements 215 , 220 , 225 , 230 , 235 are visible on front cutting blade 205 , and six cutting elements 240 , 245 , 250 , 255 , 260 , 265 are visible on back cutting blade 210 . Cutting element 215 on front cutting blade 205 and cutting element 240 on back cutting blade 210 have respective attack points 270 , 275 which are equi-spaced from a plane 280 that is coincident with the longitudinal axis 180 of the reamer body 105 ( FIG. 1 ). This means that the distance from side 285 of front cutting blade 205 to the plane 280 is shorter than the distance from side 290 of back cutting blade 210 to plane 280 . [0070] In the embodiment shown in FIG. 3 , the cutting elements 215 , 220 , 225 , 230 , 235 , 240 , 245 , 250 , 255 , 260 , 265 comprise PDC elements as shown. Although eleven PDC elements are visible, the number of PDC elements present on each blade 205 , 210 is determined in accordance with the dimensions of the PDC element and the dimension of the reamer tool itself. However, it will be appreciated that other types of cutting elements may also be used, for example, impregnated cutting elements. [0071] By having the attack points 270 , 275 equi-spaced from the plane 280 , attack points 270 , 275 will contact the formation for any opening size in the opening range. If the attack points 270 , 275 are not equi-distant from the plane 280 , the cutter arms will only have one possible opening size to ensure that both the front and back cutting blades make contact with the formation. [0072] The front and back blades 205 , 210 as described above have different numbers of cutting elements 215 , 220 , 225 , 230 , 235 , 240 , 245 , 250 , 255 , 260 , 265 which are not aligned with one another so that the attack points 270 , 275 of cutting elements 215 , 240 are at different heights with respect to the reamer body 105 . [0073] The effective outer diameter of the reamer tool 100 , that is, the opening size is determined by the positions of attack points 270 , 275 . [0074] Referring now to FIGS. 4 and 5 , a schematic longitudinal sectioned view of the reamer tool 100 is shown. Components that have previously been described with reference to FIGS. 1 and 2 have the same reference numerals. [0075] The reamer tool 100 comprises the reamer body 105 having cutter arms 110 mounted within respective housings or arm bays 115 formed in the reamer body 105 as described above. The links and the pivot points that operate the cutter arms 110 as described above are not shown for clarity. The spring 185 that is used to return the expanded cutter arms to their retracted position is shown schematically as a block. [0076] As described above, the force for expanding the cutter arms 110 is provided by pressure applied to the piston 170 due to fluid flow through the reamer tool 100 , and, the force for retracting the cutter arms is provided by the spring 185 . During expansion of the cutter arms, the pressure exerted on the piston 170 creates a force which is greater than the force provided by the spring 185 . Once the pressure exerted on the piston 170 falls sufficiently so that the force exerted becomes less than the force provided by the spring 185 , the spring 185 causes the cutter arms 110 to be retracted into their respective housings or arm bays 115 . This is described in more detail below. [0077] A control system 300 for deploying the cutter arms 110 is provided within the reamer body 105 and comprises an electric motor 310 , a gearing system 315 and a moveable sleeve 320 , the electric motor 310 and gearing system 315 being housed between the sleeve 320 and an external wall 325 of the reamer body 105 . The electric motor 310 rotates at a first predetermined speed and the gearing system 315 reduces that first predetermined speed to a second lower predetermined speed which is used for operating the moveable sleeve 320 . In one embodiment, a ball screw (not shown) may be used to transfer the rotational output from the gearing system 315 to a linear movement which is used to move the sleeve 320 to open and close port 385 as will be described in more detail below. However, it will be appreciated that other arrangements may be used for transferring rotary motion from the gearing system 315 to linear motion of the moveable sleeve 320 , for example, a pinion or worm gear forming part of the gearing system 315 may engage with a rack element provided on the moveable sleeve 320 . [0078] The electric motor 310 may be powered by a battery (not shown) or from a turbine provided in the drill string (also not shown), the turbine generating a current from the fluid flow therethrough. Although a gearing system 315 is described, it will be appreciated that drive from the motor may be converted into linear movement by any suitable means for converting the output of the motor into linear movement. [0079] The housing or arm bay 115 for each cutter arm 110 is defined by a wall 330 of the hollow central portion 190 and a portion 335 of the external wall 325 of the reamer body 105 . The piston 170 is defined by a chamber 340 adjacent the cutter arm 110 , the chamber 340 being defined by the wall 330 of the central portion 190 , external wall 325 of the reamer body 105 , sleeve 320 , first cylindrical portion 345 , second cylindrical portion 350 and end wall 355 as shown. End wall 355 also forms barrier between the electric motor 310 and gearing system 315 of the control system 300 . [0080] Annular seals 360 , 365 are provided between the first cylindrical portion 345 and respective ones of wall 330 and sleeve 320 . Additional annular seals 370 , 375 are provided between sleeve 320 and second cylindrical portion 350 and with wall 380 of hollow central portion 190 . Seal 360 can be mounted on either the first cylindrical portion 345 or the wall 330 as the first cylindrical portion 345 does not move relative to the wall 330 . [0081] The first and second cylindrical portions 345 , 350 define the port 385 which is sealed by the moveable sleeve 320 when in a first position, as shown in FIG. 4 , so that fluid flows through the hollow central portion 190 as indicated by arrow 390 . When the sleeve 320 is in a second position, as shown in FIG. 5 , the port 385 is open and fluid can flow into chamber 340 as shown by arrow 395 . [0082] An additional seal 400 is also provided between the piston 170 and the external wall 325 of the reamer body 105 as shown to prevent ingress of drilling fluid as the piston 170 moves from the position shown in FIG. 4 to the position shown in FIG. 5 . [0083] Operation of the electric motor 310 effectively moves the sleeve 320 in the same direction as arrow 390 to open the port 385 and in the opposite direction to close the port 385 , drive from the electric motor 310 being transmitted to the sleeve 320 via the gearing system 315 . A control signal for the electric motor 310 is provided by way of an increased fluid flow rate through the hollow central portion 190 and/or speed of rotation of the drill string (not shown). At least one suitable sensor (not shown) is provided to sense the change in pressure and/or rotational speed and to provide a control signal for the electric motor 310 , for example, a pressure sensor for sensing changes in pressure and an accelerometer for sensing the change in rotational speed. However, other sensors may also be used for sensing the change in rotational speed. [0084] It will be appreciated that the electric motor 310 may be a bi-directional motor that operates in two directions to effect opening and closing of the port 385 . As an alternative to the electric motor 310 , a solenoid may be used to effect opening and closing of the port 385 . [0085] Naturally, the electric motor 310 and gearing system 315 are sealed within a region 410 defined by the sleeve 320 and an external wall 325 so that it is protected from the drilling environment, that is, the mud, rock etc., that finds its way into the hollow central region 190 . In a preferred embodiment, the region 410 is filled with oil to prevent the ingress debris from the drilling environment. [0086] Before the cutter arms 110 are expanded, they are housed in their respective housings or arm bays 115 as described above. Fluid flow is through the hollow central portion 190 as indicated by arrow 390 ( FIG. 4 ). When a control signal is sent to the electric motor 310 , by way of a change in pressure of the fluid flowing through the hollow central portion 190 and/or a change in the rotational speed of the drill string as described above, the electric motor 310 operates the moveable sleeve 320 to move it in the same direction as the fluid flow as indicated by arrow 390 to open port 385 ( FIG. 5 ). [0087] When the port 385 is opened, fluid flows into the chamber 340 and pressure builds up therein. When the pressure in the chamber 340 reaches a value where the force exerted by the piston 170 is greater than the force exerted by the spring 185 , the piston 170 is pushed from the position shown in FIG. 4 towards the arm bays 115 to expand the cutter arms 110 as shown in FIG. 5 . Movement of the piston 170 towards the arm bays 115 causes each cutter arm 110 to pivot about pivot point 150 on link 135 , as well as pivot points 140 , 145 on links 125 , 130 , so that it is expanded from the within its associated arm bay 115 as shown in FIGS. 1 and 4 , to the position as shown in FIGS. 2 and 5 . Fluid built up in the chamber 340 flows out of nozzles 415 associated with the cutter arms 110 maintaining the position of the piston 170 as shown in FIGS. 2 and 5 , and hence the expansion of the cutter arms 110 , until the port 385 is closed by the sleeve 320 by the operation of the motor 310 and gearing mechanism 315 . [0088] On receipt of a further control signal, that is, another change in pressure of the fluid flow and/or a change in rotational speed of the drill string, the motor 310 is activated once again to move the moveable sleeve 320 from the position shown in FIG. 5 back to the position shown in FIG. 4 , thereby closing the port 385 so that no more fluid flows into the chamber 340 as indicated by arrow 395 . Fluid flows out of nozzles 415 until the pressure in the chamber 340 is reduced so that the force of the spring 185 causes the cutter arms 110 to be returned to their associated housing or arm bay 115 to be returned to the position shown in FIGS. 1 and 4 . In addition, the piston 170 is pushed back but the force exerted by the spring 185 to its initial position as shown in FIGS. 1 and 4 . [0089] Alternatively, instead of operating the motor 310 , the cutter arms 110 may be retracted by turning the pump off that is associated with the drill string so that fluid flow is switched off through the drill string, and the pressure in the chamber 340 falls as no further fluid flows through the port 385 and into the chamber 340 . Once the pressure in the chamber 340 falls to a value where the force exerted by the spring 185 exceeds that of provided by the pressure in the chamber 340 , the piston 170 is moved back to the position shown in FIGS. 1 and 4 and the cutting arms 110 retracted whilst still parallel to the longitudinal axis 180 due to their pivoting about points 140 , 145 , 150 ; pivoting of the links 125 , 130 about points 155 , 160 in the respective housing or arm bay 115 ; and pivoting about pivot point 165 due to movement of the piston 170 as it moves from the position shown in FIG. 5 back to the position shown in FIG. 4 . [0090] As mentioned above, the control system 300 includes a power supply (not shown), but it may also include other electronic equipment, for example, pressure sensors for sensing the pressure in the chamber 340 , accelerometers for measuring the speed of movement of the sleeve 320 and piston 170 and the rotational speed of the drill string, as well as the speed of the cutter arm 110 during its expansion and retraction phases. In addition, a communication device (not shown) may be provided through which control signals can be provided for the electric motor in the case where the control signals are not supplied by changes in pressure of the fluid flow or rotational speed of the drill string as described above. [0091] The power supply may be provided by one or more batteries or via a wired link from the surface. Additionally, the wired link may form part of the communication device through which the control signals may be transmitted to the electric motor. [0092] It will be appreciated that the cutter arm expansion mechanism can be used with other tools, for example, downhole stabilisers, and the cutter arms can be expanded using other expansion mechanisms. [0093] Although a specific embodiment of the present invention is described, it will be appreciated that this embodiment is not limiting and other embodiments may fall within the scope of the invention as defined by the appended claims.
Described herein is a reamer tool ( 100 ) having a body ( 105 ) with bays ( 115 ) in which cutter arms ( 110 ) are mounted for deployment between a stowed position and a deployed position. A deployment mechanism is provided for deploying the cutter arms from their stowed position to their deployed position that maintains each cutter arm in a position that is substantially parallel to a longitudinal axis of the body ( 105 ) whilst in its stowed position and in its deployed position as well as during its deployment from its stowed position to its deployed position. A control module ( 300 ) is also described for controlling the deployment of the cutter arms ( 110 ). The control module ( 300 ) comprises a motor ( 310 ), a gearing mechanism ( 315 ) and a moveable element ( 320 ) that closes a port ( 385 ) in a first position and opens the port ( 385 ) in a second position. Fluid flow enters a chamber ( 340 ) behind a piston ( 170 ) through the port ( 385 ) to allow pressure to build up before actuating the piston ( 170 ) and thereby the deployment mechanism for the cutter arms ( 170 ).
4
BACKGROUND 1. Field of Invention This disclosure herein relates in general to processing fibrous materials and in particular to a system for humidifying lint cotton and other fibrous materials with an enhanced manner of removing debris and other fibrous materials and compressing the fiber batt to increase its density. 2. Description of Prior Art The desirability of humidifying or adding moisture to lint cotton in the cotton gin just before baling has been recognized for years. Although humidifying lint cotton increases the weight of the cotton, there are also many significant advantages to adding moisture at this stage of cotton processing. Adding moisture to lint cotton improves the capacity of the bale press whereas dry cotton requires higher compression forces and more time to charge and compact it into the press box. Dry cotton is also more difficult to press into a bale than cotton of normal moisture content. Higher press box compaction pressures require more bale press energy consumption, which causes wear and tear on the bale press components. Thus, humidified lint requires lower compaction pressures and reduces strain on the bale press components while creating bales that are within the acceptable weight range. Adding moisture to the fiber and compressing the batt before the press also enhances the press capacity since a denser volume of cotton is available for each charge of cotton delivered to the press box. Older cotton presses use troublesome devices known as “dogs” to hold the compacted cotton in the press box while additional cotton is being added to form the bale. Modern high capacity, universal density presses do not use dogs. However, without dogs to hold the cotton in the box during bale formation, dry cotton springs out of the box requiring the tramper to work harder as it re-compacts the cotton. In contrast, humidified lint stays in the box after compaction. Bands consisting of wires or straps of steel are used to hold the formed bale together after the bale pressing operation. Dry cotton requires additional force to press it into a bale. The additional force causes excessive tension on the bands, thereby causing some of the bands to break during bale storage. Replacing broken bands is an expensive process for the warehouse. The re-banding process can also lead to contamination of the lint fiber which lowers the value of the cotton. Adding moisture to the cotton before the baling process reduces the occurrence of broken bands. Several prior art methods have had limited success in humidifying lint cotton. Spraying the cotton batt with a fine mist of water to which a wetting agent had been added was probably the first systematic way used to apply moisture to lint cotton. This method was developed by the U.S. Government's Cotton Ginning Laboratory, at Stoneville, Miss., and was described by Charles A. Bennett in his article “Engineering Progress in Cotton Ginning” which appeared in the Cotton Gin and Oil Mill Press on Mar. 22, 1947. The apparatus employing spraying a cotton batt with a fine mist of water is described in U.S. Pat. No. 3,324,513, issued Jun. 13, 1967, to D. B. Hurdt. Exposing cotton to a stream of warm, humid air is the most popular method of humidifying cotton at the gin. Typically, the warm, humid air is generated by a device manufactured by Samuel Jackson, Inc., under the trademark HUMIDAIRE and controlled by the applicant herein. This device comprises an air heater in which a gas or oil-fired burner operates with an open flame in the stream of air to be humidified. The stream of air passes through an air washer chamber in which recirculated water spray scrubs the heated air, simultaneously cooling the air and evaporating the water. A supply of warm humid air is generated with an air temperature between 120 to 160 degrees F. dry-bulb temperature and 70 to 100% relative humidity. The relative humidity of the air generated by the HUMIDAIRE device is regulated by independent control of the dry-bulb (air) and wet-bulb (water) temperatures. The closer these two temperatures are together, the higher the relative humidity. Regulating the burner fuel valve controls the dry-bulb temperature. Regulating the butterfly valve for throttling water flow to the spray nozzles in the air washer chamber controls the wet-bulb temperature. At present, a common lint cotton humidifier is the “Lint Slide Grid Humidifier,” U.S. Pat. No. 4,103,397, issued Aug. 1, 1978, to S. G. Jackson. This device comprises a set of louver-like plates, or grids, forming the bottom surface of the lint slide between the battery condenser and press. Humid air is introduced in a plenum below the grids and passes up through the grids and through the cotton batt flowing downward to the press. Although this device offers a low cost solution, it is only capable of applying a limited amount of humid air to the cotton. The effectiveness of this device is limited since some of the air escapes around the cotton batt instead of penetrating it. In addition, this device is incapable of compressing the batt into a desirable denser mass. An alternative location for applying humid air to the cotton batt is at the battery condenser of the gin. Humid air may be applied just before cotton reaches the doffing rollers of the screen drum of the battery condenser. For an example of this method, see U.S. Pat. No. 2,834,058, issued May 13, 1958, to W. R. Bryant. This humidification method has disadvantages. Since the humid air must pass through the screen drum of the condenser, moisture will often condense on the screen drum in cold weather, thereby causing the screen drum to “hair over” with cotton fibers that cannot be removed by the doffing rollers. Air blockages result and the device soon chokes, resulting in downtime. Before the introduction of the humidifier of U.S. Pat. No. 4,103,397, warm humid air was injected into the air and lint flowing to the battery condenser. A limited amount of lint humidification could be achieved this way. However, applying enough humid air to affect the moisture of the lint usually resulted in moisture condensing on the cold battery condenser screen, thus hairing the screen over as described before. U.S. Pat. No. 4,140,503, issued Feb. 20, 1979, to A. L. Vandergriff, describes a method of applying dry, heated air to the condenser screen drum after the doffer rollers to attempt to dry the condensation off the screen. This patent also describes an arrangement of rollers for receiving the humidified cotton batt from the doffing rollers and compressing the cotton batt. The batt leaves the rollers and begins the descent down the slide to the press. Unfortunately, this device retains the inherent problem of moisture condensation on the screen and rollers since it applies moisture in the battery condenser. U.S. Pat. No. 6,314,618, issued Nov. 13, 2001, to M. L. Mehner et al, describes a method for applying warm humid air to a moving batt of fibers. Here the fibers are constrained in a defined path between a rotating perforated drum and a stationary perforated screen. The fiber batt is doffed from the rotating drum by a roller that serves to both doff the batt and compress it against a smooth stationary plate increasing the density of the batt. The stationary perforated screen allows foreign material into the air plenum area. The foreign material may impede batt travel through the machine leading to chokes and operating downtime. Removing the foreign material can be time consuming. SUMMARY OF INVENTION The present disclosure includes an apparatus for processing fibrous material, wherein the fibrous material comprises debris. In one embodiment the apparatus comprises a rotatable first cylinder having a cylindrical surface defining a hollow space therein, the cylinder having an upper portion and a lower portion. The cylinder includes perforations extending through the surface forming annular protrusions on the outer periphery of the perforations, wherein the protrusions define a rough side; wherein the rough side of the surface of the first cylinder is located on the exterior of the first cylinder to enhance gripping fibrous material being processed. Also included is a feed system formed to deliver incoming fibrous material to the upper portion of the first cylinder, a fan configured to direct air flow to the upper portion of the first cylinder; and, a plenum in communication with the lower portion of the first cylinder configured to receive debris removed from the fibrous material. The air flow may comprise hot humid air. The apparatus may further comprise a rotatable second cylinder having a generally cylindrical surface which has an exterior side which has a plurality of irregularities. The second cylinder being located downstream of and spaced apart from the first cylinder by a minimal distance such that the second cylinder doffs said first cylinder. The air flow to the upper portion of the first cylinder flows into the hollow space within the cylinder through the material and perforations and exits the first cylinder into the plenum. Debris from the fibrous material is carried to the plenum by the air flow. In one embodiment, the plenum is in communication with a fan suction line. The air flow through the first cylinder preferably creates a pressure differential between the upper and lower portion of the first cylinder. The pressure differential is typically of sufficient magnitude to force fibrous material against the upper portion of the first cylinder. In one embodiment, the second cylinder comprises a plurality of longitudinal members disposed about and parallel to an axis of rotation, each of the members having a leading edge and a trailing edge, the leading edge of each member overlying and contacting the trailing edge of an adjacent one of the members. Also, a cotton gin is disclosed herein comprising, a battery condenser, and a batt conditioning apparatus formed to receive a stream of fibrous material batt from the battery condenser. The batt conditioning apparatus of the cotton gin comprises a rotatable first cylinder having a cylindrical surface defining a hollow space therein, the cylinder having an upper portion and a lower portion, perforations extending through the surface forming annular protrusions on the outer periphery of the perforations, wherein the protrusions define a rough side and wherein the rough side of the surface of the first cylinder is located on the exterior of the first cylinder to enhance gripping fibrous material being processed. The cotton gin may also include a feed system formed to deliver the batt fibrous material to the upper portion of the first cylinder, a humidifying unit configured to direct hot humid air flow to the upper portion of the first cylinder; and a plenum in communication with the lower portion of the first cylinder configured to receive debris removed from the fibrous material. The cotton gin may also include a fan formed to draw air from the plenum. The fan may be configured to discharge into the batt condenser. The combination of the air from the humidifying unit blowing on the cylinder and the fan drawing air from the plenum may form a pressure differential on the first cylinder. The pressure differential forces the batt onto the cylinder and promotes air flow through the cylinder. A method for processing a fibrous batt in a processor is also included herein. The processor comprises a rotatable hollow cylinder with perforations, a feed system, and a plenum. The method comprises feeding the batt to the upper portion of the cylinder from the feed system, directing hot humidified air through the batt as it passes over the upper portion of the cylinder, and forming a localized low pressure zone within the plenum. Debris removed from the batt is entrained in the air flow. The method may further include directing air with entrained debris from the plenum to a battery condensing unit. The step of forming a localized low pressure zone comprises drawing air from the plenum with a fan. BRIEF DESCRIPTION OF DRAWINGS Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which: FIG. 1 is a side view of an embodiment of a moisture conditioning apparatus built in accordance with the invention, having a rotatable hollow cylinder, an air plenum, a pivoting air seal door, a doffer roller, a compression roller and link arm. FIG. 2 is a sectional side view of the doffer roller of FIG. 1 . FIG. 3 is a sectional side view of the compression roller of FIG. 1 . FIG. 4 is a partial sectional side view of the apparatus of FIG. 1 showing additional elements of the invention. FIG. 5 is a schematic side view of the apparatus of FIG. 1 installed in a conventional cotton ginnery with associated equipment. While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims. DETAILED DESCRIPTION OF INVENTION The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. Referring now to FIG. 5 , lint cotton L coming from lint cleaning machines (not shown) is directed to battery condenser 130 in an air stream flowing through a lint flue riser 131 . Battery condenser screen 132 separates lint L out of the air stream and creates cotton batt B. The air stream continues out of the condenser 130 in a pipe 133 to a fan (not shown). Batt B is a blanket of cotton that flows out of battery condenser 130 and slides down an inclined surface (usually 35 to 40 degrees) called a feed ramp 134 . The feed ramp 134 directs batt B into the lint conditioner apparatus 120 . The cotton batt B moves through the lint conditioning apparatus 120 before being deposited on lint slide 150 . Referring to FIG. 1 an embodiment of the lint moisture conditioning apparatus 120 is shown in a side view. The conditioning apparatus 120 illustrated includes a hollow cylinder 2 with a perforated sheet metal surface 3 rotatable about an axle 4 . The perforations 17 on the surface 3 form annular protrusions 18 thereon formed for gripping the batt and advancing it with rotation of the cylinder 2 . In the embodiment shown, cylinder 2 has a 43-inch diameter (1.09 meter). In one embodiment, the surface of cylinder 2 and screen 3 are both formed from 16-gauge stainless steel punched with 9/32 inch (7.14 mm) holes staggered on ⅜ inch (9.53 mm) centers resulting in 51% open area through which air may pass. The hole pattern is chosen to maximize air flow therethrough. A continuous batt of cotton B is pulled into the apparatus on feed apron 16 directing the batt B to top of cylinder 2 by the gripping action of the perforated surface 3 . The feed apron 16 is between the feed ramp 134 and the cylinder 2 . The feed apron 16 and the feed ramp 134 comprise a feed system for directing the batt B to the lint conditioner apparatus 120 . A horizontally pivoted door 5 pivotally mounted on axle 6 pivots open as the fiber batt B is drawn into the inlet air plenum 7 . The batt B is in sealing contact with the bottom portion of the door 5 thus disallowing humid air to escape from inlet air plenum 7 into the atmosphere. The door 5 also prevents humid air flow towards the battery condenser (not shown) from which fiber batt B is flowing and keeps excessive ambient air from entering the apparatus with batt B. Humid air entering into air plenum 7 is distributed evenly throughout the plenum area where the batt B is flowing on the surface 3 by a set of air louvers 8 positioned in the air inlet of the air plenum 7 . The air louvers 8 are comprised of several blades which direct the humid air flow toward the batt B. One example of suitable air flow is air from about 120 deg F. to about 160 deg F. (49 deg C. to 71 deg C.) and from about 70% to about 100% relative humidity. A doffer roller 9 is rotatably mounted on an axle 10 and situated downstream of cylinder 2 . The outer surfaces of cylinder 2 and roller 9 are separated by a very small gap configured to doff the batt B from the surface 3 . During operation the roller 9 rotates in the same direction as cylinder 2 . A second roller 11 , constructed in same manner as roller 9 , rotates in an opposite direction to that of roller 9 . The fiber batt B is compressed between the doffer roller 9 and the second roller 11 after being doffed from the cylinder 2 . The second roller 11 also provides a positive feed out conveying action for the fiber batt B as roller 11 rotates in opposite direction to that of doffer roller 9 . Roller 11 is mounted on axle 12 , where both the roller 11 and axle 12 are held at a constant distance from cylinder 2 and doffer roller 9 by a pair of link arms 13 . Link arms 13 pivot about axle 4 . In the embodiment shown, four solid removable end panels 14 cover two openings in each end face of cylinder 2 . End panels 14 allow access to the interior of cylinder 2 for cleaning and inspection when they are removed. End panels 14 also seal the ends of cylinder 2 so a proper amount of air flows through the perforated surface 3 . A proper amount of air is needed to introduce moisture to the batt as well as having the batt flow through the apparatus. As discussed in more detail below, a pressure gradient is formed across the cylinder 2 sufficient to force air perpendicularly through the batt B, cylinder 2 upper surface, and cylinder 2 lower surface. For the purposes of discussion herein, the upper surface of the cylinder 2 refers to that portion of the cylinder 2 residing proximate to the inlet air plenum 7 ; similarly the lower surface of the cylinder 2 refers to the portion of the cylinder 2 proximate to the exhaust air plenum 15 . The pressure gradient across the cylinder 2 is formed by the combination of the forced air flow exiting the air louvers 8 and a fan 170 in communication with the exhaust air plenum 15 . The fan 170 is configured to draw a vacuum in the exhaust air plenum 15 . Arrows A represent the air flow passing from the louvers 8 to the exhaust air plenum 15 . Referring now to FIG. 2 , the outer surface of doffer roller 9 is formed by a plurality of irregularities. In the embodiment shown, the irregularities comprise a series of 12 gauge longitudinal stainless steel, 90-degree members of angle pieces 20 . Angles 20 are welded together around a cylindrical hub 21 on one end and roller end plate 22 the other end. In one example, the roller end plate 22 has a 12 inch diameter (305 mm). Angles 20 form a generally cylindrical exterior with one leg of each angle 20 protruding almost tangentially from the surface of roller end plate 22 . Angles 20 are disposed about and parallel to an axis of rotation hub 21 . Each angle has a leading edge and a trailing edge. The leading edge of each angle 20 overlies and contacts the trailing edge of an adjacent angle 20 . Angles 20 give roller 9 a strong and aggressive surface to doff cotton batt B from cylinder 2 and press it against compression roller 11 . The orientation of the angles 20 shown in FIG. 2 represents their installation in the apparatus relative to view of cylinder 2 shown in FIG. 1 . Referring now to FIG. 3 , the construction of compression roller 11 is constructed in the same manner as doffer roller 9 . The compression roller 11 is similar to the doffer roller 9 . the compression roller 11 is rotatably disposed on a hub axle 12 and comprises angles 20 welded between a hub 21 on one end and a roller end plate 22 on the other. The angles 20 as shown represent their installation in the apparatus relative to the cylinder 2 view shown in FIG. 1 . Angles 20 give a strong and aggressive surface to feed the cotton batt B out of the apparatus while compressing the batt B against doffer roller 9 . Referring now to FIG. 4 , a pair of pneumatic linear actuators 30 mounted on frame 31 movably support the pair of link arms 13 . Actuators 30 are positioned to act as a mechanical stop to maintain a minimum clearance of between doffer roller 9 and compression roller 11 . In one example of use the minimum clearance is about one inch (25.4 mm). Actuators 30 also limit the amount of force compression roller 11 exerts on batt B when pressing against doffer roller 9 . An air pressure regulator 32 supplies pressurized air to actuators 30 through hoses 33 . In the preferred embodiment, actuators 30 have 2.5 inch diameter (63.5 mm) bores which operate at approximately 30 psi (206.8 kPa). A cross brace 34 rigidly connects link arms 13 together to maintain them in the same rotational plane to keep the outer surfaces of doffer roller 9 substantially parallel to compression roller 11 across its entire width. Cylinder 2 , doffer roller 9 and compression roller 11 rotate on axles 4 , 10 and 12 respectively, in bearings 35 mounted on the link arms 13 and the frame 31 . Axles 4 , 10 and 12 are clamped to cylinder 2 , roller 9 and roller 11 with keyless bushings 36 . Support structure 37 provides framework for the assembly and a structure to facilitate installing the apparatus in a gin. Regarding one example of a drive train for use with the apparatus described herein, the output shaft of a 5 horsepower (3.73 kW) motor gear reducer assembly 40 is connected to axle 10 with belt 41 on sheaves 42 . As shown in the embodiment of FIG. 4 , the axle 10 of doffer roller 9 is connected to axle 4 of cylinder 2 with a No. 60 size roller chain 43 passing around a 16-tooth sprocket 44 and a 60-tooth sprocket 45 . This selection for sprockets results in a five percent increase in the surface speed of doffer roller 9 relative to cylinder 2 . This surface speed increase provides a drafting action of batt B off of cylinder 2 by doffer roller 9 . A drafting action prevents the fiber batt from compressing when passing between adjacent rollers. The fiber batt slightly stretches due to the increased surface speed of the receiving roller over that of the preceding roller. Also as shown in the embodiment of FIG. 4 , the axle 12 of compression roller 11 is connected to axle 4 of cylinder 2 with a No. 60 size roller chain 46 passing around a 16-tooth sprocket 44 mounted on axle 12 and a 60-tooth sprocket 45 mounted on axle 4 . In connecting axle 12 to axle 4 , roller chain 46 passes around a second 60-tooth sprocket 45 mounted on axle 46 on link arm 13 . Axle 46 rotates on bearings and idler take up frame 47 . Roller chain 46 creates a serpentine path to reverse direction of compression roller 12 relative to doffer roller 9 . Compression roller 11 rotates in an opposite direction from doffer roller 9 and cylinder 2 so that cotton batt B feeds out of apparatus 120 . Bearings and idler take up frame 47 allows a method to tension roller chain 46 . Referring to FIGS. 1 and 4 , warm humid air enters the inlet air plenum 7 . The air louvers 8 distribute the air evenly across the width of the air plenum 7 and direct the air toward batt B. After the air passes through the batt B and cylinder 2 , it is drawn into the exhaust air plenum 15 by virtue of the above discussed pressure differential. To ensure constant air flow through the cylinder 2 , the volumetric flow rate of air evacuated from exhaust air plenum 15 exceeds the volumetric rate of air supplied to inlet air plenum 7 thereby maintaining a steady state mass flow rate of air. As a result, none of the warm humid air escapes to condense moisture on feed inlet ramp 16 . Air seals 60 , 61 and 62 rub against doffer roller 9 , compression roller 11 and cylinder 2 , respectively, to minimize infiltration of ambient air into the apparatus 120 . Access panels 70 located on each transverse side of inlet air plenum 7 and exhaust air plenum 15 are removable, allowing access to plenums ( 7 , 15 ) for cleaning and inspection. Access panels 70 also allow access to removable end panels 14 on each end face of cylinder 2 . Access panels 70 allow access to ends of doffer roller 9 and compression roller 11 for maintenance. Brush seals 71 mounted on the end faces of cylinder 2 provide a rotating air seal between the end faces of cylinder 2 and the sides of inlet air plenum 7 and exhaust air plenum 15 . Brush seals 71 also keep lint from batt B from migrating into the void area between the end faces of cylinder 2 and inlet air plenum 7 and exhaust air plenum 15 . Horizontally pivoting door 5 mounted on axle 6 in bearings 63 also limits the ingress of ambient air into the inlet air plenum 7 and the egress of warm humid air out of inlet air plenum 7 while allowing batt B to enter the apparatus 120 . Also attached to axle 6 is a pulley arc 64 for cable 65 to pass around. One end of cable 65 is anchored to the top side of pulley arc 64 . Counterweights 66 are attached to the other end of cable 65 . The counterweights 66 protrude through a tube 67 providing a vertical path for the weights to travel up and down in. The radius of the arc travel of pulley arc 64 about axle 6 is fixed so the downward pull of cable 65 about pulley arc 64 provides a constant torque on axle 6 to oppose the weight urging pivoting door 5 onto batt B. As batt B enters the apparatus, door 5 is gently nudged upward by both the batt B and the counterweight effect on door 5 . Air seal 68 is positioned to provide a small gap between air seal 68 and the arc of the upper body of door 5 as the door 5 pivots on axle 6 . In the illustrated embodiment, the air seal 68 is a stationary strip of rubber sandwiched between metal holders having a width substantially the same as the upper body of door 5 . The air seal 68 is adjusted towards the door's upper body without touching the door. An adjustable frequency drive package 155 controls the surface speed of cylinder 2 in relation to the surface speed of battery condenser screen 132 . It is desirable for the surface speed of cylinder 2 to rotate 5 to 10 percent faster than the battery condenser screen 132 to draft batt B into the lint conditioning apparatus 120 . If cylinder 2 rotates at an equal or lesser surface speed than screen 132 , batt B will bunch up before reaching cylinder 2 , thereby creating the possibility of a chokage. If cylinder 2 rotates in excess of 10 percent faster than screen 132 , batt B will be pulled apart inside lint conditioning apparatus 120 . Pulling batt B apart diminishes the humidification performance of the apparatus as humid air escapes through the breaks in batt B flowing through the apparatus. The adjustable frequency drive package 155 adjusts the frequency of the three-phase alternating current electrical power supplied to the motor gear reducer assembly 40 to obtain the desired surface speed. The air handling systems are also shown in FIG. 5 . A fan 160 pulls air through the humidifying unit 161 . The air humidifying unit 161 heats the stream of air to a sufficient temperature to evaporate water into the air stream, thus raising the humidity level of the air. The warm humid air is directed to the fan 160 and to the inlet air plenum 7 of lint conditioner apparatus 120 through pipe 162 . An adjustable metering valve 163 regulates the volume of air to about 2,200 cubic feet (62.3 cubic meters) per minute of standard air. Another fan 170 evacuates the used humid air out of the exhaust air plenum 15 . Pipe 169 directs the air from exhaust air plenum 15 to fan 170 . Optionally, pipe 171 is used to direct flow from the discharge of the fan 170 to the lint flue riser 131 . A small amount of lint L and foreign matter like leaf trash are extracted from the batt B during processing in the apparatus 120 . Since recirculating the used humid air to lint flue riser 131 does not discharge to ambient air, the capital and operating expense of installing and operating lint removal devices is eliminated. An adjustable metering valve 172 regulates the volume of exhaust air to about 4,000 cubic feet (113.3 cubic meters) per minute of standard air. A small fan and air heater combination 180 provides about 1000 cubic feet (28.3 cubic meters) per minute of standard air to pipe 181 . The air is heated to about 180 degrees Fahrenheit (82.2 degrees Celsius). The heated air travels in pipe 181 to a dry hot air plenum 182 which is disposed under lint slide 150 which warms the surfaces of lint slide 150 . Warming the surfaces contacted by batt B eliminates moisture condensation thus preventing sticking of batt B to cold surfaces. A pipe 183 branches off from hot air pipe 181 to carry dry hot air to a point under feed inlet apron 16 . The pipe 183 discharges into the inner area of cylinder 2 which directs dry hot air through the perforated surface 3 . The hot air warms the perforated surface 3 and prevents condensation thereon. Condensate deposits can attract lint and cause the perforated surface 3 to “hair over”. After being discharged from the lint conditioning apparatus 120 , lint slide 150 directs the cotton batt B to the cotton charger 151 . The cotton charger 151 and the press box pusher 156 fill the cotton into the press box 153 . A tramper 152 compacts the cotton down in press box 153 . The cotton is pressed into dense bales for transportation and storage with the bale press 154 . The invention has several advantages over prior art designs. Passing the batt B on the upper surface of the rotating cylinder 2 and forcing warm humid air through the batt B through the cylinder 2 , areas for foreign material accumulation have been reduced. Eliminating areas for foreign material accumulation reduces operating downtime required for cleanup. Another advantage over prior art designs is the batt B is positively drafted into and out of the device by a large rotating cylinder with an aggressive screen and two aggressive rollers working in tandem to doff the batt off the rotating screen. The batt is compressed while it is fed out of the lint conditioner apparatus. It is helpful to define terminology used in regards to a lint condenser, a battery condenser and a lint separator. A lint condenser is a device that separates airborne fiber from an air stream and condenses the fiber into a batt upon exiting the device. A battery condenser is the same as a lint condenser but is used in a cotton ginnery for receiving airborne lint cotton from a battery of cotton gin stands or lint cleaners. A lint separator is the same as a lint condenser except the term lint separator is used in a certain segment of the fibrous material processing industry. It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example, the device described herein is applicable for use to humidify wool, mohair and man-made fibers. In the drawings and specification, there have been disclosed illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
An apparatus for processing a fibrous material batt like lint cotton to increase the moisture content of the material and to compress the batt of humidified fibers to increase the batt density. A stream of warm humid air is passed through the moving batt of fiber that is constrained between a rotatable hollow cylinder and a stationary perforated screen. The air passing through the batt of figure removes debris from the batt and carries the debris to an associated plenum. The batt is doffed off the rotatable cylinder by a roller that serves to both doff and compress the batt. A roller doffs the fiber batt from the rotatable cylinder and doffs and compresses the batt against a compression roller.
3
FIELD OF THE INVENTION [0001] The present invention relates to a process for the preparation of fast dissolving dosage form, such as tablet, which disintegrates quickly in the mouth. BACKGROUND OF THE INVENTION [0002] With the increase in average human life span, drug administration for elderly patients has become more important. Old age is normally accompanied by the onset of degenerative pathologies involving difficulties in coordination and in swallowing the conventional dosage forms such as tablets or capsules. Swallowing problems are also present, in other population groups, such as children. Need for dosage forms having quick onset of action is particularly felt even for those patients who do not have swallowing problems. Similarly, in cases of motion sickness, sudden episodes of allergic attacks, or coughing, the swallowing becomes difficult. Fast dissolving or disintegrating tablets provides the solution to such problems. These tablets disintegrate quickly in saliva or water. [0003] Different techniques are used to prepare fast dissolving tablets. Most of these techniques aim at making porous particles/granules or tablets, so that mouth dissolving time can be reduced. Freeze drying, spray drying, sublimation, disintegrant addition, shearform technology and tablet molding are examples of such techniques. [0004] U.S. Pat. Nos. 4,305,502; 4,371,516 and 5,738,875 describe the use of freeze-drying process to prepare an amorphous, porous structure, which dissolves rapidly. However, such formulations are very expensive and require sophisticated technologies and methods from the production point of view. The tablets prepared by this method are difficult to handle and require special packaging. [0005] U.S. Pat. Nos. 5,587,180; 5,635,210; 5,595,761 and 5,807,576 describe the spray drying technique to prepare highly porous particulate support matrix, which is then mixed with an active agent and compressed to form a tablet. This technique is quite expensive and cannot be used for drugs which become unstable on losing their crystalline structure. [0006] The sublimation technique described in U.S. Pat. Nos. 3,885,206; 4,134,943 and 5,762,961 use mannitol and camphor as pore forming agents. The tablets prepared by this method disintegrate within 10 to 20 seconds. [0007] U.S. Pat. Nos. 4,134,943 and 5,720,974 describe the use of water as a pore forming agent. A mixture containing an active ingredient and a carbohydrate is moistened with water and compressed into tablets. The removal of water yields highly porous tablets. However, this process is not practically feasible. The high water content in the granules makes the compression difficult. [0008] U.S. Pat. No. 6,149,938 describes that mouth-soluble, rapidly disintegrating tablets can be prepared by fluidized bed granulating an aqueous solution of a water-soluble or water-dispersible polymer in a polyalcohol, optionally in mixture with other solid components. [0009] Disintegrant addition is another method of making fast dissolving tablets. Use of effervescent mixture, which generally consists of an acid and a gas-generating base as a disintegrant for the preparation of porous granulates, or particles is also known. [0010] Different processes have been used to prepare porous granulates of effervescent mixture suitable to the preparation of fast dissolving tablets. [0011] U.S. Pat. No. 3,207,824 describes a process for preparing effervescent granules which involves mixing the dry powders together to form a dry mix, adding a small amount of water which starts the effervescence reaction so that a workable mass is obtained; quickly drying the mass in ovens or heated dishes to stop the reaction; and grinding the mass under the dry conditions to form powder or granules. [0012] U.S. Pat. No. 3,401,216 describes a technique consisting of suspending a dry mixture of the acid and the base in powder form in the stream of gas, thereby forming a constantly agitated “fluidized bed” and introducing into this bed just so much of a fluid which causes said chemical ingredient to react to only a limited extent. [0013] French Patent Nos. 7112175 and 7135069 describe a technique which involves the careful humidification of sodium bicarbonate by a very small quantity of demineralized water, then addition of citric acid and optionally a binding agent, in a mixture, which starts off the reaction of the bicarbonate on the citric acid. This mixture is pre-dried in a fluid bed dryer by blowing hot air, which interrupts the reaction. The final drying is again done in fluid bed dryer by blowing hot air. [0014] This technique has a drawback of necessitating the transfer of the filler, from the mixer to the drier. Consequently, the effervescent reaction triggered off in the mixer cannot be mastered with total precision as its interruption, in the drier, depends on the time for emptying and transferring the filler towards the drier. [0015] U.S. Pat. No. 5,437,873 describes a process for the preparation of superior tasting pharmaceutical composition having porous particles. Stiochiometeric amounts of an appropriate base and an appropriate acid are mixed and compressed in a press to form a compact. The compact is then milled to form an evenly distributed stiochiometeric mixture of the base and the acid. A pharmacologically active is then added to the mixture and wet granulated. The wet granulated material is then dried whereby the applied heat and the water cause the acid and the base to react releasing gas from the wet granulation to form porous particles. The porous particles are then milled to form powder, which is then compressed to form a tablet. [0016] EP 494972 patent describes effervescent tablets suitable to the direct oral administration, i.e. without a previous development of the effervescence in water, consisting of microcapsules containing the active ingredients and an amount of effervescent agents sufficient to promote the release of the microgranules when ingested and to give a “fizzing” sensation when in contact with the buccal mucosa to the patient. Such a preparation technique yields tablets having friability values higher than those involving the humid granulation of the mixture to be pressed. Tablets prepared by this technique have higher dissolution time. [0017] All the above mentioned prior art processes, except the freeze drying and sublimation techniques describe the preparation of porous particles or granules, which are then compressed to form the fast dissolving tablets. However, due to compression pressure these porous particles/granules undergo rearrangement to form a less porous structure. This decrease in porosity results in increased dissolution/disintegration time. So the whole purpose of making fast dissolving tablets by using porous particles/granules gets defeated once compression pressure is applied to them. SUMMARY OF THE INVENTION [0018] The present invention addresses the drawbacks and problems associated with currently available technologies. It avoids the use of expensive and non-conventional equipment like freeze dryer or spray dryers. [0019] The present invention relates to a process for the preparation of fast dissolving/disintegrating tablets wherein the porosity is produced by in-situ gas generation through moisture activation of the tablets comprising effervescent mixture. [0020] The present invention provides tablets with short dissolution/disintegration time as porosity is achieved in the tablet rather than by making porous particles or granules. When such tablets are placed in the oral cavity, saliva quickly penetrates into the pores to cause rapid disintegration/dissolution. The tablets prepared by the process of present invention dissolve in saliva in preferably less than 20 seconds. The present invention has a further advantage as markedly lower amounts of effervescent mixture than those usually employed in conventional effervescent tablets can be used. The use of lower effervescent mixture concentration gives the advantage of better taste and pleasant mouth feel against the abrasiveness and burning sensation experienced with higher concentrations. [0021] Furthermore, the process of the present invention is simple and cost effective. It can easily be carried out in a traditional effervescent tablet plant. The tablets prepared by the process of the present invention maintain their structural integrity and can be handled and packed as conventional effervescent tablets. DETAILED DESCRIPTION OF THE INVENTION [0022] The present invention provides a process of preparing fast dissolving dosage form for oral administration, comprising the steps of [0023] a) compressing a blend comprising a pharmaceutical active ingredient and effervescent mixture comprising an acid source and a base to produce a tablet, and [0024] b) subjecting said tablet to moisture activation. [0025] The term “moisture activation” means activating an acid base reaction by providing moisture. The moisture causes the acid and the base present in the tablet to effervesce, the gas produced tries to escape forming pores in the tablets. The moisture activation can be done by subjecting the tablets comprising the effervescent mixture to either controlled humidity or controlled heating. [0026] The moisture activation by controlled humidity can be achieved by subjecting the tablets containing the effervescent mixture to careful humidification, which starts off the reaction of the base and acid. This can easily be done by keeping the tablets in relative humidity chamber at a percentage relative humidity of 20 to 100% depending on the temperature. [0027] An alternative process for moisture activation is by controlled heating. In this method, tablets containing the effervescent mixture are heated to liberate water of crystallization. The water thus liberated initiates the acid and base reaction, releasing carbon dioxide which generates pores. For this method, the presence of at least one ingredient having water of crystallization is required. Heating can be done as such or under vacuum. The heating temperature would vary according to the ingredient from which the water of crystallization is to be liberated. [0028] The tablets comprising an effervescent mixture can be prepared by any method known in the art. The effervescent mixture consists of an acid source and a base. [0029] The acid source can be an acid, anhydride or an acid salt. The acid is selected from the group consisting of citric, tartaric, malic, fumaric, adipic, succinic, and alginic acids. The acid salts include dihydrogen phosphate, disodium dihydrogen phosphate, and citric acid salts. [0030] The bases can be solid carbonates of salts such as sodium carbonate, sodium bicarbonate, potassium bicarbonate, potassium carbonate, magnesium carbonate, sodium glycine carbonate, L-lysine carbonate, arginine carbonate and amorphous calcium. [0031] The amount of effervescent mixture is from 1% to 35% by weight of the total composition, preferably 15-20%. [0032] Since the tablets of the present invention consist of an intimate mixture of components which are highly reactive in the presence of moisture, it is apparent that the control of humidity is an extremely important factor in the production of commercially acceptable and stable tablets. Uncontrolled humidity or prolonged exposure to moisture, or even excessive moisture content, will cause the base and the acid to react. Since this reaction not only forms salt and carbon dioxide but water as well, the decomposition reaction is progressive. Therefore, preferably the acid base reaction is interrupted by applying vacuum. The vacuum is applied until the entire moisture is removed. [0033] The active ingredient may be selected from the pharmaceuticals but may also include vitamins, minerals or dietary supplements. Pharmaceuticals may include antacids such as omeprazole, non-steroidal anti-inflammatory drugs such as rofecoxib and nimesulide, steroidal anti-inflammatory drugs such as betamethasone, anti-psychotic drugs such as olanzapine, hypnotic drugs such as alprazolam, antiepileptic drugs such as sodium valproate, antiparkinsonism drugs such as levodopa, hormone drugs such as progestin, analgesic drugs such as aspirin, serotonin 5HT receptor antagonists such as ondansetron, diuretic drugs such as sulphamethoxazole, H2 receptor antagonists such as ranitidine hydrochloride, antiarrhythmic drugs such as pindolol, cardiotonic drugs such as digitoxin, coronary vasdilators such as nitroglycerin, calcium antagonists such as diltiazem hydrochloride, antihistaminic drugs such as fexofenadine hydrochloride, antibiotics such as doxycycline, antitumor drugs such as actinomycin, antidiabetic drugs such as metformin, gout treating drugs such as allopurinol, antiallergic drugs such as loratadine, antihypertensive drugs such as quinapril, central nervous system acting drugs such as indeloxazine hydrochloride, antispasmodic drugs such as butylscopolamine, antihyperlipidemic drugs such as simvastatin, bronchodilators such as salbutamol, α-adrenergic receptor blockers such as tamsulosin hydrochloride, osteoporosis treating drugs such as sodium alderonate, antifungal drugs such as fluconazole, antiviral drugs such as lamivudine, drugs for erectile dysfunction such as sildenafil and antidepressant such as sertraline. [0034] The invention is further illustrated by the following examples but they should not be construed as limiting the scope of this invention in any way. EXAMPLE 1 [0035] Rofecoxib Mouth Soluble Tablets (50 mg Strength) Ingredients Mg/Unit Rofecoxib 50 Polyvinylpyrrolidone 0.375 Water qs mannitol 172.226 Microcrystalline cellulose 50 L-hydroxypropyl cellulose 20 Sodium bicarbonate 48 Citric acid (anhydrous) 36 Aspartame 11.6 Colloidal Silicon dioxide 2.0 Mango Flavour 4.166 Banana Flavour 0.833 Magnesium stearate 4.8 Total 400.00 [0036] Method [0037] 1. Rofecoxib (granulated), mannitol, sodium bicarbonate (preheated at 80° C. for 1 hour), L-hydroxypropyl cellulose, microcrystalline cellulose, Aspartame, colloidal silicon dioxide, Mango flavour, Banana flavour are sifted through 44 BSS sieve. [0038] 2. The blend is mixed for 10 minutes in a double cone blender. [0039] 3. Citric acid (preheated at 80° C. for 1 hour) is sifted through 100 (BSS) sieve and added to step 2. [0040] 4. The blend is mixed again for 10 minutes in double cone blender. [0041] 5. Magnesium stearate is passed through 44 (BSS) sieve and the final blending was done for 5 minutes. [0042] 6. Lubricated blend of step 5 is compressed on 11 mm flat round punch, on 16-station rotary compression machine. [0043] 7. The tablets of step 5 are subjected to relative humidity. [0044] 8. The tablets of step 7 are vacuum dried. [0045] These tablets had mouth-dissolving time of less than 20 seconds. EXAMPLE 2 [0046] Simvastatin Mouth Soluble Tablets (5 mg Strength) Ingredients Mg/Unit Simvastatin 5.0 Butylhydroxyanisole 0.25 Mannitol 29.75 Directly compressible lactose 40.0 L-hydroxypropyl cellulose 6.0 Sodium bicarbonate 15.0 Citric acid (anhydrous) 15.0 Aspartame 5.0 Pineapple Flavour 2.0 Magnesium stearate 2.0 Total 120.00 [0047] Process: [0048] 1. Simvastatin (BHA-treated), directly compressible lactose, L-hydroxypropyl cellulose, mannitol, pineapple flavour, aspartame, sodium bicarbonate (preheated at 80° C. for 1 hour), are sifted through 44 BSS sieve. [0049] 2. The blend of step 1 is mixed for 10 minutes in double cone blender. [0050] 3. Citric acid (anhydrous) is sifted through 100 BSS sieve (preheated at 80° C. for 1 hour) and mixed with the blend of step 2; the blend is then mixed for 10 minutes in a double cone blender. [0051] 4. The blend of step 3 is lubricated with magnesium stearate (sifted through sieve 44 BSS) by mixing for five minutes in a double cone blender. [0052] 5. The blend of step 4 is compressed using 7 mm standard concave punch. [0053] 6. The tablets of step 5 are subjected to relative humidity. [0054] 7. These tablets are then vacuum dried. [0055] These tablets had a mouth dissolving time of less than 20 seconds. EXAMPLE 3 [0056] Olanzapine Mouth Soluble Tablets (5 mg Strength) Ingredients Mg/Unit Olanzapine USP 5.0 Mannitol 30 Directly compressible Lactose 35 Croscarmellose sodium 4 Sodium bicarbonate 8 Citric acid (anhydrous) 12 Aspartame 3 Orange Flavour 2 Magnesium stearate 1 Total 100.00 [0057] Process: [0058] 1. Olanzapine, directly compressible lactose, croscarmellose sodium, mannitol, orange flavour, aspartame, sodium bicarbonate (preheated at 80° C. for 1 hour), are sifted through 44 BSS sieve. [0059] 2. The blend of step 1 is mixed for 10 minutes in double cone blender. [0060] 3. Citric acid anhydrous (preheated at 80° C. for 1 hour) is sifted through 100 BSS sieve and mixed with the blend of step 2; the blend is then mixed for 10 minutes in a double cone blender. [0061] 4. The blend of step 3 is lubricated with magnesium stearate (sifted through sieve 44 BSS) by mixing for five minutes in a double cone blender. [0062] 5. The blend of step 4 is compressed using 6.4 mm flat round punch. [0063] 6. The tablets of step 5 are subjected to relative humidity. [0064] 7. These tablets are then vacuum dried. [0065] These tablets had a mouth dissolving time of less than 20 seconds. EXAMPLE 4 [0066] Rofecoxib Mouth Soluble Tablets (50 mg Strength) Ingredients Mg/Unit Rofecoxib 50 Polyvinylpyrrolidone 0.375 Water qs Mannitol 168.625 Microcrystalline cellulose 50 L-hydroxypropyl cellulose 20 Sodium bicarbonate 48 Citric acid (anhydrous) 40 Aspartame 12.0 Colloidal Silicon dioxide 2.0 Mango Flavour 4.2 Banana Flavour 0.8 Magnesium stearate 4.0 Total 400.00 [0067] Method [0068] 1. Rofecoxib (granulated), mannitol, sodium bicarbonate (preheated at 80° C. for 1 hour), L-hydroxypropyl cellulose, microcrystalline cellulose, Aspartame, colloidal silicon dioxide, Mango flavour, Banana flavour are sifted through 44 BSS sieve. [0069] 2. The blend is mixed for 10 minutes in a double cone blender. [0070] 3. Citric acid bicarbonate (preheated at 80° C. for 1 hour) is sifted through 100 (BSS) sieve and added to step 2. [0071] 4. The blend is mixed again for 10 minutes in double cone blender. [0072] 5. Magnesium stearate is passed through 44 (BSS) sieve and the final blending was done for 5 minutes. [0073] 6. Lubricated blend of step 5 is compressed on 11 mm flat round punch, on 16-station rotary compression machine. [0074] 7. The tablets of step 6 are subjected to a temperature of 80° C. for 30 minutes and the kept at ambient temperature for 8 hours. [0075] 8. The tablets of step 7 are vacuum dried. [0076] These tablets had mouth-dissolving time of less than 20 seconds. [0077] Scanning Electron micrographs (FIGS. 1 & 2) of the rofecoxib tablets prepared using composition of Example 1 clearly show the pore formation in the tablets after the moisture activation. [0078] While the present invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the present invention.
The present invention relates to a process for the preparation of fast dissolving dosage form, such as tablet, which disintegrates quickly in the mouth.
0
CROSS-REFERENCE [0001] This is a divisional application claiming priority of co-pending application Ser. No. 14/545,792 filed Jun. 19, 2015. BACKGROUND OF THE INVENTION Field of the Invention [0002] A structural support beam for use in buildings, bridges, automotive frames and the like. Description of the Prior Art [0003] A beam is a structural element that is capable of withstanding load primarily by resisting bending. The bending force induced into the material of the beam as a result of the external loads, own weight, span and external reactions to these loads is called a bending moment. [0004] Beams are traditionally descriptions of building or civil engineering structural elements, but smaller structures such as truck or automobile frames, machine frames, and other mechanical or structural systems contain beam structures that are designed and analyzed in a similar fashion. [0005] In engineering, beams are of several types: Simply supported—a beam supported on the ends which are free to rotate and have no moment resistance. Fixed—a beam supported on both ends and restrained from rotation. Over hanging—a simple beam extending beyond its support on one end. Double overhanging—a simple beam extending beyond its supports ends. Continuous—a beam extending over more than two supports. Cantilever—a projecting beam fixed only at one end. Trussed—a beam strengthened by adding a cable or rod to form a truss. [0013] Most beams in reinforced concrete buildings have rectangular cross sections, but a more efficient cross section for a beam is an I or H section which is typically seen in steel construction. Because of the parallel axis theorem and the fact that most of the material is away from the neutral axis, the second moment of area of the beam increases, which in turn increases the stiffness. [0014] An I-beam is only the most efficient shape in one direction of bending: up and down looking at the profile as an I. If the beam is bent side to side, it functions as an H where it is less efficient. The most efficient shape for both directions is a box (a square shell) or tube. But, however the most efficient shape for bending in any direction is a cylindrical shell or tube. But, for unidirectional bending, the I or wide flange beam is superior. [0015] Cross-sectional views of more typical configurations or shapes are depicted in FIG. 1A through FIG. 1F . [0016] Internally, beams experience compressive, tensile and shear stresses as a result of the loads applied to them. Typically, under gravity loads, the original length of the beam is slightly reduced to enclose a smaller radius arc at the top of the beam, resulting in compression, while the same original beam length at the bottom of the beam is slightly stretched to enclose a larger radius arc, and so is under tension. The same original length of the middle of the beam, generally halfway between the top and bottom, is the same as the radial arc of bending, and so it is under neither compression nor tension, and defines the neutral axis dotted line in the beam figure. Above the supports, the beam is exposed to shear stress. There are some reinforced concrete beams in which the concrete is entirely in compression with tensile forces taken by steel tendons. These beams are known as prestressed concrete beams, and are fabricated to produce a compression more than the expected tension under loading conditions. High strength steel tendons are stretched while the beam is cast over them. Then, when the concrete has cured, the tendons are slowly released and the beam is immediately under eccentric axial loads. This eccentric loading creates an internal moment, and, in turn, increases the moment carrying capacity of the beam. They are commonly used on highway bridges. [0017] The following references illustrate the prior art. [0018] U.S. Pat. No. 1,843,318 discloses an arch comprising a curved lower chord having reinforcing bars 24 and 24′ secured at each side of the lower curved edge of the arch to absorb the thrust (see FIG. 16). [0019] U.S. Pat. No. 4,831,800 relates to a beam and reinforcing member comprising a longitudinally extending beam having a concrete upper flange, a web having greater tensile strength than concrete and rigidly connected to the upper flange with shear connectors. The web extends transversely downward from the upper flange longitudinally spaced apart leg portions with an intermediate arched portion extending between the leg portions. [0020] U.S. Pat. No. 4,704,830 shows a flexible tension load bearing member such as a chain strung alongside an I-beam web portion end to end and hooked over the top flange. The mid-section of the chain is then attached in a load bearing capacity to the lower flange, preferably by a post tension controlling adjustable link controlling the chain tension. [0021] Additional examples are found in U.S. Pat. No. 3,010,257; U.S. Pat. No. 3,101,272; U.S. Pat. No. 3,283,464; U.S. Pat. No. 3,300,839; U.S. Pat. No. 3,535,768; U.S. Pat. No. 4,424,652; U.S. Pat. No. 4,576,849 and U.S. Pat. No. 5,125,207. SUMMARY OF THE INVENTION [0022] Numerous different shapes and configurations of support beam structures have been designed for specific applications and strengths. [0023] The present invention relates to a structural support beam configured for enhanced structural strength. [0024] The structural support beam comprises a top flange held in fixed spaced relationship relative to a bottom concave flange by an interconnecting web including a lower concave surface having a radius of curvature substantially equal to the radius of curvature of the bottom concave flange such that when assembled the top flange, bottom concave flange and interconnecting web form an integral structural beam. [0025] It has been observed that excessive tension forces exerted on opposite ends of the structure support beam may cause the bottom concave flange to separate from the interconnecting web. A lower stabilizer or retainer is secured to the structural support beam to prevent the bottom concave flange and the interconnecting web from separating. When the structural support beam and lower stabilizer or retainer are affixed together in the inner surface of each retainer member engages the corresponding end surface of the bottom concave flange, the corresponding end surface of the interconnecting web and the corresponding end surface of the top flange to secure the top flange, bottom concave flange, and interconnecting web together. [0026] The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims. BRIEF DESCRIPTION OF THE DRAWINGS [0027] For a fuller understanding of the nature and object of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which: [0028] FIG. 1A is a cross-sectional end view of a T-shaped support beam of the present invention. [0029] FIG. 1B is a cross-sectional end view of a T-shaped support beam of the present invention. [0030] FIG. 1C is a cross-sectional end view of an I-shaped support beam of the present invention. [0031] FIG. 1D is a cross-sectional end view of a triangular shaped support bias of the present invention. [0032] FIG. 1E is a cross-sectional end view of a triangular shaped support beam of the present invention. [0033] FIG. 1F is a cross-sectional end view of a C or U shaped beam of the present invention. [0034] FIG. 2 is a side view of an I-beam under stress supported on pilings or pillars. [0035] FIG. 3 is an exploded side view of the structural support beam of the present invention. [0036] FIG. 4 is a partial side view of the structural support beam of the present invention. [0037] FIG. 5 is a cross-sectional end view of the structural support beam of the present invention taken along line 5 - 5 of FIG. 4 . [0038] FIG. 6 is an exploded side view of an alternate embodiment of the structural support beam of the present invention. [0039] FIG. 7 is a side view of another alternate embodiment of the structural support beam of the present invention. [0040] FIG. 8 is a top view of yet another embodiment of the structural support beam of the present invention. [0041] FIG. 9 is a cross-sectional end view of the structural support beam of the present invention taken along line 9 - 9 of FIG. 8 . [0042] FIG. 10 is a top view of still another alternate embodiment of the structural support beam of the present invention. [0043] FIG. 11 is a side view of the structural support beam of the present invention with an alternate embodiment of the lower stabilizer or retainer. [0044] Similar reference characters refer to similar parts throughout the several views of the drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0045] Numerous shapes and configurations of support beam structures are exemplified in FIGS. 1A through 1F . Generally, these configurations are selected for specific application and strength. To provide additional strength different materials are employed. In addition, the gauge or thickness of the material used is varied to meet specific stress and strength requirement. [0046] FIG. 2 illustrates the compression and tension forces exerted on a load bearing support I-beam. [0047] These designs have inherent limitations due to the geomety of the beams in dealing with forces depicted in FIG. 2 . [0048] The purpose of the present invention is to create a new geometry design that will provide greater strength while reducing weight in a single member unit to be used in load carrying applications similar to a beam. [0049] Its function is to redirect the downward forces of gravity in such a manner as to cause the forces into compression on the load carrying top section thus causing the forces to be lateral or horizontal and then to transfer the forces to the ends where the connection will be made. The bottom section will not be connected except on the ends where connections will be made, and the downward forces will transfer. It should be noted the upper section and lower section are not connected except on the ends and thus remove the shear effect from the upper section and remove the deflection effects from the lower section and allow effects to be altered needed. [0050] FIGS. 3 through 5 depict the structural support beam of the present invention generally indicated as 10 . The structural support beams described below may be constructed from a variety of materials such as metals including steel, aluminum or magnesium, fiberglass, concrete, wood, carbon fiber or generally used construction materials. [0051] The structural support beam 10 comprises a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the bottom substantially concave flange 14 such that when assembled the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 form an integral structural beam as best shown in FIG. 4 . [0052] As depicted in FIG. 5 , the substantially flat interconnecting web 16 is substantially perpendicular to the top substantially flat flange 12 and the bottom substantially concave flange 14 . [0053] It has been observed that excessive tension forces exerted on opposite ends each generally indicated as 20 of the structural support beam 10 may cause the bottom substantially concave flange 14 to separate from the substantially flat interconnecting web 16 . A lower stabilizer or retainer generally indicated as 24 is secured to the structural support beam 10 to prevent the bottom substantially concave flange 14 and the substantially flat interconnecting web 16 from separating or substantially deflecting. Specifically, the lower stabilizer or retainer 24 comprises a substantially flat longitudinally disposed brace 26 having a substantially flat retainer member 28 formed at each end thereof. The substantially flat longitudinally disposed brace 26 is substantially parallel to the top substantially flat flange 12 ; while, the retainer members 28 are substantially perpendicular to the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 . [0054] Thus, when the structural support beam 10 and lower stabilizer or retainer 24 are affixed together as shown in FIG. 4 , the inner surface 30 of each retainer member 28 engages the corresponding end surface 32 of the bottom substantially concave flange 14 , the corresponding end surface 34 of the substantially flat interconnecting web 16 and the corresponding end surface 36 of the top substantially flat flange 12 to secure the top substantially flat flange 12 , bottom substantially concave flange 14 , and substantially flat interconnecting web 16 together. [0055] FIG. 6 depicts an alternative embodiment of the structural support beam. [0056] Specifically, the structural support beam 10 comprised a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the substantially concave flange 14 such that when assembled, the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 for an integral structural beam 10 similar to that best shown in FIGS. 4 and 5 . [0057] In addition, a substantially flat retainer member 28 ′ is formed on each end of the substantially concave bottom flange 14 . The substantially flat retainer members 28 ′ are substantially perpendicular to the top substantially flat flange beam 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 such that when the structural support beam 10 is fully assembled the inner surface 30 ′ of each substantially flat retainer member 28 ′ engage the corresponding end surface 34 of the substantially flat interconnecting web 16 and corresponding end surface 36 of the top substantially flat flange 12 to secure the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 together as an integrated unit by welding or similar method. [0058] FIG. 7 shows another alternate embodiment of the structural support beam 10 . Specifically, the structural support beam 10 comprises a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the substantially concave flange equal to the radius of curvature of the substantially concave flange 14 such that when assembled, the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 form an integral structural beam 10 similar to that shown in FIG. 4 . Each end portion of the bottom substantially concave flange 14 comprises a flat end portion 15 . [0059] As depicted in FIG. 7 , the substantially flat interconnecting web is substantially perpendicular to the top substantially flat flange 12 and the bottom substantially concave flange 14 . [0060] A lower stabilizer or retainer generally indicated as 24 is secured to the structural support beam 10 to prevent the bottom substantially concave beam 18 and the substantially flat interconnecting web 16 from separating or substantially deflecting. Specifically, the lower stabilizer or retainer 24 comprises a substantially flat longitudinally disposed brace 26 having a substantially flat retainer member 28 formed at each end thereof. The substantially flat longitudinally disposed brace 26 is substantially parallel to the top substantially flat flange 12 ; while, the retainer members 28 are substantially perpendicular to the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 . [0061] Thus, when the structural support flange 10 and lower stabilizer or retainer 24 are affixed together as shown in FIG. 7 , the inner surface 30 of each retainer member 28 engages the corresponding end surface 30 of the bottom substantially concave flange 14 , the corresponding end surface 34 of the substantially flat interconnecting web 16 and the corresponding end surface 36 of the top substantially flat flange 12 to secure the top substantially flat flange 12 , bottom substantially concave flange 14 , and substantially flat interconnecting web 16 together. In addition, each flat end portion 15 is welded or otherwise affixed to the upper surface at each end of the substantially flat longitudinally disposed brace 26 . [0062] FIGS. 8 and 9 depict yet another alternative embodiment of the structural support beam 10 similar to the structural support beam 10 shown in FIGS. 3 through 5 . [0063] Specifically, the structural support beam 10 comprised a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the substantially concave flange 14 such that when assembled, the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 for an integral structural beam 10 similar to that best shown in FIGS. 4 and 5 . [0064] In addition, a substantially flat reinforcing rib 38 is formed on and substantially perpendicular to each side portion 40 of the substantially flat longitudinally disposed brace 26 and each side portion 42 of each substantially flat retainer member 28 . [0065] FIG. 10 depicts still another alternative embodiment of the structural support beam. [0066] Specifically, the structural support beam 10 comprised a top substantially flat flange 12 held in fixed spaced relationship relative to a bottom substantially concave flange 14 by a substantially flat interconnecting web 16 including a lower concave surface 18 having a radius of curvature substantially equal to the radius of curvature of the substantially concave flange 14 such that when assembled, the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 for an integral structural beam 10 similar to that best shown in FIGS. 4 and 5 . [0067] In addition, a substantially flat reinforcing rib 44 is formed on and substantially perpendicular to the longitudinally mid portion 46 of the substantially flat longitudinally disposed brace 26 and the mid portion 48 of each substantially flat retainer member 28 . [0068] FIG. 11 shows an alternate embodiment of the lower stabilizer or retainer 24 . Specifically, the lower stabilizer or retainer 24 comprises a pair of retainer members each generally indicated as 28 operatively coupled together by an intermediate longitudinally disposed brace 29 by a corresponding pair of coupling devices each generally indicated as 35 . [0069] Each retainer member 28 comprises a first retainer leg 31 substantially parallel to the top substantially flat flange and a second retainer leg 33 disposed substantially perpendicular to the top substantially flat flange 12 , bottom substantially concave flange 14 and substantially flat interconnecting web 16 . [0070] The intermediate longitudinally disposed brace 29 comprises a flexible member such as a cable or chain drawn tight or taut by the coupling devices each generally indicated as 35 such as a turn-buckle or the like. [0071] When the structural support beam 10 and lower stabilizer or retainer 24 are affixed together, the inner surface 30 of each second retainer leg 33 engages the corresponding end surface 32 of the bottom substantially concave flange 14 , the corresponding end surface 34 of the substantially flat interconnecting web 16 and the corresponding end surface 36 of the top substantially flat flange 12 to secure the top substantially flat flange 12 , bottom substantially concave flange 14 , and substantially flat interconnecting web 16 together. [0072] Of course, each of the structural elements are welded or otherwise affixed together. [0073] It will thus be seen that the objects set forth above, among those made apparent from the preceding description are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense. [0074] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. [0075] Now that the invention has been described,
A structural support beam for use in buildings, bridges, mechanical frames and the like to resist bending due to gravitational and external forces comprising a top substantially flat flange disposed in fixed spaced relationship relative to a bottom substantially concave flange by an interconnecting web and a lower stabilizing brace disposed to engage the opposite end portions of the bottom substantially concave flange and the opposite end portions of the interconnecting web to reinforce the interconnection therebetween.
4
CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 12/060,541, filed Apr. 1, 2008, which is a continuation of U.S. patent application Ser. No. 10/867,508, filed Jun. 14, 2004 and issued on May 20, 2008 as U.S. Pat. No. 7,376,178, which is a continuation of U.S. patent application Ser. No. 10/269,606, filed Oct. 11, 2002 and issued on Jul. 6, 2004 as U.S. Pat. No. 6,760,370, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/369,655 filed Apr. 3, 2002, which are incorporated by reference as if fully set forth. FIELD OF THE INVENTION The invention relates to processing of communications signals. More particularly, the invention relates to the estimation of the communication signal power in terms of signal-to-noise ratio. BACKGROUND OF THE INVENTION In the field of communications, various types of systems use algorithms that depend on a signal-to-noise ratio (SNR) estimate for proper operation. Code division multiple access (CDMA) systems, such as time division duplex CDMA (TDD/CDMA) and time division synchronous CDMA (TDSCDMA) and frequency division duplex CDMA (FDD/CDMA) and CDMA 2000, use SNR estimation for power control to maintain the required link quality while using the minimum transmitted power. An asymmetric digital subscriber loop (ADSL) system uses SNR for the bit allocation algorithm to select the maximum transmission data rate. In turbo decoders, both the determined signal power and noise power are required. Rate adaptive transmission systems often use SNR to dynamically adapt the modulation scheme or the coding rate. Several algorithms are known for performing SNR estimation. One such algorithm, the received data-aided (RXDA) estimation, is based on the following equation: SNR = ( 1 N ⁢ ∑ k = 1 N ⁢  r k  ) 2 1 N ⁢ ∑ k = 1 N ⁢ r k 2 - ( 1 N ⁢ ∑ k = 1 N ⁢  r k  ) 2 Equation ⁢ ⁢ 1 where r is the received signal vector and N is the number of sample points read by the receiver for the vector r. Another known algorithm is the transmitted data-aided (TXDA) algorithm, which is represented by the equation: SNR = ( 1 N ⁢ ∑ k = 1 N ⁢ r k ⁢ a k ) 2 1 N - 3 ⁢ ∑ k = 1 N ⁢ r k 2 - 1 N ⁡ ( N - 3 ) ⁢ ( ∑ k = 1 N ⁢ r k ⁢ a k ) 2 Equation ⁢ ⁢ 2 A third known algorithm for SNR estimation is represented as: SNR = N 2 ⁢ ( ∑ k = 1 N / 2 ⁢ (  r 2 ⁢ ⁢ k - 1  -  r 2 ⁢ ⁢ k  ) 2 r 2 ⁢ ⁢ k - 1 2 + r 2 ⁢ ⁢ k 2 ) - 1 Equation ⁢ ⁢ 3 The algorithms for Equations 1 and 3 are performed blind without any pilot signal. In contrast, the TDXA algorithm uses a pilot signal with known training sequences, which provides enhanced performance. The drawback of TDXA is that additional equipment is required to process the training sequence. Although the RXDA and Equation 3 algorithms work well when the SNR is high, their performance suffers at low and negative SNRs, where they are known to have a high bias. This is problematic for various communication systems. For example, turbo code applications are known to experience negative ratios of symbol energy to noise density. In CDMA systems, the chip energy to noise density is often negative. Hence, there is a need to develop a blind SNR estimation method that works well at low and negative values without the benefit of a training sequence. SUMMARY An apparatus and method for low bias estimation of small or negative signal-to-noise ratio (SNR) for a communication signal is presented. The estimation is iterative and comprises choosing an initial minimum and maximum estimate of the signal amplitude and determining the mean thereof. Associated minimum and maximum noise variances are calculated based on the amplitude values. Using probability density, maximum likelihood estimates of the minimum, maximum and mean amplitudes are derived. Based on whether the mean amplitude estimate increases or decreases, the initial minimum or maximum estimate is set equal to the maximum likelihood mean amplitude, and the resolution between the new minimum and maximum estimates is determined. These steps are repeated until the resolution is within the acceptable limit, at which point the SNR is calculated from the mean amplitude. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a process flow diagram of method 100 for SNR estimation. FIG. 2 shows a process flow diagram of method 200 for SNR estimation. FIG. 3 shows a graph of calculated SNRs plotted against assumed SNRs using method 100 . FIG. 4 shows a comparison of mean SNR estimates of a BPSK signal performed by method 200 , RXDA, TXDA and a third other algorithm, with sampling N=1024. FIG. 5 shows a comparison of mean square errors (MSE) normalized to SNR of a BPSK signal, performed by method 200 , RXDA, TXDA, a third algorithm and the Cramer-Rao (CR) bound, with sampling N=1024. FIG. 6 shows a comparison of mean SNR estimates of an 8PSK signal performed by method 200 , a decision directed algorithm, RXDA and TXDA, with sampling N=100. FIG. 7 shows a comparison of mean square errors (MSE) normalized to SNR of an 8PSK signal performed by method 200 , a decision directed algorithm, RXDA, TXDA and the Cramer-Rao (CR) bound, with sampling N=100. FIG. 8 shows a comparison of mean SNR estimates of an 8PSK signal performed by method 200 , a decision directed algorithm, RXDA and TXDA, with sampling N=1024. FIG. 9 shows a comparison of mean square errors (MSE) normalized to SNR of an 8PSK signal performed by method 200 , a decision directed algorithm, RXDA, TXDA and the Cramer-Rao (CR) bound, with sampling N=1024. FIG. 10 shows a comparison of mean SNR estimates of a 16PSK signal performed by method 200 , a decision directed algorithm, RXDA and TXDA, with sampling N=100. FIG. 11 shows a comparison of mean square errors (MSE) normalized to SNR of a 16PSK signal performed by method 200 , a decision directed algorithm, RXDA, TXDA and the Cramer-Rao (CR) bound, with sampling N=100. FIG. 12 shows a comparison of mean SNR estimates of a 16PSK signal performed by method 200 , a decision directed algorithm, RXDA and TXDA, with sampling N=1024. FIG. 13 shows a comparison of mean square errors (MSE) normalized to SNR of a 16PSK signal performed by method 200 , a decision directed algorithm, RXDA, TXDA and the Cramer-Rao (CR) bound, with sampling N=1024. FIG. 14 shows a convergence of estimation iterations for several trials of method 200 . FIG. 15 shows a system for communications between a base station and user equipments employing SNR estimation methods 100 and 200 . DESCRIPTION OF THE PREFERRED EMBODIMENTS For a BPSK modulated signal, the time and carrier phase synchronization can be obtained so the received samples can be expressed as: r k =s k +n k ,  Equation 4 where s k is the transmitted signal taking amplitude values from {−A, A} with equal probability and n k is real additive white Gaussian noise with variance of σ 2 . In order to determine the unknown value A, a probability density function is a preferred technique. The probability density function of r k can be expressed as: f ⁡ ( r k ) = 1 2 ⁢ { f + ⁡ ( r k ) + f - ⁡ ( r k ) } Equation ⁢ ⁢ 5 where f + ⁡ ( r k ) = 1 2 ⁢ ⁢ π ⁢ σ ⁢ ⅇ - ( r k - A ) 2 2 ⁢ ⁢ σ 2 Equation ⁢ ⁢ 6 and f - ⁡ ( r k ) = 1 2 ⁢ ⁢ π ⁢ σ ⁢ ⅇ - ( r k + A ) 2 2 ⁢ ⁢ σ 2 . Equation ⁢ ⁢ 7 For a received sample of consecutive symbols of length N (r 1 , r 2 , . . . , r N ), the probability density function can be expressed as: f N ⁡ ( r 1 , r 2 , … ⁢ , r N ) = ∏ k = 1 N ⁢ ⁢ f ⁡ ( r k ) Equation ⁢ ⁢ 8 An equation for amplitude A which maximizes the probability function can be determined by taking the partial derivative of Equation 8 with respect to amplitude A, and setting the partial derivative equal to zero: ∂ f N ⁡ ( r 1 , r 2 , … ⁢ , r N ) ∂ A = 0 Equation ⁢ ⁢ 9 The determination of a maximum likelihood estimate of A is then the solution to Equation 10: A = 1 N ⁢ ∑ k = 1 N ⁢ r k ⁢ th ⁡ ( Ar k σ 2 ) Equation ⁢ ⁢ 10 where th ⁡ ( x ) = ⅇ x - ⅇ - x ⅇ x + ⅇ - x . Equation ⁢ ⁢ 11 Since the SNR is unknown, it may possibly be high or low. If the SNR is high, an acceptable approximation for value th can be made as follows: th ⁡ ( Ar k σ 2 ) ≅ { + 1 , r k > 0 - 1 , r k < 0 Equation ⁢ ⁢ 12 The decision-directed amplitude estimate is then: A ^ = 1 N ⁢ ∑ k = 1 N ⁢ ⁢  r k  Equation ⁢ ⁢ 13 The noise power can be estimated as total power minus the signal power, and the SNR can therefore be estimated as: S ⁢ ⁢ N ⁢ ⁢ R = ( 1 N ⁢ ∑ k = 1 N ⁢ ⁢  r k  ) 2 1 N ⁢ ∑ k = 1 N ⁢ r k 2 - ( 1 N ⁢ ∑ k = 1 N ⁢ ⁢  r k  ) 2 Equation ⁢ ⁢ 14 In an alternative embodiment, for a signal in which the time synchronization and the carrier phase synchronization have been obtained for MPSK modulation, the value s k of Equation 4 is the transmitted M-ary PSK signal, represented as: Ae j2πk/M , k= 0, 1, . . . , M− 1  Equation 15 with equal probability of 1/M, and A as the amplitude of MPSK signal s k . Value n k from Equation 4 is the complex additive white Gaussian noise with variance of 2σ 2 . The probability density function of r k , where r k =x k +jy k   Equation 16 can be expressed as: f ⁡ ( x k , y k ) = 1 M ⁢ ∑ l = 0 M - 1 ⁢ ⁢ 1 2 ⁢ ⁢ π ⁢ σ ⁢ exp ⁢ { - ( x k - X l ⁢ A ) 2 + ( y k - Y l ⁢ A ) 2 2 ⁢ ⁢ σ 2 } Equation ⁢ ⁢ 17 where X l +jY l =e j2πl/M   Equation 18 and j=√{square root over (−1)}. For a received sample of consecutive MPSK symbols of length N (r 1 , r 2 , . . . , r N ), the probability density function can be expressed as: f N ⁡ ( r 1 , r 2 , … ⁢ , r N ) = ∏ k = 1 N ⁢ ⁢ f ⁡ ( x k , y k ) Equation ⁢ ⁢ 19 Using Equation 9, the partial derivative of Equation 19 with respect to amplitude A is performed and set to zero, resulting in the following equation: ∑ k = 1 N ⁢ ⁢ ∂ f ⁡ ( x k , y k ) ∂ A f ⁡ ( x k , y k ) = 0 Equation ⁢ ⁢ 20 According to Equation 20, the equation for amplitude A which maximizes the probability function is derived and expressed as follows: A = 1 N ⁢ ∑ k = 1 N ⁢ ⁢ ∑ l = 0 M - 1 ⁢ [ x k ⁢ X l + y k ⁢ Y l ] ⁢ exp ⁢ { ( x k ⁢ X l + y k ⁢ Y l ) ⁢ A σ 2 } ∑ l = 0 M - 1 ⁢ ⁢ exp ⁢ { ( x k ⁢ X l + y k ⁢ Y l ) ⁢ A σ 2 } Equation ⁢ ⁢ 21 If the actual SNR is high, an acceptable decision-directed amplitude estimation is then: A ^ ≈ 1 N ⁢ ∑ k = 1 N ⁢ ⁢ [ x k ⁢ X ^ k + y k ⁢ Y ^ k ] Equation ⁢ ⁢ 22 where ({circumflex over (X)} k , Ŷ k ) is the estimated signal that maximizes X l and Y l : ( X ^ k , Y ^ k ) = arg ⁢ { max X l , Y l ⁢ { x k ⁢ X l + y k ⁢ Y l , l = 0 , 1 , … ⁢ , M - 1 } } Equation ⁢ ⁢ 23 A method 100 for an iterative SNR estimation for a BPSK signal using Equation 10 is shown in FIG. 1 . Given an amplitude estimate A 0 and a noise variance estimate σ 0 2 , a new amplitude estimate A 1 is calculated by Equation 24, which is based on Equation 10: A 1 = 1 N ⁢ ∑ k = 1 N ⁢ ⁢ r k ⁢ th ⁡ ( A 0 ⁢ r k σ 0 2 ) , Equation ⁢ ⁢ 24 and a new noise variance estimate σ 1 2 by: σ 1 2 = 1 N ⁢ ∑ k = 1 N ⁢ ⁢ r k 2 - A 1 2 Equation ⁢ ⁢ 25 As the method is updated, A 0 2 /σ 0 2 converges to A 1 2 /σ 1 2 . Since the SNR to be estimated is unknown, an initial SNR is assumed (step 101 ), denoted as: SNR 0 =A 0 2 /σ 0 2   Equation 26 In step 102 , corresponding values for A 0 and σ 2 are calculated as: A 0 = S ⁢ ⁢ N ⁢ ⁢ R 0 1 + S ⁢ ⁢ N ⁢ ⁢ R 0 Equation ⁢ ⁢ 27 and σ 0 2 = 1 1 + S ⁢ ⁢ N ⁢ ⁢ R 0 . Equation ⁢ ⁢ 28 Next in step 103 , Equations 24 and 25 are used to calculate A 1 , σ 1 2 , and SNR 1 is calculated in step 104 by Equation 29: SNR 1 =A 1 2 /σ 1 2   Equation 29 Step 105 performs a decision as to whether estimate SNR 0 is within a predetermined acceptable resolution compared to the calculated SNR 1 . If the resolution is acceptable, then SNR 0 can be accepted as the final estimate (step 107 ). Otherwise, SNR 0 is adjusted (step 106 ) and the process repeats starting at step 102 . As an example with a predetermined acceptable resolution of 0.1 dB as the benchmark, steps 102 through 106 are repeated until the difference between calculated SNR 1 and estimate SNR 0 is less than or equal to 0.1 dB. Alternatively, steps 102 through 106 are repeated for a predetermined number of times before bringing an end to the estimation process (step 107 ), and accepting the resulting estimate value, regardless of the intermediate resolutions. A similar method for MPSK signals can be performed by replacing Equation 24 in step 103 with Equation 30, which is based on Equation 21, to calculate amplitude A 1 : A 1 = 1 N ⁢ ∑ k = 1 N ⁢ ⁢ ∑ l = 0 M - 1 ⁢ [ x k ⁢ X l + y k ⁢ Y l ] ⁢ exp ⁢ { ( x k ⁢ X l + y k ⁢ Y l ) ⁢ A 0 σ 0 2 } ∑ l = 0 M - 1 ⁢ ⁢ exp ⁢ { ( x k ⁢ X l + y k ⁢ Y l ) ⁢ A 0 σ 0 2 } Equation ⁢ ⁢ 30 FIG. 3 shows curves of calculated SNRs versus assumed SNRs for twenty 1024-point sample vectors each with a real SNR of 3 dB. Each curve crosses the straight line “calculated SNR=assumed SNR” at one point. The crossing point is the estimated SNR for a converged method. It is noteworthy that the crossing points are concentrated around the true SNR of 3 dB. Variations among the 20 curves are due to the random nature of the noise component during each trial. The calculated values vary approximately between −1 dB and +0.5 dB. When the assumed SNR value is greater than the actual SNR, the calculated SNR value is less than the assumed value. This relationship is useful for quick convergence as each successive assumed SNR value can properly be increased or reduced accordingly. An alternative method is to iteratively solve for amplitude A, then to compute the SNR estimate upon convergence, as shown by flow diagram of method 200 in FIG. 2 . In Step 201 , the received vector is normalized such that: 1 N ⁢ ∑ k = 1 N ⁢ ⁢ r k 2 = 1 Equation ⁢ ⁢ 31 Assumed minimum and maximum amplitudes of interest A min and A max are selected, and a predetermined resolution Δ is selected. Values A 0 and A 1 are initialized as follows: A 0 =A min and A 1 =A max . In steps 202 and 203 , the mean of A 0 and A 1 is calculated by: A m =( A 0 +A 1 )/2  Equation 32 and the corresponding noise variances are determined by: σ 0 2 =1− A 0 2   Equation 33 σ 1 2 =1− A 1 2   Equation 34 σ m 2 =1− A m 2   Equation 35 In step 204 , three estimated amplitude values, A′ 0 , A′ 1 and A′ m are calculated using Equation 24 by substituting the initial amplitude values A 0 , A 1 and A m , for A 0 in Equation 24 and initial noise variances σ 0 , σ 1 and σ m , respectively, for σ 0 in Equation 24. For step 205 , if A m >A′ m , then the maximum amplitude A 1 is updated as follows: A 1 =A′ m . Otherwise, the minimum amplitude A 0 is updated: A 0 =A′ m . In an alternative embodiment for step 205 , if A m >A′ m , then amplitude A 1 can be updated so that A 1 =A m ; otherwise the minimum amplitude A 0 is updated: A 0 =A m . For step 206 , the resolution Δ is evaluated. If A 1 −A 0 <Δ, then the estimated amplitude is the updated value A OUT =(A 0 +A 1 )/2 with either A 0 or A 1 as updated amplitude values from step 205 . The final estimated signal-to-noise ratio SNR OUT is calculated from the estimated amplitude value A OUT as follows: SNR OUT =A OUT 2 /(1−A OUT 2 ). Otherwise the process is repeated by returning to step 202 and repeating the steps through step 206 until an acceptable resolution Δ is achieved. As with method 100 , method 200 can be modified to accommodate an MPSK signal. This is achieved by calculating amplitude estimates A′ 0 , A′ 1 and A′ m using Equation 30 instead of Equation 24 in step 204 . The lower bias of method 200 can be seen in FIGS. 4-13 in which the mean SNR and normalized mean square error (MSE) results are compared against various SNR algorithms. Simulation results for the iterative SNR estimation method 200 are graphically compared to the RXDA, the TXDA, and the Equation 3 SNR estimation algorithms as shown in FIGS. 4-5 . As aforementioned, the TXDA algorithm is based on exact knowledge of the received data, which is only applicable to known training sequences. The TXDA curve is therefore shown as a baseline for comparison purposes. FIG. 4 shows means of the various SNR estimations generated using a received vector of 1024 samples (N=1024) versus the actual SNR. The iterative SNR estimation method 200 has a lower bias (excepting the known data case) and the useful range extends down to about −5 dB. For comparison, the useful range in each case for RXDA and Equation 3 algorithms only extends down to about 8 dB. FIG. 5 shows the normalized mean square error (MSE) of the SNR estimations where N=1024 and also shows the Cramer-Rao (CR) bound that is lower bounded by C ⁢ ⁢ R ≥ 2 ⁢ { 2 A 2 ⁢ N + 1 N } . The estimation by method 200 produces results having a lower normalized MSE than that for RXDA and Equation 3. FIGS. 6-9 show mean and MSE results of method 200 compared with RXDA, TXDA, and decision-directed for an 8PSK signal. Comparison of FIGS. 6 , 7 to FIGS. 8 , 9 show the improvement in mean and MSE versus SNR by method 200 when the sample length is increased from N=100 to N=1024, respectively. It should be noted that improvements are evident for method 200 whereas those for Equations 1 and 3 show no improvement. Similarly, FIGS. 10-11 show mean and MSE results for a 16PSK signal for N=100 and FIGS. 12 , 13 show mean and MSE results for a 16PSK signal for N=1024 with similar results. FIG. 14 shows several trajectories of convergence within 9 iterations for method 200 . In general, the number of iterations depends on A min , A max and the resolution Δ. In this example, A min =0.001, A max =0.999 and Δ=0.0002. As shown in FIG. 14 , the estimated SNR stabilizes after 7 iterations and by the 9 th iteration, A 1 −A 0 <Δ, and the estimation is finished. FIG. 15 shows an embodiment for using methods 100 and 200 , comprising a system for wireless communications, such as CDMA, with base station 301 and user equipments (UEs) 302 - 305 . Base station 301 and (UEs) 302 - 305 each include an SNR estimator which performs the low bias SNR estimation method 200 . Improved SNR estimation provides several advantages for base station and UE performance. For instance, improved SNR estimation for a UE is enhanced power control from having more accurate assessment of the required uplink power. At the base station, improved channel selection results from better SNR estimation.
A method implemented by a user equipment includes selecting a first estimate of a signal-to-noise (SNR) ratio, calculating a first amplitude and first noise variance, calculating a second amplitude and a second noise variance, calculating a second SNR, calculating a resolution value, adjusting the first SNR, and performing estimation iterations until the resolution value is equal to a predetermined value.
7
CROSS REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of U.S. patent application Ser. No. 10/650,709 filed on Aug. 29, 2003, now abandoned the entirety of which is incorporated herein by reference. FIELD OF THE INVENTION This invention relates to a method and apparatus to stimulate a well through ignition of a propellant in a well adjacent openings such as perforations and then to immediately thereafter circulate foam for removing blockage material from an underground formation. BACKGROUND OF THE INVENTION The primary bottlenecks to the production of hydrocarbons from a well is the inflow rate from the hydrocarbon formation into the wellbore. The inflow is affected by near wellbore condition and formation characteristics. The near wellbore conditions and the formations of damaged wells can be positively influenced, with increased hydrocarbon production, through stimulation treatment. Methods for well stimulation include, but are not limited to, treatments with various chemicals, hydraulic fracturing where liquids are injected under high pressure (usually with propping agents), methods in which explosives are detonated within the formations to effect mechanical fracture, and combinations of the above procedures. Oil and gas wells are subject to many ailments, some of which are treatable. One such ailment is a blockage of perforations resulting in dramatic or catastrophic decline in production. Some formations, such as an unconsolidated formation contain fines, such as sand, which flow into the perforation and become trapped, creating a plug or blockage in the perforation. Other examples of blockages, or bridging, are perforation debris, clays, silts, asphaltenes, drilling damage, and foreign or manmade objects. It is therefore desirable to remove these blockages from the perforations. One such method is described in U.S. Pat. No. 4,617,997 to Jennings, Jr. which teaches a method to create or enhance fractures in a formation and extending these fractures with foam generated downhole. A foaming agent is mixed with an aqueous fluid and placed into the wellbore fluid, the level of the wellbore fluid being above the perforations and productive interval of the formation. A propellant housed in a canister, which is attached to a retrievable wire line, is placed next to the fractures. The propellant is ignited creating heat, gas and pressure while simultaneously initiating the formation of foam. The foam enters the fractures under such increased pressure for extending the radial fractures. When the pressure decreases and the foam collapses, the decreased viscosity of the wellbore fluid causes any resultant fluid and debris which has accumulated in the fractures to return into the wellbore. It is not disclosed if or how resulting accumulated and recovered debris is removed from the wellbore. Another method is taught by Mohaupt in U.S. Pat. No. 6,138,753. Mohaupt teaches a technique for treating hydrocarbon wells, using two separate propellant ignition phases. A gas generator comprising a propellant charge, housed in a carrier having many openings, is lowered into the well in-line with the perforated interval. The gas generator is ignited and produces sufficient energy to breakdown and clean-out all of the perforations and create micro-fractures originating from the perforations. This is followed by igniting a second gas generator to inject a treatment liquid into the formation with energy less than that required to fracture the formation. No removal of resulting debris is contemplated. A technique to both remove blockage mechanisms, debris and fines from perforations and to ensure the complete removal of this debris from the wellbore is needed. Although blockage removal from perforations or fractures is a by-product of some fracturing procedures, the method and results vary. Jennings Jr. uses the foam primarily for a different purpose, to extend the fractures and is limited to the amount of foam produced by the foaming agent. Mohaupt breaks down debris and cleans-out perforations but does not remove the debris from the well. Mohaupt also does not use foaming techniques. If blockage debris and fines are not completely removed from the wellbore, the remaining debris can re-block perforations, erode production equipment and seals, or plug the outside or the inside of the production tubing reducing or totally restricting production. Well clean-out procedures would be repeatedly required at a large expense. SUMMARY OF THE INVENTION A process is described for formation treatment or stimulation and which accommodates clean-up of debris associated with the stimulation. In one embodiment, a propellant is ignited adjacent openings to the formation and, substantially immediately thereafter, foam is continuously injected adjacent the openings and circulated up through a wellbore to remove debris from the formation and convey the debris therefrom. The tubing string extends sufficiently above the wellbore at surface to enable lowering of the tubing string and foam discharge port to below the openings for enhanced removal of debris. In a broad aspect, a process for treating a wellbore having openings in communication with a damaged formation comprises: running in a tubing string into the wellbore to position a propellant carrier adjacent the openings; overbalancing the wellbore to establish hydrostatic pressure on the formation; igniting the propellant so as to produce a pressure event and a volume of gas directed into the formation; injecting low density foam through the tubing string and into the wellbore at a location above the propellant carrier so as to reduce the hydrostatic pressure and produce at least some debris from the formation and into the wellbore; and conveying the debris from the wellbore by circulating the foam out of the wellbore at surface until sufficient debris is removed. Typically thereafter the tubing string is then removed. It is preferable to lower the tubing string during foam circulation so as to re-position the location of foam injection below the openings In another broad aspect, novel apparatus for achieving this process comprises: a tubing string in the casing and extending downhole from surface for positioning a propellant in a propellant carrier adjacent the openings and forming an annulus between the tubing string and the casing; means for igniting the propellant; and means, such as a foam discharge port in the tubing string adjacent and above the propellant, for injecting and circulating foam from an injection location adjacent the openings, up the annulus and out of the wellbore. More preferably, the tubing string extends sufficiently above surface to enable lowering the foam discharge port below the openings for enhanced debris recovery. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 a is a simplified cross-section of a wellbore illustrating apparatus run in on a tubing string for placement of propellant carrier adjacent a formation before ignition; FIG. 1 b illustrates a partial cross-section of an optional arrangement according to FIG. 1 a without a lubricator; FIG. 2 a is a simplified cross-section of a wellbore illustrating actuation of the tubing string for ignition and foam circulation; FIG. 2 b illustrates a partial cross-section of an optional arrangement according to FIG. 2 b for actuating ignition and foam circulation using pressure-actuation; FIGS. 3 a – 3 h are a series of schematics of a sequence of events according to one embodiment of the invention; and FIG. 4 a–c are sequential flowcharts of some steps of an embodiment of the invention according to FIGS. 3 a–h. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to FIG. 1 a , in a preferred embodiment of the invention, it is desirable to dislodge blockage mechanisms or debris from the wellbore area of a formerly productive interval of an underground formation 10 adjacent openings in a casing 12 of a wellbore annulus or wellbore 13 . Herein, openings are referred to as perforations 11 which are to include other alternate openings enabling communication between the wellbore 13 and formation through the casing 12 including screens, and slots for example. Generally, debris is removed by igniting a propellant 16 in the wellbore 13 and then substantially immediately commencing to inject and circulate low density foam to the surface 18 for the removal of resulting debris. The formation 10 and wellbore 13 , which is no longer producing desired or even commercial rates, is prepared for a workover treatment using an embodiment of the present invention. A suitable wellhead configuration comprises a spool 15 having a foam and debris outlet 19 providing communication with the wellbore 13 , a blow-out preventor 21 and a pack-off 22 at a wellhead W, and a pup length of tubing 23 with a foam injection inlet 24 . In one embodiment, propellant 16 is ignited with the assistance of a lubricator 30 further comprising lubricator tubing 31 , a drop bar 32 and a trigger 33 such as a mechanical release mechanism or valve for temporarily retaining and releasing the drop bar 32 on command. Alternatively, the propellant 16 may be pressure actuated, both embodiments being described in greater detail below. With reference also to FIGS. 3 a – 3 h and FIGS. 4 a – 4 c , a candidate well is selected 100 ( FIG. 4 a ) and a workover string is prepared comprising a tubing string 40 fit at its distal end with a propellant carrier 26 having a firing head (not shown) and a foam injection means 28 such as a foam discharge port 29 in the tubing string 40 adjacent to and uphole of the propellant carrier 26 . The tubing string 40 is made up with conventional components to assist in establishing a tubing tally and the like. As shown at FIGS. 3 a , 4 a and at 101 , the tubing string 40 is lowered into wellbore 13 such that at 103 the propellant carrier 26 is located across from the existing perforations 11 communicating with the formation 10 to be treated. Of course, safe procedures must be used in a workover including proper tubing string entry techniques. The tubing string 40 is suspended in the wellbore 13 at the packoff 22 , the pup length of tubing 23 is installed, having sufficient length to manipulate the tubing string 40 from above the perforations to below the perforations. A lubricator 30 can be installed. The foam injection means 28 can further comprise a differential fill flow sub (not detailed), employed at the bottom of the tubing string 40 to exclude debris and the like during running in. In FIGS. 3 b , 4 a and at 104 , In no particular order a conventional wellbore liquid 43 is rapidly added to the wellbore 13 for increasing a fluid level 20 and resulting hydrostatic head to about maximum, sufficiently above the perforations 11 or productive interval, maximizing the head which tends to place the well in an overbalanced condition. Also the tubing string 40 is filled with liquid, such as produced water, above the differential fill flow sub. At FIGS. 3 c , 4 a , the propellant 16 is ignited and the foam discharge port 29 is opened, as described in process step 105 . The head of liquid in the tubing string 40 assists in directing the resulting high pressure event into the formation 10 rather than permitting the energy to escape uphole along the tubing string. As shown in FIG. 1 a , in one embodiment the lubricator 30 temporarily houses the drop bar 32 and is used to cooperate with the firing head to initiate ignition of the propellant 16 . The fill sub remains sealed from the wellbore 13 , excluding liquids therefrom, until actuated by the falling drop bar 32 . As shown in FIG. 2 a , in the context of a lubricator 30 , the trigger 33 is actuated for releasing the drop bar 32 . The drop bar 32 actuates a firing head which ignites the propellant 16 . In FIG. 4 b and at 105 and 106 , should a misfire occur, the drop bar 32 is fished out and re-set to repeat at 104 . As well as igniting the propellant 16 , the drop bar 32 also actuates the fill sub for opening the foam discharge port 29 . In an alternate embodiment, the firing head is pressure actuated. Accordingly, there is no need for a drop bar nor a lubricator. Additionally, the foam injection means 28 comprises the foam discharge port 29 fit with a pressure-actuated plug. In FIG. 2 b , in the context of a pressure-actuated firing head, a pump 44 is employed to pressurize the tubing string 40 to a first pressure for initiating a pressure-actuated firing head. Unless the pressure-actuated plug is already opened due to the propellant ignition, further pumping is applied and pressure increase releases the pressure-actuated plug at the foam discharge port 29 enabling communication with the wellbore 13 . In FIGS. 3 c , 4 a , and at 104 , hydrostatic pressure of the liquid 43 in the wellbore 13 as well as that of the liquid in the tubing 40 assists in directing the resulting high pressure event into the formation 10 rather than wasting the energy uphole. Rapidly expanding gas and pressure 45 assists in removing blockages from the formation 10 about the perforations 11 . At FIGS. 3 d , 4 b and at 107 and substantially immediately after igniting the propellant 16 , conventional low density foam 46 is injected into the wellbore 13 through the foam discharge port 29 . The circulation of foam 46 is established through the injection inlet 24 at the pup length of tubing 23 at surface and wellbore liquid 43 and foam 46 are recovered from the wellbore 13 through the spool 15 at surface. The foam 46 dramatically lowers the hydrostatic head on the formation 10 stimulating production of formation fluids. The wellbore 13 is now exposed to larger formation pressure and inflow. As a result, debris is produced into the wellbore 13 . Additionally, circulation of the foam 46 and its relatively high viscosity aid in conveying the produced debris up the wellbore 13 to the surface. The foam 46 is circulated and transports wellbore liquid 43 and debris to the surface 18 where it is removed with the foam 46 . Circulation of foam 46 ensures the capture and removal of substantially all produced debris, as the low density foam 46 rises to the surface 18 . At FIGS. 3 e , 4 b and at 108 , when circulating foam 46 and for more effective removal of debris, the tubing string 40 is slowly lowered so that foam discharge port 29 is below the perforations 11 . The ability to lower the tubing string 40 and the depth it can be lowered is predetermined by the pup length of tubing 23 above the packoff seal 22 . In FIG. 4 c and at 109 , it can be desirable in some instances to stroke, or lower and raise, the tubing string 40 periodically to prevent lodging of the debris and sand flowing into the wellbore 13 between the tubing string 40 and well casing 12 . This action is recommended to continue until sufficient debris has been successfully removed. At FIGS. 3 f , 4 c once sufficient debris has been removed, the formation 10 is sufficiently rejuvenated so as to re-establish useful inflow. At 110 , the tubing string 40 then raised to elevate the propellant carrier 26 above the perforations 11 and, at 111 , one of a variety of techniques can be used to apply sufficient hydrostatic head to kill the well before safely pulling the tubing string 40 from the wellbore 13 at FIGS. 3 g , 4 c . Typically the methodology for killing the well is tailored to the particular well and can include simply diminishing foam circulation or circulating air to allow formation fluid 47 production to fill the annulus 13 and kill the well or more aggressively to load up with a suitable wellbore liquid 43 . At FIGS. 3 h , 4 c , and as an objective of rehabilitating the formation 10 , a production string 50 with pump 51 can be run in to re-establish production from the treated well. Note that propellant carriers and foam formulations are known and include those set forth in Jennings Jr. U.S. Pat. No. 4,617,997. As suggested in FIG. 4 a at 100 , some wells are better candidates than others for this process, and while this process was developed for the criteria described below, is not limited to these applications: The well would have a shut-in fluid level, or low cumulative production, to indicate some recoverable reserves are still in place; The well would have exhibited a dramatic, or catastrophic, decline in production, indicating a blockage mechanism has occurred and the decline rate is not natural depletion; Offset wells where previous re-perforating, and propellant stimulation operation has provided incremental production, even briefly, where the increased production may sustain due to the increased depth of stimulation from the propellant or removal of the debris by the stable foam operation; Wells with diagnosed shale collapse are excellent candidates due to suspicion of the presence of large particulate debris and suspicions that such deposits are a distance from the wellbore; and This method is further recommended in cases where less aggressive work over techniques have failed, or have failed to sustain increased production.
A damaged formation is stimulated by igniting a propellant adjacent openings in the wellbore in communication with the damaged formation. Substantially immediately thereafter, low density foam is injected adjacent the openings and circulated to the surface for the removal of debris released from the formation. A tubing string has a foam discharge port at a distal end and a foam injection port at surface. The tubing string extends sufficiently above the wellbore at surface to enable lowering of the tubing string and foam discharge port to below the openings for enhanced removal of debris.
4
CROSS-REFERENCE TO RELATED APPLICATION Not applicable. STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not applicable. BACKGROUND OF THE INVENTION The present invention relates to plumbing valves, and in particular to adjustable mounting systems for use therewith. Tub/shower faucets are typically mounted through a wall surrounding the tub or the shower stall. They are anchored against rear studs and/or to the wall board, and linked to the water supply from behind the wall, and they have a valve stem that projects forward adjacent a wall opening to provide control over the valve from the room side of the wall. Most of these valves are mixer valves which accept both hot and cold water, control the proportioning and volume of water there through, and deliver a mixed outlet stream to a tub filler, shower head and/or the like when the valve is activated. See e.g. U.S. Pat. No. 5,467,799. Other such valves merely control the volume of a single supply of cold or hot water. Such valves are typically designed so that a valve stem protrudes into the room through a hole in the room wall, with a surrounding decorative escutcheon that effectively hides the wall hole. The escutcheon also prevents leakage through the wall hole and restricts heat/cold transfer between opposite sides of the wall. Since the thickness of the wall will vary depending on the construction material selected by the builder or customer, the plumbing installer often first makes a rough-in installation, and then corrects for the final materials. The final adjustment is often achieved by providing threads on the valve housing which the escutcheon can tighten down on, thus providing some range of adjustment. See e.g. U.S. Pat. No. 5,947,149. However, where the wall is particularly thin or unusually thick the amount of adjustment allowed by such threads may be insufficient, thereby requiring the plumber to reposition the valve at a time when access to the valve is restricted. This can be time consuming and may damage construction that has already occurred. Various mounting assemblies have been developed to try to address this problem. For example, U.S. Pat. No. 4,662,389 discloses a valve assembly with a valve extension that can be threaded to vary the position of the escutcheon. This assembly has the disadvantage of requiring many components and separate fasteners. U.S. Pat. No. 4,842,009 discloses an assembly which is suitable to receive a variety of adapters. The length of the assembly can be varied by eliminating or adding extension pieces. This system requires multiple parts. U.S. Pat. No. 4,445,529 provides a less complex assembly in which a plastic insert with internal splines is adjustably mounted along the length of the stem by a set screw. However, use of a set screw in this context can be awkward. Thus, a need still exists for an improved adjustable valve assembly which can be mounted through room walls of widely varying thickness. SUMMARY OF THE INVENTION The invention provides a valve assembly with a three-position adapter for adjustably mounting a valve handle to a valve stem. In one aspect the invention provides a valve assembly having a rotatable valve stem for controlling fluid flow through the valve assembly, a stem adapter having first and second ends with openings suitable to alternately receive pre-defined different first and second lengths of the valve stem, and a handle linked to the valve stem via the stem adapter. By flip-flopping the adapter one can switch from a setting for a thin wall to a setting for a wall of intermediate thickness. In preferred forms the stem adapter has an internal stop element located closer to the first end than to the second end, the stem is splined, and the stem adapter openings engage the stem splines to restrict relative rotation there between. The stem adapter openings can be part of a single axial opening through the stem adapter, and the stem adapter can be suitable to receive a third length of the valve stem which is different than the first and second lengths when the stop element has flexed in a radially outward direction. In another aspect the stem adapter can have planar outer surfaces that slope radially inwardly towards the first and second ends from an intermediate location there between, and the outer surfaces can join at slotted corners. There can also be a stem driver mounted to the handle and defining a socket engaging outer surfaces of the stem adapter. In yet another preferred form there can be a retainer mounted to the valve having a threaded end. A bonnet is mounted to the threaded end of the retainer to conceal the stem driver and the stem adapter such that the bonnet is rotatable with respect to the handle. In another aspect the invention provides valve assembly where there is a rotatable valve stem for controlling fluid flow through the valve assembly. A stem adapter has an opening extending through opposite first and second ends and has a radial stop member positioned closer to the first end than the second end such that the opening alternatively is suitable to receive a first distance of the valve stem from the first end and a second distance of the valve stem (different from the first distance) from the second end. The opening can also receive a third distance of the valve stem when the radial stop has flexed radially outwardly. A handle is linked to the valve stem via the stem adapter. Thus, an installer can adjust the assembly from the room side of the wall for a thin wall by having the valve stem be inserted into the end of the adapter which is closest to the stop. Alternatively, the adapter can be flipped to provide the ability for the valve stem to be inserted into an end of the adapter which is the farthest from the stop (resulting in an assembly suitable for a thicker wall). For extremely thin walls the adapter can be pushed hard onto the stem so as to cause the stop flex outwardly. This allows more of the valve stem to enter the adapter. This assembly is comprised of few parts, is inexpensive to manufacture, and is easy to assembly without complex tools. Further, unlike set screws, the parts of the present invention are not so small that they are easily dropped or lost. These and other advantages of the invention will be apparent from the detailed description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective view of an embodiment of the present invention; FIG. 2 is a cross-sectional view of the valve assembly of FIG. 1 (when assembled and mounted through a room wall), where an adapter element is fully pressed onto a valve stem; FIG. 3 is an enlarged view of a portion of the FIG. 2 drawing; FIG. 4 is a view similar to FIG. 2, albeit with the adapter pressed onto the valve stem somewhat less than in FIG. 2, to accommodate a thicker wall; FIG. 5 is an enlarged view of a portion of the FIG. 4 drawing; FIG. 6 is a view similar to FIG. 4, but with the adapter pressed onto the valve stem even less than as shown in FIG. 4, to accommodate a still thicker room wall; FIG. 7 is an enlarged view of a portion of the FIG. 6 drawing; FIG. 8 is an enlarged perspective view of an adapter in accordance with the present invention; FIG. 9 is a cross-sectional view taken along line 9 — 9 of FIG. 8; FIG. 10 is an top view of the adapter; and FIG. 11 is a side elevational view of the adapter. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring first to FIG. 1, a valve assembly 10 of the present invention includes a handle 12 , a bonnet 14 , a stem driver 16 , an adapter 18 , a decorative escutcheon 20 , a retainer 22 and a valve unit 24 . One possible valve unit to be used with this construction is that described in U.S. Pat. No. 5,467,799, the disclosure of which is hereby incorporated by reference as if fully set forth herein. The handle 12 is used to rotate a valve stem 26 of the valve 24 , and is coupled thereto via a coupling of the stem driver 16 to the handle (so that it rotates therewith), a coupling of the stem driver 16 with the adapter 18 (so that it rotates therewith), and a coupling of the adapter to the valve stem 26 (so that it rotates therewith). The bonnet 14 shrouds this connection and the escutcheon 20 conceals the hole through the wall through which valve 24 projects. As shown in FIG. 2, the valve 24 can include a separate valve cap 25 that bolts onto a valve body and also permits a mounting of the valve body to a rear of the room wall. The usual hot and cold water supply lines link to the valve. Valve stem 26 adjusts the flow rate and temperature of the water through the valve 24 via at least rotational movement. As indicated in FIG. 1, the valve stem 26 has the usual axially extending splines 28 along its outer periphery. The valve stem 26 also has a fixed rotational stop member 30 extending parallel with the valve stem 26 . As is well known, such a member can cooperate with another member (not shown) that can be mounted on the valve stem to rotate therewith. This limits the arc of rotation of the valve stem 26 and thus provides a maximum hot temperature. As seen in FIG. 2, the retainer 22 bolts to the valve cap 25 with the valve stem 26 extending towards the room. The retainer 22 has four notches that accommodate four ribs of the valve cap and help align the retainer 22 . The escutcheon 20 fits onto and around the retainer 22 . It is large enough to conceal the wall hole, as well as any attachments between the valve cap 25 and the wall. The escutcheon 20 has two tabs at its inner diameter that mate with cut outs in the retainer 22 to properly orient graphics and/or text on the escutcheon 20 (e.g. the word “hot”, the word “cold” and an arrow there between to suggest a rotary direction). The handle 12 fits over an opening in one end of the bonnet 14 . The stem driver 16 is fixed to the handle 12 to rotate therewith by an axial bolt 32 extending outward through the opening in the bonnet 14 . The stem driver 16 has a shoulder at an outer end that is larger than the opening in the bonnet 14 so that the bonnet 14 is captured between the handle 12 and the stem driver 16 while both can rotate relative to the bonnet. Thus, once the bonnet 14 is threaded onto the retainer 22 at the inward end of the bonnet, it no longer rotates. A washer 34 can be inserted between the handle 12 and the bonnet 14 to ease rotation of the handle 12 , if desired. Alternatively, a lubricant can be provided at this position, and/or the materials can be selected to permit sliding contact. It should be noted that the stem driver 16 has a squared inward socket. This is suitable to axially slidably receive the outer walls of the adapter 18 . The adapter 18 is not bolted onto the valve stem. Rather, its internal splines permit no relative rotation between the adapter 18 and valve stem 26 , and the bonnet 14 (by virtue of being anchored to the retainer 22 ) holds the driver, and thus the adapter, axially in place on the stem. Referring next to FIGS. 8-11, adapter 18 has sides with planar surfaces tapering to opposite ends from an offset intermediate location along its length. The tapered surfaces ease the insertion of the adapter 18 into the stem driver socket and ensure a tight grip at the radially outermost edges of all four sides. This reduces wobble so that the handle has a solid feel and ensures that there is no slip between the stem driver 16 , the adapter 18 and the valve stem 26 . The corners (preferably all four, but alternatively 1 , 2 , or 3 ) of the adapter 18 have elongated slots or other cut out geometry 36 allowing for outward deflection of the sides if needed when mounting the adapter 18 onto the valve stem 26 . The slots 36 also allow the sides to be compressed inwardly when pressed into the stem driver 16 . The adapter 18 has an internally splined cylindrical bore 38 there through for engaging the splines 28 of the valve stem 26 . Small, radially inwardly projecting stop elements 40 are formed integrally with the adapter 18 in a circular pattern in valleys between the splines of the adapter 18 , at an intermediate location approximately ⅓ of the way in from one end. The adapter 18 can be mounted onto the valve stem 26 at any one of three pre-defined positions along its length, depending on the thickness of the wall in which the valve assembly is being installed. FIGS. 2-3 show the adapter 18 fully pressed onto the end of the valve stem 26 . Note that the sides of the adapter 26 have flexed outward slightly to allow the stop elements 40 to pass over the splines of the valve stem 26 . In this position, the stop elements 40 will be disposed in a circumferential groove 42 in the valve stem 26 . This position accommodates the least thick room walls as bonnet 14 can thread farther onto the retainer 22 . FIGS. 4-5 show the assembly as mounted to a wall of intermediate thickness. Here, the adapter 18 is pressed onto the valve stem 26 with the end farthest from the stop elements 40 first until they contact the end of the valve stem 26 . Note that the adapter 18 remains “wedged” into the socket of the stem driver 16 , providing a tight connection. FIGS. 6-7 show the assembly as mounted to a wall of even thicker construction, such as one that is wall board with tile mounted thereon (not shown). Here, the adapter 18 is pressed onto the valve stem 26 with the end nearest from the stop elements 40 first until they contact the end of the valve stem 26 . Note again that the adapter 18 is still wedged into the socket of the stem driver 16 . Thus, there are three well defined mounting positions. In one, the stem is completely forced through most of the adapter because of the ability of the sides of the adapter to flex outwardly. Two other positions are defined by an offset stop in the cavity of the adapter, and the adapter can be flipped to change between them. Thus, significant variability in room wall depth can be accommodated. Further, three specific defined starting positions are created. Of course, use of different size adapters could create even greater flexibility. The stem driver 16 , “flip-flop” adapter 18 and the retainer 22 can be made of Celcon®. The escutcheon 20 can be a stamped sheet metal, such as brass or stainless steel, and the handle 12 and the bonnet 14 can be chrome plated ABS plastic. One can easily determine which adapter position is appropriate without trial and error. One can measure the distance from the end of the retainer 22 to a flat surface at the center of the escutcheon 20 while holding it firmly against the wall. This distance will indicate the proper adapter position to select. The system can be assembled easily with minimal tools. Moreover, the assembly has no exposed fasteners, thus providing an aesthetically pleasing assembly. A preferred embodiment of the invention has been described above. However, modifications and variations to the preferred embodiment will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. For example, the assembly can be used to mount a faucet valve on a kitchen or lavatory sink top. Therefore, the invention should not be limited to just the described embodiment. To ascertain the full scope of the invention, the following claims should be referenced. INDUSTRIAL APPLICABILITY The invention provides an improved adjustable valve assembly for facilitating mounting of shower controls and the like on walls.
A tub/shower valve assembly includes a three-position valve stem adapter for varying the depth dimension of the assembly. The stem adapter has a splined bore with stop members located at a position skewed towards one end of the stem adapter. The stem adapter can thus be pushed onto the valve stem different distances depending on which is the leading end. The stem adapter can be disposed onto the valve stem a further distance by pushing the stop members past the end of the valve stem, allowed by outward expansion of the sides of the stem adapter.
4
FIELD OF THE INVENTION This invention relates to a rotary vacuum pump employing a particular pump seal liquor in order to eliminate contamination in the production of dihydric phenols particularly Bisphenol-A which is used in substantial quantities to synthesize polymers particularly aromatic carbonate polymers. The novel feature of this invention is employing liquid phenol as the vacuum pump seal liquor as will be described hereinafter. BACKGROUND OF THE INVENTION Bisphenol-A has been an extremely useful chemical for many decades. AS a difunctional monomer, it has been used in the preparation of numerous polymers. For example Bisphenol-A [2,2'-bis(4-hydroxyphenyl)propane] has been utilized in preparing such materials as epoxy resins, polyetherimides, polyarylates and, in particular, polycarbonates. In certain of these polymer systems, particularly the epoxy systems, the purity of the Bisphenol-A (hereinafter referred to as BPA) employed in the polymer reaction need not be that high. Epoxy resins only need BPA of approximately 95% purity. The impurity which is present in the greatest amount in such systems is generally orthopara BPA. However with other polymer systems, particularly polycarbonates, the purity of the BPA must be substantially higher. Purities of BPA of about 99.50% or higher preferably 99.80 or 99.90% or higher are desirable and in many cases necessary for the preparation of BPA polycarbonates. Therefore there has been substantial attention directed to the preparation and purification of BPA. The art is replete with references directed to the preparation of BPA. Usually this is done by the condensation of phenol with acetone in the presence of a catalyst system. Generally the catalyst is an acidic catalyst. For many years one of the particularly useful catalyst systems in the patent art and employed commercially was hydrochloric acid. Although the economics of the process are initially good with respect to the conversion of the reactants to BPA, the maintenance of the apparatus is costly. The hydrochloric acid is extremely corrosive and ordinary metallic reactors and piping must be changed on a frequent basis. Obviously glass lined reactors or certain alloyed metals can be employed, however, these are quite expensive. In later years there seems to be the tendency to use heterogeneous acidic catalyst system wherein the acidic catalyzation occurs at the catalyst surface and is actually bound to the catalyst. in this manner the "acid" does not flow with the unused reactants and BPA. Such catalyst systems are generally sulfonated polystyrenes which are substantially crosslinked such as the Amberlites and like materials. However, such sulfonated polystrenes, because they contain sulfonic pendent groups may form sulfonic acids. The sulfonic acids, along with hydrochloric acid, if employed as part of or a contaminant in the catalyst system, and any other acids can be very corrosive to the equipment, particularly rotary vacuum pumps. Consequently, aqueous caustic has been used as the liquid vacuum seal in rotary vacuum pumps in order to neutralize the acids in the BPA condensation reaction products generally comprised of BPA, phenol, and water and other materials. The reaction products are sent to a crystallizer system wherein a BPA/phenol crystal slurry is formed. The slurry is sent to a rotary vacuum filter, equipped with vacuum pumps which pull the slurry through a filter drum. A cake (BPA/phenol adduct) is formed on the drum and the extracted liquid often referred to as the mother liquor is recycled to the reactor in which BPA is formed. The mother liquor may be subjected to dehydration in order to remove water of reaction and other unwanted materials before recycling the mother liquor back to the reactor. Optionally, the BPA adduct may be redissolved in phenol and sent to a second rotary filter (second stage) equipped with vacuum pull for further purification. After the BPA is prepared, various isolation and purification procedures are known. Many of these appear in the relatively voluminous patent art. Generally phenol is distilled off to a great extent and/or the initial purification by adduct crystallization of the BPA/phenol adduct Distillation of BPA itself can also be employed. The purification of the BPA can then be further accomplished through the addition of various organic solvents such as toluene or methylene chloride so as to remove the BPA from various impurities. Additionally water and various glycols such as ethylene glycol and glycerin have been used alone or together to separate and thus purify the BPA from its impurities. Therefore, it is an object of this invention to provide a process whereby sodium ions are not introduced into the BPA. Another object of this invention is to employ liquid phenol as a seal liquor in rotary vacuum pumps. The foregoing and other objects of this invention will become apparent from the following description and appended claims. SUMMARY OF THE INVENTION In accordance with the invention, there is a method of reducing contamination in BPA upon separating an adduct slurry and a mother liquor. In the process of separating the adduct slurry from the mother liquor, rotary vacuum filters may be employed. The rotary vacuum filters are operated under a vacuum wherein the pressure is controlled at a level below atmospheric and operate in a range of 50 mm Hg to about 250 mm Hg absolute. In systems employing rotary vacuum filters, the rotary filters may be mechanical liquid ring pumps to provide the vacuum source. In such systems, aqueous caustic (sodium hydroxide/water) solution has been used to provide the liquid seal for these pumps. The fans or blades of the pump cannot touch the inside of the pump housing since wear would be extremely extensive. The vacuum pump seal liquor is essential to the ability of the pumps to pull a vacuum (reduced pressure) down to the operating level. Sodium hydroxide solution has been used as the liquid seal in such pumps when producing BPA as described heretofore. However, it has been determined that small amounts of acidic and/or basic ionic contamination, such as sodium, are catalytic in causing undesirable reactions to occur in the BPA and/or polymer products produced therewith such as aromatic carbonate polymers. It has also been determined that the use of aqueous sodium hydroxide solutions as pump seal liquor provides for a direct source of process contamination with sodium. It has now been discovered that by employing phenol as a liquid ring seal for a rotary pump, undesirable contamination from sodium hydroxide solution is completely eliminated. DETAILED DESCRIPTION OF THE INVENTION BPA is generally prepared by the reaction of phenol and acetone in the presence of an acidic catalyst, such as HCl or an ion exchange resin. During the reaction, some unwanted by-products and color are formed which affect yield and quality. Also in the filtration of a BPA/phenol adduct slurry generally comprising a liquor (often referred to as a mother liquor), BPA and phenol, the adduct slurry is deliquored by vacuum filtration which slurry comprises BPA and phenol. The mother liquor is essentially recycled back to the reaction for producing BPA as described heretofore. In the filtration system, rotary vacuum filters are used to separate the adduct cake from the mother liquor. The process for producing the BPA can be any process and is not critical in the practice of this invention. The critical feature is the use of phenol as the liquid in a liquid ring seal rotary pump. These pumps are employed to provide a vacuum source for removal or separation of the mother liquor from the adduct slurry. AS stated previously, the use of sodium hydroxide as the liquid ring seal in rotary vacuum pumps introduces contamination into the BPA. The use of phenol essentially eliminates undesirable sodium contamination from the BPA. In addition, it has also been surprisingly discovered that the use of phenol results in the elimination of an amount of waste water that would come from the aqueous caustic, which waste water must be recovered for environmental purposes. This also results in significant reduction in process investment and operating costs by eliminating these water sources. Another advantage is that it is possible to discontinue the use of sulfuric acid which is required to neutralize the aqueous caustic effluents which are contaminated with phenol. Since phenol is a solid at room temperature, the phenol used as a liquid seal is kept at a temperature above its melting point under process conditions such that it is in a liquid state, preferably at a temperature of at least about 150° C. and more preferably at a temperature of about 150 to about 175° F. In another embodiment of this invention, a small amount of fresh phenol may be continuously fed to the rotary pumps. The replaced or used phenol may then be treated for removal of contaminants before recycling the replaced phenol back to the reactor for forming BPA. Since phenol does not neutralize the acid contaminants as described heretofore when employing aqueous caustic, the acid contaminants can be removed by continuously feeding fresh phenol to the rotary vacuum pumps. The replaced or used phenol will carry off the acid contaminants. The following examples are intended to provide exemplification of the invention and are not intended to limit the invention. EXAMPLE 1 A two stage rotary vacuum pump system is employed to obtain a BPA/phenol cake. After each stage, a BPA/phenol cake is obtained by crystallization and vacuum filtering a BPA/phenol adduct (slurry). After the first stage, the cake is dissolved in phenol and the liquid system is then sent to a second stage or second rotary vacuum pump. In each stage, the rotary vacuum pump has a sodium hydroxide (caustic) liquid vacuum pump seal. Three different flow rates are evaluated and, in each case, the BPA/phenol cake after the second stage is analyzed for sodium (Na) contamination in the BPA/phenol cake. The results obtained are as follows: TABLE 1______________________________________Flow Rate of Caustic Seal Liquor Na in BPA/phenol Cake______________________________________5 Kg/hr. 30 ppb 10-11 Kg/hr. 50-60 ppb 15 Kg/hr. 90 ppb______________________________________ Kg-Kilograms Ppbparts per billion The sodium hydroxide solution employed as a liquid seal is a 6.0 weight % aqueous sodium hydroxide. EXAMPLE 2 Example 1 is repeated except that in place of the caustic liquid seal ring, liquid phenol is employed herein. The liquid phenol is at a temperature of about 160° F. It is found that when analyzing for sodium in the BPA/phenol cake no sodium was detected at the parts per billion level. What is claimed is set forth in the claims appended to the application. Variations in this invention may be made without departing from the scope of the claims appended hereto.
An improved process for producing Bisphenol-A which is essentially free of sodium impurity using rotary vacuum filter pumps which utilize a liquid ring seal to effect drawing a vacuum on a Bisphenol-A/phenol slurry, the improvement is in using phenol as the liquid ring seal medium.
2
FIELD OF THE INVENTION The present invention relates to a method for reliably manufacturing stampers/imprinters utilized for rapid, cost-effective patterning of a layer or body of a recording medium. The invention has particular utility in the formation of patterns, e.g., servo patterns, in the surfaces of recording layers of data/information storage and retrieval media, e.g., hard disks. BACKGROUND OF THE INVENTION Recording media of various types, e.g., magnetic, optical, magneto-optical (“MO”), read-only memory (“ROM”), readable compact disks (“CD-R”), and readable-writable compact disks (“CD-RW”) are widely used in various applications, e.g., in hard disk form, particularly in the computer industry for storage and retrieval of large amounts of data/information. Typically, such media types require pattern formation in the major surface(s) thereof for facilitating operation thereof. For example, magnetic and magneto-optical (MO) recording disks require formation of servo patterns for positioning the read-write transducer over a particular band or region of the media; ROM disks require formation of memory patterns therein; and CD-R and CD-RW disks require formation of wobble groove patterns therein. Magnetic and magneto-optical (MO) recording media are conventionally fabricated in thin film form; the former are generally classified as “longitudinal” or “perpendicular”, depending upon the orientation (i.e., parallel or perpendicular) of the magnetic domains of the grains of the magnetic material constituting the active magnetic recording layer, relative to the surface of the layer. In operation of magnetic media, the magnetic layer is locally magnetized by a write transducer or write head to record and store data/information. The write transducer creates a highly concentrated magnetic field which alternates direction based on the bits of information being stored. When the local magnetic field applied by the write transducer is greater than the coercivity of the recording medium layer, then the grains of the polycrystalline magnetic layer at that location are magnetized. The grains retain their magnetization after the magnetic field applied by the write transducer is removed. The direction of the magnetization matches the direction of the applied magnetic field. The pattern of magnetization of the recording medium can subsequently produce an electrical response in a read transducer, allowing the stored medium to be read. A typical contact start/stop (CSS) method employed during use of disk-shaped recording media, such as the above-described thin-film magnetic recording media, involves a floating transducer head gliding at a predetermined distance from the surface of the disk due to dynamic pressure effects caused by air flow generated between mutually sliding surfaces of the transducer head and the disk. During reading and recording (writing) operations, the transducer head is maintained at a controlled distance from the recording surface, supported on a bearing of air as the disk rotates, such that the transducer head is freely movable in both the circumferential and radial directions, thereby allowing data to be recorded and retrieved from the disk at a desired position in a data zone. Adverting to FIG. 1 , shown therein, in simplified, schematic plan view, is a magnetic recording disk 30 (of either longitudinal or perpendicular type) having a data zone 34 including a plurality of servo tracks, and a contact start/stop (CSS) zone 32 . A servo pattern 40 is formed within the data zone 34 , and includes a number of data track zones 38 separated by servo tracking zones 36 . The data storage function of disk 30 is confined to the data track zones 38 , while servo tracking zones 36 provide information to the disk drive which allows a read/write head to maintain alignment on the individual, tightly-spaced data tracks. Although only a relatively few of the servo tracking zones are shown in FIG. 1 for illustrative simplicity, it should be recognized that the track patterns of the media contemplated herein may include several hundreds of servo zones to improve head tracking during each rotation of the disk. In addition, the servo tracking zones need not be straight radial zones as shown in the figure, but may instead comprise arcs, intermittent zones, partial spirals, or irregularly-shaped zones separating individual data tracks. In conventional hard disk drives, data is stored in terms of bits along the data tracks. In operation, the disk is rotated at a relatively high speed, and the magnetic head assembly is mounted on the end of a support or actuator arm, which radially positions the head on the disk surface. If the actuator arm is held stationary, the magnetic head assembly will pass over a circular path on the disk, i.e., over a data track, and information can be read from or written to that track. Each concentric track has a unique radius, and reading and writing information from or to a specific track requires the magnetic head to be located above that track. By moving the actuator arm, the magnetic head assembly is moved radially on the disk surface between tracks. Many actuator arms are rotatable, wherein the magnetic head assembly is moved between tracks by activating a servomotor which pivots the actuator arm about an axis of rotation. Alternatively, a linear actuator may be used to move a magnetic head assembly radially inwardly or outwardly along a straight line. As has been stated above, to record information on the disk, the transducer creates and applies a highly concentrated magnetic field in close proximity to the magnetic recording medium. During writing, the strength of the concentrated magnetic field directly under the write transducer is greater than the coercivity of the recording medium, and grains of the recording medium at that location are magnetized in a direction which matches the direction of the applied magnetic field. The grains of the recording medium retain their magnetization after the magnetic field is removed. As the disk rotates, the direction of the writing magnetic field is alternated, based on bits of the information being stored, thereby recording a magnetic pattern on the track directly under the write transducer. On each track, eight “bits” typically form one “byte” and bytes of data are grouped as sectors. Reading or writing a sector requires knowledge of the physical location of the data in the data zone so that the servo-controller of the disk drive can accurately position the read/write head in the correct location at the correct time. Most disk drives use disks with embedded “servo patterns” of magnetically readable information. The servo patterns are read by the magnetic head assembly to inform the disk drive of track location. In conventional disk drives, tracks typically include both data sectors and servo patterns and each servo pattern typically includes radial indexing information, as well as a “servo burst”. A servo burst is a centering pattern to precisely position the head over the center of the track. Because of the locational precision needed, writing of servo patterns requires expensive servo-pattern writing equipment and is a time consuming process. Commonly assigned, co-pending U.S. patent application Ser. No. 10/082,178, filed Feb. 26, 2002 , the entire disclosure of which is incorporated herein by reference, discloses an improvement over the invention disclosed in commonly assigned U.S. Pat. No. 5,991,104, and is based upon the finding that very sharply defined magnetic transition patterns can be reliably, rapidly, and cost-effectively formed in a magnetic medium containing a longitudinal or perpendicular type magnetic recording layer without requiring expensive, complicated fabrication of a master disk. Specifically, the invention disclosed in U.S. patent application Ser. No. 10/082,178 is based upon recognition that a stamper/imprinter (analogous to the aforementioned “master”) comprised of a magnetic material having a high saturation magnetization, B sat , i.e., B sat ≧about 0.5 Tesla, and a high permeability, μ, i.e., μ≧about 5, e.g., selected from Ni, NiFe, CoNiFe, CoSiFe, CoFe, and CoFeV, can be effectively utilized as a contact “stamper/imprinter” for contact “imprinting” of a magnetic transition pattern, e.g., a servo pattern, in the surface of a magnetic recording layer of a magnetic medium (“workpiece”), whether of longitudinal or perpendicular type. A key feature of this invention is the use of a stamper/imprinter having an imprinting surface including a topographical pattern, i.e., comprised of projections and depressions, corresponding to a desired magnetic transition pattern, e.g., a servo pattern, to be formed in the magnetic recording layer. An advantage afforded by the invention is the ability to fabricate the topographically patterned imprinting surface of the stamper/imprinter, as well as the substrate or body therefor, of a single material, as by use of well-known and economical electroforming techniques (described below in more detail). According to this invention, the magnetic domains of the magnetic recording layer of the workpiece are first unidirectionally aligned (i.e., “erased” or “initialized”), as by application of a first external, unidirectional magnetic field H initial of first direction and high strength greater than the saturation field of the magnetic recording layer, typically ≧2,000 and up to about 20,000 Oe. The imprinting surface of the stamper/imprinter is then brought into intimate (i.e., touching) contact with the surface of the magnetic recording layer. With the assistance of a second externally applied magnetic field of second, opposite direction and lower but appropriate strength H re-align , determined by B sat /μ of the stamper material (typically ≧100 Oe, e.g., from about 2,000 to about 4,500 Oe), the alignment of the magnetic domains at the areas of contact between the projections of the imprinting surface of the stamper/imprinter (in the case of perpendicular recording media, as schematically illustrated in FIG. 2 ) or at the areas facing the depressions of the imprinting surface of the stamper/imprinter (in the case of longitudinal recording media, as schematically illustrated in FIG. 3 ) and the magnetic recording layer of the workpiece is selectively reversed, while the alignment of the magnetic domains at the non-contacting areas (defined by the depressions in the imprinting surface of the stamper/imprinter) or at the contacting areas, respectively, is unaffected, whereby a sharply defined magnetic transition pattern is created within the magnetic recording layer of the workpiece to be patterned which essentially mimics the topographical pattern of projections and depressions of the imprinting surface. According to the invention, high B sat and high μ materials are preferred for use as the stamper/imprinter in order to: (1) avoid early magnetic saturation of the stamper/imprinter at the contact points between the projections of the imprinting surface and the magnetic recording layer, and (2) provide an easy path for the magnetic flux lines which enter and/or exit at the side edges of the projections. Another process which has been recently studied and developed as a low cost alternative technique for fine dimension pattern/feature formation in a substrate surface is thermal imprint lithography. A typical thermal imprint lithographic process for forming nano-dimensioned patterns/features in a substrate surface is illustrated with reference to the schematic, cross-sectional views of FIGS. 4(A)–4(D) . Referring to FIG. 4(A) , shown therein is a stamper/imprinter 10 including a main (or support) body 12 having upper and lower opposed surfaces, with an imprinting layer 14 formed on the lower opposed surface. As illustrated, stamper/imprinter 14 includes a plurality of features 16 having a desired shape or surface contour. A workpiece 18 carrying a thin film layer 20 on an upper surface thereof is positioned below, and in facing relation to the molding layer 14 . Thin film layer 20 , e.g., of polymethylmethacrylate (PMMA), may be formed on the substrate/workpiece surface by any appropriate technique, e.g., spin coating. Adverting to FIG. 4(B) , shown therein is a compressive molding step, wherein stamper/imprinter 10 is pressed into the thin film layer 20 in the direction shown by arrow 22 , so as to form depressed, i.e., compressed, regions 24 . In the illustrated embodiment, features 16 of the imprinting layer 14 are not pressed all of the way into the thin film layer 20 and thus do not contact the surface of the underlying substrate 18 . However, the top surface portions 24 a of thin film 20 may contact depressed surface portions 16 a of imprinting layer 14 . As a consequence, the top surface portions 24 a substantially conform to the shape of the depressed surface portions 16 a , for example, flat. When contact between the depressed surface portions 16 a of imprinting layer 14 and thin film layer 20 occurs, further movement of the imprinting layer 14 into the thin film layer 20 stops, due to the sudden increase in contact area, leading to a decrease in compressive pressure when the compressive force is constant. FIG. 4(C) shows the cross-sectional surface contour of the thin film layer 20 following removal of stamper/imprinter 10 . The imprinted thin film layer 20 includes a plurality of recesses formed at compressed regions 24 which generally conform to the shape or surface contour of features 16 of the molding layer 14 . Referring to FIG. 4(D) , in a next step, the surface-imprinted workpiece is subjected to processing to remove the compressed portions 24 of thin film 20 to selectively expose portions 28 of the underlying substrate 18 separated by raised features 26 . Selective removal of the compressed portions 24 may be accomplished by any appropriate process, e.g., reactive ion etching (RIE) or wet chemical etching. The above-described imprint lithographic processing is capable of providing sub-micron-dimensioned features, as by utilizing a stamper/imprinter 10 provided with patterned features 16 comprising pillars, holes, trenches, etc., by means of e-beam lithography, RIE, or other appropriate patterning method. Typical depths of features 16 range from about 5 to about 200 nm, depending upon the desired lateral dimension. The material of the imprinting layer 14 is typically selected to be hard relative to the thin film layer 20 , the latter comprising a thermoplastic material which is softened when heated. Thus, suitable materials for use as the imprinting layer 14 include metals, dielectrics, semiconductors, ceramics, and composite materials. Suitable materials for use as thin film layer 20 include thermoplastic polymers which can be heated to above their glass temperature, T g , such that the material exhibits low viscosity and enhanced flow. Referring now to FIG. 5 , schematically illustrated therein, in simplified cross-sectional view, is a sequence of processing steps for performing nano-imprint lithography of a metal-based workpiece, e.g., a disk-shaped substrate for a hard disk recording medium, utilizing a stamper/imprinter with a lubricated imprinting surface, as disclosed in commonly assigned, co-pending U.S. patent application Ser. No. 09/946,939, filed Sep. 5, 2001, the entire disclosure of which is incorporated herein by reference. In a preliminary step according to the method, a thin film of a thermoplastic polymer, e.g., polymethylmethacrylate (PMMA), is spin-coated on the substrate surface. In another preliminary step, a stamper/imprinter, e.g., formed of Ni, having an imprinting surface with a negative image of servo pattern features having a lateral dimension of about 600 nm and a height of 170 nm is fabricated by conventional optical lithographic patterning/etching techniques and provided with a thin layer of an anti-sticking or release agent. In the next steps according to the disclosed invention, the system of substrate/workpiece and Ni-based stamper/imprinter is heated to above the glass transition temperature (T g ) of the PMMA, i.e., above about 105° C., and the negative image of the desired pattern on the imprinting surface of the stamper/imprinter is embossed into the surface of the thermoplastic PMMA layer at a pressure of about 10 MPa. The stamper/imprinter is then maintained in contact with the PMMA layer and under pressure until the system cools down to about 70° C., and then removed from the substrate/workpiece to leave replicated features of the imprinting surface in the surface of the PMMA layer. Subsequent processing of the imprinted substrate/workpiece involves selective removal of substrate material utilizing the imprinted layer of thermoplastic material as a pattern defining (etching) mask, followed by removal of the imprinted layer of thermoplastic material. Still another process which has been recently studied and developed as a low cost alternative technique for fine dimension pattern/feature formation in a substrate surface is imprinting of a sol-gel layer on a substrate surface, as for example, disclosed in commonly assigned, co-pending U.S. patent application Ser. No. 09/852,084, filed May 10, 2001, the entire disclosure of which is incorporated herein by reference. According to the process disclosed therein, problems attendant upon the use of very hard surfaced, high modulus materials, e.g., of glass, ceramics, or glass-ceramic composites, as substrates in the manufacture of hard disk recording media are addressed, and the invention is based upon the discovery that the surfaces of such materials may be modified, i.e., reduced in hardness, so as to facilitate formation of servo patterns therein, as by a simple and conveniently performed embossing process. According to the invention, modification (i.e., reduction) of surface hardness of high modulus substrates for use in the manufacture of thin film recording media is obtained by first forming a relatively soft sol-gel coating layer on the substrate surface, embossing the desired servo pattern in the exposed upper surface of the relatively soft sol-gel layer utilizing a stamper/imprinter with an appropriately patterned imprinting surface comprising a patterned plurality of depressions and protrusions having a negative image of the desired servo pattern, and then converting the embossed, relatively soft sol-gel layer to a relatively hard glass-like layer while retaining the embossed servo pattern therein. The thus-formed substrate with embossed servo pattern in the exposed surface thereof is then subjected to thin film deposition thereon for forming the layer stack constituting the magnetic recording medium. The inventive methodology advantageously provides servo-patterned recording media without requiring servo-writing subsequent to media fabrication. Stampers/imprinters for use in a typical application, e.g., servo pattern formation in the recording layer of a disk-shaped, thin film, longitudinal or perpendicular magnetic recording medium, comprise an imprinting surface having topographical features consisting of larger area data zones separated by smaller areas with well-defined patterns of projections and depressions corresponding to conventionally configured servo sectors, as for example, disclosed in the aforementioned commonly assigned U.S. Pat. No. 5,991,104. For example, a suitable topography for forming the servo sectors may comprise a plurality of projections having a height in the range from about 20 to about 500 nm, a width in the range from about 0.01 to about 1 μm, and a spacing of at least about 0.01 μm. Stampers/imprinters suitable for use in performing the foregoing patterning processes may be manufactured by a sequence of steps as schematically illustrated in FIG. 6 , which steps include providing a “master” comprised of a substantially rigid substrate with a patterned layer of a resist material thereon, the pattern, which is formed in the resist layer by conventional lithographic techniques, including, e.g., e-beam or laser beam exposure of selected areas of the resist, comprising a plurality of projections and depressions corresponding (in positive or negative image form, as necessary) to the desired pattern, e.g., a servo pattern, to be formed in the surface of the stamper/imprinter. Stampers/imprinters are made from the “master” by initially forming a thin, conformal layer of an electrically conductive material (e.g., Ni) over the patterned resist layer and then electroforming a substantially thicker (“blanket”) metal layer (e.g., Ni in the case of magnetic stampers/imprinters) on the thin layer of electrically conductive material, which electroformed blanket layer replicates the surface topography of the resist layer. Upon completion of the electroforming process, the stamper/imprinter is separated from the “master”. In practice, however, since the “master” with fragile resist layer thereon is effectively destroyed upon separation of the stamper/imprinter from the “master”, a process has been developed involving forming a “family” of stampers/imprinters, as schematically illustrated in FIG. 7 . As shown in the figure, the stamper/imprinter formed directly from the “master” is termed a “father” and has a reverse (i.e., negative) replica of the topographical pattern of the “master”. The “father” is then utilized for forming several (illustratively two) “mothers” therefrom (e.g., as by a process comprising electroforming, as described above), and each “mother” is in turn utilized for forming several (illustratively two, for a total of four) “sons” therefrom (also by a process comprising electroforming). The “sons” are positive replicas of the “father” and are utilized as the stampers/imprinters for media patterning. Since, as described above, the “master” is effectively destroyed in the process of making the “father” therefrom, the “family” making process avoids the need for repeatedly manufacturing “master” stampers/imprinters by preserving the “father” and utilizing the “sons”. Therefore, process time and cost of making “masters” is substantially reduced by means of the “family” making process. The thus-formed “sons” are then subjected to further processing for forming stampers/imprinters with a desired dimension (i.e., size) and geometrical shape or contour, e.g., an annular disk-shaped stamper/imprinter for use in patterning of annular disk-shaped media such as hard disks, which stampers/imprinters necessarily include a circularly-shaped central aperture defining an inner diameter (“ID”) and a circularly-shaped periphery defining an outer diameter (“OD”). The “family” making process, as described supra, is made possible/practical only if the “mothers” are readily separated from the “father” without incurring damage to the patterned surface(s), and the “sons” are similarly readily separated from the “mothers” without incurring damage to the patterned surface(s). As a consequence, the patterned surfaces of the “father” and the “mothers” are each provided with a coating layer of a material, termed a “release” layer and typically comprised of a passivating material, prior to formation of the respective “mothers” and “sons”, for facilitating separation, i.e., “release”, of the “mothers” from the “father” and the “sons” from the “mothers”. A typical method for forming the release layer, such as when at least the imprinting surface of the stamper/imprinter is comprised of a metal or alloy, e.g., a magnetic metal or alloy, such as Ni or a Ni-based alloy, involves formation of a thin layer of a passivating oxide of the metal or metal alloy on the imprinting surface of the “father” and the “mothers” by means of a “wet” process, such as, for example, electrochemical anodization or application of an oxidizing solution. Electrochemical anodization of the Ni or Ni-based alloys utilized in the formation of magnetic stampers/imprinters is typically performed utilizing an alkaline aqueous solution of tri-sodium phosphate (Na 3 PO 4 ). However, the “wet” process of electrochemical anodization for forming passivating oxides for use as release layers is disadvantageous in that it: (1) is a source of defect generation in the topographical pattern of the imprinting surface; and (2) is incompatible with the other, i.e., “dry”, processes utilized for manufacture of the stampers/imprinters, such as the sputtering processing utilized for forming thin metal layers on the patterned surfaces prior to the electroforming step. In view of the foregoing problems, drawbacks, and disadvantages attendant upon the use of conventional “wet” processing techniques, e.g., electrochemical anodization, for forming passivation layers on the imprinting surfaces of the “father” and “mothers” to facilitate separation of the respective “mothers” and “sons” therefrom in a “family” making process for manufacturing stampers/imprinters for use in patterning of recording media, there exists a need for methodologies for manufacturing a “family” of stampers/imprinters which are free of the above-described problems, drawbacks, and disadvantages associated with the use of wet techniques for the formation of passivation layers utilized for facilitating release or separation of the “mothers” and “sons” from the respective “father” and “mothers”. Moreover, there exists a need for methodologies which facilitate rapid, reliable, and cost-effective manufacture of “families” of stampers/imprinters for use in rapid, reliable, accurate, and cost-effective patterning of a variety of types of recording media including, but not limited to, formation of servo patterns in magnetic and magneto-optical (MO) recording media. The present invention addresses and solves the aforementioned problems, drawbacks, and disadvantages associated with the use of conventional wet techniques for the formation of passivation layers utilized for facilitating release or separation of the “mothers” and “sons” from the respective “father” and “mothers”, while maintaining full compatibility with the requirements of automated manufacturing technology. DISCLOSURE OF THE INVENTION An advantage of the present invention is an improved method of manufacturing a stamper/imprinter for use in patterning of a recording medium. Another advantage of the present invention is an improved method of manufacturing a plurality of stampers/imprinters for use in contact patterning of a magnetic recording medium. Additional advantages and other features of the present invention will be set forth in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from the practice of the present invention. The advantages of the present invention may be realized as particularly pointed out in the appended claims. According to an aspect of the present invention, the foregoing and other advantages are obtained in part by an improved method of manufacturing a stamper/imprinter for use in patterning of a recording medium, comprising sequential steps of: (a) providing a substrate/workpiece comprising a topographically patterned surface including a plurality of projections and depressions corresponding to a pattern to be formed in a surface of a recording medium; (b) forming a thin release layer in conformal contact with the topographically patterned surface by means of a dry process; (c) forming (e.g., by electroforming) a thicker layer of a material in conformal contact with the thin release layer on the topographically patterned surface; and (d) separating the thicker layer of material from the topographically patterned surface to form therefrom a stamper/imprinter including an imprinting surface having a negative image replica of the topographically patterned surface, separation of the thicker layer of material from the topographically patterned surface being facilitated by the thin release layer formed by the dry process. According to embodiments of the present invention, step (a) comprises providing a substrate/workpiece wherein the topographical pattern corresponds to a magnetic pattern including a servo pattern for a magnetic or magneto-optical (MO) recording medium, a read-only memory (ROM) pattern, or a wobble groove pattern for a readable compact disk (CD-R) or a readable-writable compact disk (CD-RW). Preferred embodiments of the invention include those wherein step (a) comprises providing a substrate/workpiece wherein the topographical pattern corresponds to a magnetic pattern including a servo pattern for a magnetic or magneto-optical (MO) recording medium, in which instance step (a) comprises providing a substrate/workpiece wherein at least the topographically patterned surface is comprised of at least one magnetic material having a high saturation magnetization B sat ≧0.5 Tesla and a high permeability μ≧˜5; step (b) comprises forming at least one passivating oxide of the at least one magnetic material as said the release layer, e.g., step (b) comprises forming at least one passivating oxide as a thin release layer from about 50 to about 200 Å thick; and step (c) comprises forming a layer of at least one magnetic material having a high saturation magnetization B sat ≧0.5 Tesla and a high permeability μ≧˜5 as the thicker layer. According to embodiments of the present invention, step (b) comprises forming the at least one passivating oxide by thermal oxidation of the at least one magnetic material in an O 2 -containing atmosphere. Preferred embodiments of the present invention include those wherein step (b) comprises forming the at least one passivating oxide by means of a plasma; as when step (b) comprises treating the topographically patterned surface with an oxygen (O 2 ) plasma under conditions selected for minimizing deformation and/or degradation of the pattern and for an interval sufficient for facilitating release of the thicker layer of at least one magnetic material therefrom in step (d). According to alternative preferred embodiments of the present invention, step (b) comprises forming the at least one passivating oxide by means of a DC, RF, or microwave plasma, or a combination thereof; e.g., step (b) comprises exposing the topographically patterned surface to an oxygen (O 2 ) plasma, under conditions selected for minimizing deformation and/or degradation of the pattern and for an interval sufficient for facilitating release of the thicker layer of at least one magnetic material therefrom. In accordance with particularly preferred embodiments of the present invention, step (a) comprises providing a substrate/workpiece comprising at least one magnetic material selected from the group consisting of: Ni, NiFe, CoNiFe, CoSiFe, CoFe, and CoFeV; step (b) comprises forming the thin release layer as comprising at least one passivating oxide of at least one magnetic material selected from the group consisting of Ni, NiFe, CoNiFe, CoSiFe, CoFe, and CoFeV; step (c) comprises forming a layer comprising at least one magnetic material selected from the group consisting of: Ni, NiFe, CoNiFe, CoSiFe, CoFe, and CoFeV as the thicker layer; and step (d) comprises separating the thicker layer of at least one magnetic material from the topographically patterned surface to form therefrom a magnetic stamper/imprinter including an imprinting surface having a negative image replica of the topographically patterned surface, the magnetic stamper/imprinter being usable for contact patterning of magnetic recording media; wherein step (b) comprises treating said topographically patterned surface of said substrate/workpiece with an oxygen (O 2 ) plasma under conditions selected for minimizing deformation and/or degradation of said pattern and for an interval sufficient for facilitating release of said thicker layer of at least one magnetic material therefrom. Further preferred embodiments of the present invention include those wherein the method further comprises repeating steps (a)–(d) at least once, utilizing the same substrate/workpiece provided in step (a), to form at least one additional stamper/imprinter therefrom, or utilizing the stamper/imprinter formed in step (d) as the substrate/workpiece for performing a sequence of steps (a)–(d) for manufacturing at least one additional stamper/imprinter therefrom. Another aspect of the present invention is a method of manufacturing a plurality of stampers/imprinters for use in contact patterning of a magnetic recording medium, comprising sequential steps of: (a) providing a first stamper/imprinter comprising a topographically patterned surface including a plurality of projections and depressions corresponding to a magnetic pattern including a servo pattern to be formed in a surface of a recording medium, the topographically patterned surface comprised of at least one magnetic material having a high saturation magnetization B sat ≧0.5 Tesla and a high permeability μ≧˜5, selected from the group consisting of: Ni, NiFe, CoNiFe, CoSiFe, CoFe, and CoFeV; (b) forming a thin release layer, from about 50 to about 200 Å thick, in conformal contact with the topographically patterned surface by means of a dry process, said thin release layer comprising at least one passivating oxide of at least one magnetic material selected from the group consisting of Ni, NiFe, CoNiFe, CoSiFe, CoFe, and CoFeV; and (c) forming a thicker layer of at least one magnetic material in conformal contact with the thin release layer, the thicker layer comprised of at least one magnetic material having a high saturation magnetization B sat ≧0.5 Tesla and a high permeability μ≧˜5, selected from the group consisting of: Ni, NiFe, CoNiFe, CoSiFe, CoFe, and CoFeV; (d) separating the thicker layer of at least one magnetic material from the topographically patterned surface to form therefrom a second stamper/imprinter including an imprinting surface having a negative image replica of the topographically patterned surface, separation of the thicker layer of at least one magnetic material from the topographically patterned surface being facilitated by the thin release layer formed by the dry process, wherein: the first stamper/imprinter is a “father” and the second stamper/imprinter is a “mother”, or the first stamper/imprinter is a “mother” and the second stamper/imprinter is a “son”. According to preferred embodiments of the invention, step (b) comprises treating the topographically patterned surface with an oxygen (O 2 ) plasma to form the thin release layer under conditions selected for minimizing deformation and/or degradation of the pattern and for an interval sufficient for facilitating release of the thicker layer of material therefrom in step (d); and the method further comprises repeating steps (a)–(d) at least once, utilizing the “father” or “mother” provided in step (a) as the first stamper/imprinter, to form at least one additional “mother” or “son” therefrom, or utilizing a “mother” stamper/imprinter formed in step (d) as the first stamper/imprinter for performing a sequence of steps (a)–(d) for manufacturing at least one “son” stamper/imprinter therefrom. Additional advantages and aspects of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein embodiments of the present invention are shown and described, simply by way of illustration of the best mode contemplated for practicing the present invention. As will be described, the present invention is capable of other and different embodiments, and its several details are susceptible of modification in various obvious respects, all without departing from the spirit of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as limitative. BRIEF DESCRIPTION OF THE DRAWINGS The following detailed description of the embodiments of the present invention can best be understood when read in conjunction with the following drawings, in which the various features are not necessarily drawn to scale but rather are drawn as to best illustrate the pertinent features, wherein: FIG. 1 illustrates, in simplified, schematic plan view, a magnetic recording disk designating the data, servo pattern, and CSS zones thereof; FIG. 2 illustrates, in schematic, simplified cross-sectional view, a sequence of process steps for contact printing a magnetic transition pattern in the surface of a perpendicular magnetic recording layer, utilizing a stamper/imprinter formed of a high saturation magnetization, high permeability magnetic material having an imprinting surface with a surface topography corresponding to the desired magnetic transition pattern; FIG. 3 illustrates, in schematic, simplified cross-sectional view, a similar sequence of process steps for contact printing a magnetic transition pattern in the surface of a longitudinal magnetic recording layer; FIGS. 4(A)–4(D) illustrate, in simplified cross-sectional view, a process sequence for performing thermal imprint lithography of a thin resist film on a substrate (workpiece), according to the conventional art; FIG. 5 schematically illustrates, in simplified cross-sectional view, another sequence of steps for performing imprint lithography of a resist film; FIG. 6 schematically illustrates, in simplified cross-sectional view, a sequence of steps for forming a stamper/imprinter for recording media patterning; FIG. 7 is a schematic flow chart for illustrating a sequence of process steps for manufacturing a plurality of stampers/imprinters from a single “master”; and FIG. 8 schematically illustrates, in simplified cross-sectional view, a sequence of steps for forming a magnetic stamper/imprinter for use in contact patterning of magnetic recording media, according to the methodology of the present invention. DESCRIPTION OF THE INVENTION The present invention addresses and solves problems, disadvantages, and drawbacks attendant upon the formation of “families” of stampers/imprinters, e.g., magnetic stampers/imprinters for use in rapidly and cost-effectively performing servo patterning of magnetic recording media (e.g., hard disks) by contact patterning, by means of a fabrication process sequence wherein a “mother” stamper/imprinter is initially formed with a topographically patterned imprinting surface in conformal contact with a similarly topographically patterned surface of a “father” stamper/imprinter and subsequently separated therefrom, or a “son” stamper/imprinter is initially formed with a topographically patterned imprinting surface in conformal contact with a similarly topographically patterned surface of a “mother” stamper/imprinter and subsequently separated therefrom, followed by utilization of the resultant stampers/imprinters for forming servo patterns in the surfaces of magnetic recording media by contact patterning, as described supra. Specifically, the present invention eliminates problems, disadvantages, and drawbacks associated with the use of “wet” processing techniques, such as electrochemical anodization or treatment with an oxidizing solution, for forming thin, metal oxide passivation/release coating layers on the topographically patterned imprinting surfaces of the “father” or “mother” stampers/imprinters prior to formation of the respective “mother” or “son” stampers/imprinters in conformal contact therewith, which release layers facilitate separation and multiple re-use of the “father” and “mother” stampers/imprinters. As indicated above, electrochemical anodization of the Ni or Ni-based alloys utilized in the formation of magnetic stampers/imprinters is typically performed utilizing an alkaline aqueous solution of tri-sodium phosphate (Na 3 PO 4 ). However, the “wet” process of electrochemical anodization for forming passivating oxides for use as release layers is disadvantageous in that it: (1) is a source of defect generation in the topographical pattern of the imprinting surface; and (2) is incompatible with the other, i.e., “dry”, processes utilized for manufacture of the stampers/imprinters, such as the sputtering processing utilized for forming thin metal layers on the patterned surfaces prior to the electroforming step. According to preferred embodiments of the present, therefore, formation of the release layer on the topographically patterned (e.g., servo patterned) imprinting surfaces of stampers/imprinters, e.g., magnetic stampers/imprinters comprised of at least one magnetic metal or alloy (as enumerated above), is accomplished by means of a plasma, e.g., plasma oxidation utilizing an oxygen (O 2 ) plasma for forming a thin passivating oxide layer which functions as a release layer facilitating separation of the stampers/imprinters. Since a principal feature of the invention is oxidation of the topographically patterned imprinting surface of the stamper/imprinter, e.g., a Ni or Ni alloy surface, to form a Ni oxide or an oxide of the Ni alloy, an O 2 plasma process which differs from the O 2 plasma treatments typically utilized for material removal (i.e., etching) and cleaning, is utilized. More specifically, according to the inventive methodology, the O 2 plasma is very “soft” and gentle compared to the conventional O 2 plasmas, e.g., wherein the pressure ≧200 mTorr and the power ≦100 W, in order to avoid exposing the topographically patterned imprinting surfaces to a harsh environment capable of disadvantageously resulting in deformation and/or degradation of the pattern features. According to the invention, after a “father” stamper/imprinter is separated from a “master”, as at the beginning of a “family” making process, e.g., as schematically illustrated in FIG. 7 and described above, the topographically patterned imprinting surface of the “father” stamper/imprinter comprising a negative image replica of the topographically patterned surface of the “master” stamper/imprinter is subjected to a preliminary treatment with ozone (O 3 ) and UV irradiation for removing any resist residue from the “master”. Referring to FIG. 8 , which schematically illustrates, in simplified cross-sectional view, a sequence of steps for forming a magnetic stamper/imprinter for use in contact patterning of magnetic recording media, according to the inventive methodology, the O 3 /UV treated “father” stamper/imprinter is then immediately treated with a soft and gentle O 2 plasma (wherein, as previously indicated, the pressure ≧200 mTorr and the power ≦100 W)), e.g., a DC, RF, or microwave plasma, or a combination thereof, for forming a thin (e.g., from about 50 to about 200 Å thick) layer of a passivating oxide as a release layer facilitating separation therefrom of a subsequently electroformed “mother” stamper/imprinter having an imprinting surface which is a negative image replica of the imprinting surface of the “father” stamper/imprinter. A similar O 2 plasma process, not necessarily requiring the preliminary O 3 /UV treatment for residual resist removal, is performed on the “mother” stampers/imprinters prior to their use in fabricating “son” stampers/imprinters, as illustrated in FIG. 7 . According to the invention, the topographically patterned imprinting surface of the stamper/imprinter is treated with the O 2 plasma under conditions selected for minimizing deformation and/or degradation of the pattern (e.g., a servo pattern) and for an interval sufficient for facilitating release of the “mother” or “son” from the respective “father” or “mother”. The O 2 plasma-treated imprinting surface of the stamper/imprinter is then subjected to sputtering of a thin, electrically conductive layer thereon, e.g., a Ni or Ni alloy layer, which thin, electrically conductive layer is necessary for effecting subsequent formation, by an electroforming process, of a thicker, mechanically robust “blanket” layer of a magnetic material, e.g., Ni or a Ni alloy, in conformal contact with the release layer-coated imprinting surface of the stamper/imprinter. After the “mother” or “son” is electroformed on the respective “father” or “mother”, the “father”/“mother” or “mother”/“son” pair is removed from the electroforming bath, rinsed, and thoroughly dried before separation. The “mother” is then separated from the “father”, or the “son” is separated from the “mother”, utilizing the passivating oxide as a release layer for facilitating separation of the pairs of stampers/imprinters. In cases where the “father” or the “mother” stamper/imprinter is to be re-used for forming additional “mothers” and “sons”, it is then immediately placed back into the apparatus (comprising interconnected vacuum chambers) for re-formation of the thin passivation/release layer on the topographically patterned imprinting surface by means of O 2 plasma treatment, followed by sputtering of the thin, electrically conductive layer and electroforming of the “blanket” layer. In this way, liquid contamination and defect generation of the O 3 /UV and O 2 plasma-treated imprinting surfaces is effectively minimized. The advantageous nature, features, and capabilities of the invention will now be illustrated by reference to the following non-limitative examples, wherein an Oxford RIE “Plasmalab 80 plus” apparatus was utilized for performing the O 2 plasma oxidation/passivation process for forming release layers. A pair of topographically patterned Ni-based “mother” stampers/imprinters (i.e., Nos. 1 and 2 ) and a Ni-based mirror-finished “mother” stamper/imprinter were treated with a soft and gentle O 2 plasma for different intervals to form a passivating oxide layer thereon for use as a release layer during subsequent formation of a “son” stamper/imprinter therefrom. A separation test was performed on each of the “mother”/“son” pairs after electroforming of the “blanket” layer. the results are given in Table I below. TABLE I “Son” stamper “Mother” stamper O 2 plasma treatment separation Patterned No. 1 2 min., 100 W, 200 mTorr, O 2 Failed flow 50 sccm Mirror-finished 10 min., 100 W, 200 mTorr, O 2 Successful flow 50 sccm Patterned No. 2 10 min., 100 W, 200 mTorr, O 2 Successful flow 50 sccm As is evident from the results presented in Table I, successful separation of the “son” stamper/imprinter from the “mother” stamper/imprinter (i.e., No. 2 ) occurred when the O 2 plasma treatment was of sufficient duration, i.e., ˜10 min., as to cause formation of an effective oxide passivation/release layer. Microscopic inspection of the imprinting surface of patterned “mother” stamper/imprinter No. 2 after separation therefrom of the “son” stamper/imprinter indicated essentially complete absence of pattern deformation, tearing, or debris formation. Results of Atomic Force Microscopy (“AFM”) measurements of the topographically patterned imprinting surface of the “mother” stamper/imprinter No. 2 after the 10 min. O 2 plasma treatment are given in Table II below, which results indicate that the pattern features are very well preserved upon separation and no significant changes in the pattern occur as a result of the dry (O 2 ) plasma passivation process. TABLE II Before O 2 plasma After O 2 plasma treatment treatment Average depth  97 nm  97 nm Average width 159 nm 156 nm Average wall angle 72° 74° The present invention thus affords a number of significant advantages over previous processes for forming stampers/imprinters utilized for patterning various types of recording media, including, but not limited to, formation of servo patterns in magnetic recording layers, including the ability to form stampers/imprinters from larger-sized substrates/workpieces without damaging or otherwise compromising the quality of the topographical pattern. It should be apparent to one of ordinary skill in the art that the present invention provides a significant improvement over the conventional art such as has been described above, particularly with respect to the ease and simplicity of manufacturing high replication fidelity stampers/imprinters for use in various types of media patterning processes. Further, the imprinting surface of the stampers/imprinters according to the invention can be formed with a wide variety of topographical patterns, whereby the inventive methodology can be rapidly, easily, and cost-effectively implemented in the automated manufacture of a number of articles, devices, etc., requiring patterning, of which servo patterning of longitudinal and perpendicular magnetic recording media merely constitute examples of the versatility and utility of the invention. In the previous description, numerous specific details are set forth, such as specific materials, structures, processes, etc., in order to provide a better understanding of the present invention. However, the present invention can be practiced without resorting to the details specifically set forth. In other instances, well-known processing materials and techniques have not been described in detail in order not to unnecessarily obscure the present invention. Only the preferred embodiments of the present invention and but a few examples of its versatility are shown and described in the present disclosure. It is to be understood that the present invention is capable of use in other combinations and environments and is susceptible of changes and/or modifications within the scope of the inventive concept as expressed herein.
A method of manufacturing a stamper/imprinter for use in patterning of a recording medium comprises sequential steps of: (a) providing a substrate/workpiece comprising a topographically patterned surface including a plurality of projections and depressions corresponding to a pattern to be formed in a surface of the recording medium; (b) forming a thin release layer in conformal contact with the topographically patterned surface by means of a dry process; (c) forming a thicker layer of a material in conformal contact with the thin passivation layer on the topographically patterned surface; and (d) separating the thicker layer of material from the topographically patterned surface to form therefrom a stamper/imprinter including an imprinting surface having a negative image replica of the topographically patterned surface, separation of the thicker layer of material from the topographically patterned surface being facilitated by the thin release layer formed by the dry process.
2
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a pressure-sensitive recording paper. More particularly, it relates to a pressure-sensitive recording paper using a compound, in which two alkyl-substituted benzene nuclei are connected with each other through the unit --C n H 2n ), as a solvent for a color former: ##STR2## wherein n is an integer of from 1 to 8, R and R' each is an alkyl group having one to eight carbon atoms or a hydrogen atom, p and q each is the number of alkyl groups, p+q being an integer of 1-3, and wherein R and R' may be the same. 2. Description of the Prior Art The object of the present invention is to obtain a pressure-sensitive recording paper having no unpleasant smell and toxicity, and capable of forming a color image having a higher density without giving a color fog. Usually, as pressure-sensitive recording paper, there are those comprising so-called upper paper prepared by dissolving a substantially colorless compound (hereinafter referred to as a "color former") in an organic solvent, encapsulating it, and then coating the capsules onto a support; lower paper prepared by coating a color-developing material (hereinafter referred to as a "color developer"), which is capable of forming colored images, onto another support; and, in some cases, middle paper prepared by coating capsules containing a color former onto one side of a support and a color developer onto the other side thereof, or those containing said capsules and a color developer onto the same side of a support. In the case of the combination of upper and lower paper, or upper, middle and lower paper, color is developed by locally pressing in such a way that the capsule layer comes into contact with the color developer layer to decompose the capsules located at the pressed part and to cause reaction between the color former and the color developer. When a pressure sensitive recording paper having capsules and a color developer agent on the same surface thereof is used, color will be developed by pressing in the same way. As the color developer, active clay materials, such as acid clay, active zeolite and bentonite, or organic acidic materials, such as succinic acid, tannic acid, gallic acid, pentachlorphenol and phenol resin are generally used. As a color former for a pressure sensitive recording paper, malachite green lactone, benzoyl leucomethylene blue, crystal violet lactone, rhodamine B lactom, 3-dialkylamino-7-alkylfluorans, 3-methyl-2,2'-spirobi(benzo[f]chromene), etc. are used. The conditions a solvent dissolving a color former for pressure sensitive recording paper should satisfy are: a. to have enough solubility to dissolve a necessary amount of color former, b. to have a high boiling point so as not to vaporize in a heat-drying process and in a place of elevated temperature, c. not to be eluted on encapsulation, d. not to desensitize or prevent the color formation on the lower paper, e. not to provide changes, such as decomposition of the color former, color formation, etc., f. to have a low viscosity so that the effusion thereof from inside the capsules can be freely done on breakage of the capsules, and to have a small rise in viscosity, even at low temperature, g. to have no unpleasant smell, h. to have little toxicity to human beings and animals, and the like. Among these, conditions (a)-(e) are especially of importance and, if one of these conditions is not satisfied, the solvent cannot be used as a solvent for a color former. In fact, however, solvents satisfying conditions of said (a)-(h) have so far not been found. Therefore, as things are, those prepared by mixing several kinds of solvents in a suitable ratio are used. That is, ethers do not satisfy the conditions of (a) and (d), alcohols do not satisfy the conditions of (a), (c) and (d), parafins do not satisfy the conditions of (a), ketones, esters, olefins and amines do not satisfy the conditions of (d), and organic acids to not satisfy the conditions of (c), and usual aromatic hydrocarbons do not satisfy the conditions of (a), (g) and (h). Chlorinated diphenyl now used as a solvent for pressure sensitive recording paper, nearly satisfies the conditions of (a) to (e). It has, however, defects in that, at a low chlorination degree, it has a peculiar unpleasant smell, while it has low viscosity and that, at high chlorination degree, it has high viscosity, and does not have much of an unpleasant smell. That is, the viscosities of low chlorinated trichlorodiphenyl and tetrachlorodiphenyl are comparatively low. However, they have a peculiar unpleasant smell. Highly chlorinated pentachlorodiphenyl and hexachlorodiphenyl have considerably reduced unpleasant smell, but their viscosity conspicuously increases on the other hand. Hexachlorodiphenyl has no fluidity at a room temperature. Therefore, the pressure-sensitive recording paper wherein low chlorinated trichlorodiphenyl and tetrachlorodiphenyl are used, has the defect of having an unpleasant smell. The pressure sensitive recording paper wherein highly chlorinated pentachlorodiphenyl and hexachlorodiphenyl are used, has the defect in that the effusion thereof is difficult to be freely done due to their high viscosity and that sufficient color density cannot be obtained, while they have less of an unpleasant smell. The pressure-sensitive recording paper wherein the mixture of chlorinated diphenyl with a low chlorination degree and the same with high chlorination degree is used, is a little more improved in the smell than that wherein chlorinated diphenyl with low chlorination degree is used separately and, in the density of the color formed, the former is a little more improved than that wherein highly chlorinated diphenyl is used independently, but the former has still considerable unpleasant smell and the density of color formed is not sufficient. In addition, chlorinated diphenyl is slightly decomposed by light to form hydrogen chloride. Accordingly, the capsule coated sheet wherein chlorinated diphenyl is used has the defect that, when it is exposed to light for a long time, the generated hydrogen chloride will be reacted with the color former to cause colored fog. Furthermore, this capsule coated sheet wherein the colored fog took place has less color developing ability onto the lower paper, and a sufficient density of the color formed cannot be obtained. Besides, chlorinated diphenyl has appreciable toxicity to human beings and animals. Therefore, the conventional pressure sensitive recording paper wherein chlorinated diphenyl is used, has had the defects that it has unpleasant smell, that sufficient density of the color formed cannot be obtained, that when exposed to light for a long time, colored fog on capsule coated sheet and the lowering of the color developing ability thereof to the lower paper take place, and that it has a problem in its toxicity. SUMMARY OF THE INVENTION We, the inventors, as the result of many investigations concerning these kind of solvents, have found that the specific compound represented by the general formula I has properties which are quite adequate for our purpose, and accomplished this invention. That is, the present invention is characterized in that, in the pressure sensitive recording paper, the compound represented by the general formula (I) is used as a solvent for the color former, separately or in combination with other solvents. The compound (I) in this invention is characterized in that two alkyl substituted benzene nuclei are connected with each other through a --C n H 2n ) bond and, as is different from the usual aromatic compounds, the compound (I) of the present invention has a considerably high boiling point, does not vaporize off in a heat drying process or in a place of the elevated temperature, has no unpleasant smell, and in addition, it has no toxicity to human beings and animals. DETAILED DESCRIPTION OF THE INVENTION The reason why p+q in the compound (I) used in the present invention is restricted to not more than 3, is that, when p+q is not less than 4, the viscosity thereof conspicuously increases or the compound becomes solid, which is not desirable. The reason why the number of the carbon atoms contained in R and R', and that in the --C n H 2n ) existing between the two benzene nuclei is not more than 8 and 8, respectively, is that, when the number of the carbon atoms contained in R and R' becomes not less than 9 and n becomes not less than 9, the viscosity thereof conspicuously increases and the solubility of a color former thereto decreases, which is not desirable. The compound of this invention having a particularly restricted structure, satisfies the aforesaid conditions of (a)-(e) demanded for a solvent for the color former of pressure sensitive recording paper. In addition, it has the excellent advantages that there is little rise in viscosity, even at a low temperature, that it has no unpleasant smell or toxicity to human beings and animals, that it raises the stability of the capsule coated sheet to light, that, even when the capsule coated sheet is exposed to light for a long time, the colored fog of the sheet is remarkably less compared with conventional ones, that the color developing ability in developing this capsule coated sheet onto the lower paper does not decrease like the conventional ones, and the like. The pressure sensitive recording paper of this invention is excellent also in that it has a higher density with respect to the color formed compared with conventional pressure sensitive recording paper, wherein chlorinated diphenyl is used. Therefore, it can be said that the compound (I) used in the present invention having a particularly restricted structure is extremely excellent as a solvent for a color former of pressure sensitive recording paper. The compound of the general formula (I) of the present invention may be used in combination with other solvents. As solvents to be mixed together, there are petroleum fractions such as liquid paraffin, kerosene, naphtha, etc., synthesized oils, such as chlorinated paraffin, chlorinated diphenyl, hexahydroterphenyl, alkylnaphthalenes, alkylated polyphenyls, etc., and vegetable oils, such as cotton seed oil, linseed oil, etc. These solvents are mixed and used together in order to adjust the viscosity, to control the solubility of a color former, and to increase the quantity for the reduction of cost, etc. This invention is characterized by using the compound of the general formula (I) having a particularly restricted structure as a solvent for a color former of pressure sensitive recording paper and, accordingly, all of the publicly known art can be applied as a method or process for encapsulating this solvent. Therefore, the present invention is not restricted by the method or process for the encapsulation. The present invention will be further explained by the following Examples, which are merely illustrative and not limitative of the present invention. In the examples of the present invention, there is used as a clay paper (lower paper) prepared as follows. That is, 100 g of sulfuric acid processed acidic terre abla was dispersed in 280 g of water containing 6 g of 40 percent sodium hydroxide aqueous solution using homogenizer. Thereafter, 50 g of a 10 percent aqueous solution of sodium salt of casein and 30 g of a styrene butadiene latex (trade name: Dow Latex 626, made by Dow Chemical Co.), were added thereto as a binder, and coated on a paper by air knife coating, and dried to obtain the clayed paper. EXAMPLE 1 To 100 g of 2,4-dimethyldiphenylmethane obtained by the reaction between meta-xylene and benzyl chloride, having the following formula (b.p. 295°-296° C/760 mmHg, specific gravity (D 4 20 ) 0.9951); ##STR3## was dissolved 3 g of crystal violet lactone. The resulting solution was then added to a solution of 20 g of gum arabic and 160 g of water to emulsify. Thereafter, 20 g of acid processed gelatin and 160 g of water were added thereto and the pH thereof was reduced to 5 by the addition of acetic acid under constant stirring. 500 g of water was then added to cause coacervation. On coacervation, a dense liquid membrane of gelatin-gum arabic was formed around the oil droplets containing a color former. The pH was further reduced to 4.4, and 4 g of 37 percent formation was successively added for hardening the membrane. Said operation was carried out keeping the temperature of the system at a temperature of 50° C. Then the system was cooled to 10° C in order to gel the dense liquid membrane. Furthermore, in order to raise the effect of hardening, the pH thereof was raised to 9 and the system was allowed to stand for several hours to accomplish the encapsulation. The capsule solution thus obtained was coated on a sheet of paper by air knife coating, then dried. The pressure sensitive recording paper thus obtained had no unpleasant smell like that of the conventional pressure sensitive recording paper wherein chlorinated diphenyl was used as a solvent. When this paper (upper paper) was superposed on a clay paper (aforesaid lower paper coated with active clay substance) and writing was conducted with pressure, there was developed a blue image on a clayed paper in an instant. The density of this color developed image was remarkably high compared with that of the conventional pressure sensitive recording paper. In addition, even when this upper paper was exposed to sun light for a long time, the lowering in the color developing ability and colored fog were not recognized. EXAMPLE 2 3 g of rhodamine B lactam was dissolved in 100 g of 2,5-dimethyldiphenylmethane obtained by the reaction between para-xylene and benzyl chloride, having the following formula (b.p. 293.5°-294.5° C/760 mmHg, specific gravity (D 4 20 ) 0.9950); ##STR4## and treated in the same manner as in Example 1 to obtain upper paper. The upper paper thus obtained had no unpleasant smell like that of the conventional pressure sensitive recording paper. When this upper paper was superposed on a clay paper and writing was conducted with pressure, there was developed red image on a clay paper in a moment. The density of color developed image was remarkably high compared with that of the conventional recording paper wherein chlorinated diphenyl was used. Besides, even when this upper paper was exposed to sun light for a long time, the lowering in the color developing ability and fog were not observed. EXAMPLE 3 2 g of 3-diethylamino-7-methylfluoran was dissolved in a mixture of 80 g of octadecyldiphenylmethane having the following structure (mixture of several kinds of isomers, b.p. 232°-244° C/10 mmHg); ##STR5## and 20 g of paraffin containing 10-12 carbon atoms, treated in the same was as in Example 1 to obtain upper paper. The upper paper for pressure sensitive recording paper thus obtained had no unpleasant smell like that of the conventional pressure sensitive recording paper prepared by the analogous treatment using chlorinated diphenyl. When this upper paper was superposed on a clay paper and writing was conducted with pressure, there was developed a red image on a clay paper. The density of this color developed image was remarkably high compared with that of the conventional pressure sensitive recording paper wherein chlorinated diphenyl was used. In addition, even when this upper paper was exposed to sun light for a long time, the lowering in the color developing ability and colored fog were not observed. EXAMPLE 4 3 g of 3-diethylamino-7-dibenzylaminofluoran was dissolved in a mixed oil of 70 g of a mixture of dimethyldiphenylmethane and ethyl-diphenylmethane having a specific gravity of 0.984 at 25° C, a viscosity of 2.27 centistokes at 50° C and a refractive index of 1.5684 at 20° C. ##STR6## and 30 g of isoparaffin containing 12 - 14 carbon atoms, treated in the same way as in Example 1 to obtain upper paper. This upper paper had no unpleasant smell like that of the conventional pressure sensitive recording paper wherein chlorinated diphenyl was used. When this upper paper was superposed on a clay paper and writing was done with pressure, there was developed a blackish green image on a clay paper. The density of this color developed image was remarkably high compared with that of the conventional pressure sensitive recording paper wherein chlorinated diphenyl was used. In addition, even when this upper paper was exposed to sun light for a long time, the lowering in the color developing ability and colored fog were not observed. EXAMPLE 5 0.2 g of 3-diethylamino-7-diethylaminofluoran was dissolved in 20 g of 1,1-di-p-toluylethane (having a melting point lower than 20° C and a boiling point of 295°-300° C/760 mmHg) represented by the following structure: ##STR7## and to this were added 5 g of toluylenediisocyanate and 10 g of methylene chloride containing 3 g of bisphenol A to prepare a first solution. Thereafter, 3 g of polyvinyl alcohol was dissolved in 25 g of water, and to this was added said first solution under vigorous stirring to emulsify. The resulting emulsion was poured into 150 g of water kept at 50° C, and the temperature of the system was raised to 80° C under stirring. The system was maintained at this temperature for 30 minutes to cause polymerization between the toluylenediisocyanate and bisphenol A on the surface of the oil droplets to form a capsule wall, whereby encapsulation was accomplished. The capsule solution thus obtained was coated on a paper by way of roll coating, then dried. The upper paper obtained in this way did not have the unpleasant smell like that of the conventional pressure sensitive recording paper obtained by the analogous treatment using chlorinated diphenyl. When this upper paper was superposed on a clay paper and writing was conducted, there was developed a blackish green image on a clay paper. The density of this color developed image was remarkably high compared with that of the conventional pressure sensitive recording paper wherein chlorinated diphenyl was used. Furthermore, even when this upper paper was exposed to sun light for a long time, the lowering in the color developing ability and colored fog were not observed. EXAMPLE 6 Example 1 was duplicated using 2-methyl-5-isopropyldiphenylmethane (having a boiling point of 307°-310° C and specific gravity of 0.9916 at 20° C) instead of 2,4-dimethyldiphenylmethane, and using 3-methyl-2,2'-spirobi(benzo[f]chromene) instead of crystal violet lactone. The result thereof was the same as in Example 1. .[.EXAMPLE 7.]. .[.Example 1 was duplicated, except that 1,1-diphenyl-1-heptylmethane (having a boiling point of 143°-145° C/0.1 mmHg, a melting point of -5 to -4° C and a specific gravity of 0.9444 at 20° C).]. ##STR8## .[.was used instead of 2,4-dimethyldiphenylmethane. The result thereof was the same as in Example 1..]. EXAMPLE .[.8.]. .Iadd.7 .Iaddend. Example 1 was duplicated, except that 1,2-bis-tolylethane (having a boiling point of 290°-340° C and a specific gravity of 0.968 (25° C), viscosity 3.2 cp (50° C) was used instead of 2,4-dimethyldiphenylmethane. ##STR9## The result thereof was the same as in Example 1. EXAMPLE .[.9.]. .Iadd.8 .Iaddend. Example 1 was duplicated, except that dimethyl-t-butyldiphenylmethane (mixture of several kinds of isomers, having a boiling point of 132°-148° C/0.1 mmHg) was used instead of 2,4-dimethyldiphenylmethane, and the same result as in Example 1 was obtained. Although the present invention has been adequately set forth in the foregoing specification and Examples included therein, it is readily apparent that various changes and modifications can be made without departing from the spirit and scope thereof.
A pressure-sensitive recording paper comprising a support having coated thereon a layer of color former, said color former dissolved in at least one compound represented by the following formula: ##STR1## wherein n is an integer of 1 to 8, R and R' each represent a member selected from the group consisting of alkyl groups containing one to eight carbon atoms, and a hydrogen atom, p and q represent the number of alkyl groups, p+q being an integer of 1 to 3, and R and R' may be the same.
8
BACKGROUND OF THE INVENTION This invention relates generally to analog-to-digital converters, and in particular to a multiple-slope integrating analog-to-digital converter having improved accuracy and resolution. Conventional dual-slope integrating analog-to-digital converters (ADCs) are well known to those skilled in the art, and operate by placing a charge on a capacitor associated with an operational amplifier integrator proportional to an unknown voltage to be measured (charging the capacitor for a predetermined period of time, resulting in the first slope of the dual-slope system), applying a reference voltage to discharge the integrator capacitor at a known rate (resulting in the second slope) and measuring the amount of time for discharge, and finally calculating the unknown voltage as a ratio of the measured time and the predetermined time multiplied by the reference voltage. Because of the long time periods and perhaps relatively high voltage headroom required to charge and discharge in the integrator capacitor in high resolution ADC systems, multiple slope integrating ADCs were devised which periodically remove or add known quantities of charge (represented by slopes of known polarity and duration) during the integrate, or charge cycle (also known as the run-up cycle) so that an unknown input voltage is never large enough to saturate the integrator, and a relatively small charge remains on the integrating capacitor to be discharged during the de-integrate, or discharge cycle (also known as the run-down cycle). The charge removed or added during the integrate cycle is kept track of by counting slopes which represent the known quantities of charge removed or added, and accounted for in making the final determination of the value of the unknown voltage. The multiple slope techniques may also be applied during the de-integrate or run-down cycle to shorten the amount of time required to discharge the integrator capacitor, resulting an ADC with increased sensitivity and speed. An example of a multiple slope integrating ADC is taught in U.S. Pat. No. 4,357,600 to Ressemeyer et al. Many of the problems associated with prior art multiple slope integrating ADCs stem from the large number of high-speed switching operations that occur in a short period of time, particularly during the integrate cycle. For example, mismatches in the physical characteristics of the switches themselves, however slight, will result in timing errors that will add up over the course of two thousand switching operations. Mismatches in reference currents, rectification of cross coupling of switch control signals which pumps extraneous current into the integrator summing node, and switch charge injection which also delivers unwanted current into the integrator summing node all result in non-linear errors, offset, and scale factor errors which cumulatively degrade measurement accuracy. These errors are very critical in analog-to-digital converters with 51/2 or 61/2 digits of resolution. The errors are significantly worse when standard components such as off-the-shelf analog switches are used for the input switching circuits. Prior art investigators have attempted to overcome these problems by implementing the input switching circuits in application-specific integrated circuit form and tightly controlling the manufacturing process, leading to very expensive solutions. Another problem associated with prior art multiple slope integrating ADCs is what is known as the "toning" effect, or fixed pattern that occurs with the integrator after many, many switching operations in which the switching sequence is always the same. As an example, for input voltages near zero volts, a small change in input voltage may result in a larger than expected change in the measured output due to a change in the pattern. This error is referred to as differential non-linearity. SUMMARY OF THE INVENTION In accordance with the present invention, an improved multiple slope analog-to-digital converter overcomes the foregoing problems and provides increased accuracy and resolution. The multiple slope ADC comprises an integrator followed by slope amplifier and a comparator in which an input voltage to be measured is applied to a summing node at the input of the integrator during an integrate cycle, while at the same time positive and negative reference currents are selectively applied to the summing node by a controller which monitors the output of the comparator in order to limit the voltage magnitude at the output of the integrator and to determine the order and sequence in which the positive and negative currents are applied. Thereafter, during a de-integrate cycle, the input voltage is disconnected while progressively shallower ramps are measured with a high-speed clock for greater resolution and accuracy. The slope amplifier expands the ramp around the comparator switching threshold to increase the switching sensitivity of the comparator. Diode clamps prevent overdriving the comparator input, facilitating quick recovery of the comparator, whose output is monitored by the controller. Also, the comparator has a slight hysteresis built in to slightly separate the switching thresholds for positive-going and negative going ramps, reducing the tendency of the comparator to chatter or oscillate when very shallow ramps are applied from the slope amplifier. The switches which control selection of the positive and negative reference currents are implemented in such a way that current surges are minimized. That is, each switch is a series-parallel pair of switches in which the series switch of the pair provides a path to the integrator summing node while the parallel switch of the pair provides a path to ground, and one of the switches in the switch pair is closed while the other of the pair is closed. State machine diagrams are used to express the algorithms used by the controller in operating the switches throughout the integrate and de-integrate cycles. The order and sequence in which the switches are operated eliminates the effects of charge injection due to operation of the switches as well as signals that are cross-coupled from the control lines of adjacent switches. The controller maintains in storage a history of the switching sequence and present comparator output, and from that information determines which reference (or both references) to apply or not apply to the integrator summing node. Counters are provided separately to keep track of the length of time the respective positive and negative currents are turned on during the integrate cycle, and adjustments may be made using predetermined calibration factors to correct reference current mismatch, offset, and gain errors in the ADC system. Thus, circuit parameters and values need not be precise as long as they are stable, permitting the use of readily-available and inexpensive off-the-shelf parts and components. It is therefore one feature of the present invention to provide an improved multiple slope analog-to-digital converter having increased accuracy and resolution. It is another feature of the present invention to provide an improved multiple slope analog-to-digital converter in which the effects of cross-coupled switch charge injection are eliminated. It is a further feature of the present invention to provide an improved multiple slope analog-to-digital converter which can be calibrated to resolve errors, thus obviating the need for precise operating parameters and components. Other objects, features, and advantages of the present invention will become obvious to those having ordinary skill in the art upon a reading of the following description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram of a multiple slope integrating analog-to-digital converter in accordance with the present invention; FIG. 2 is a set of waveforms of the integrator output voltage for negative, zero, and positive voltage inputs during a partial integrate cycle; FIG. 3 is a set of waveforms of the integrator output voltage in response to switching reference voltages during an integrate cycle for two-pass and interleaved operation; FIGS. 4A and 4B are waveforms to explain one aspect of the present invention; FIGS. 5A and 5B are state machine diagrams for integrate and de-integrate cycles, respectively; and FIGS. 6A and 6B are waveform diagrams of the integrator output voltage during the integrate cycle in association with the state machine operation of FIGS. 5A and 5B, respectively. DETAILED DESCRIPTION OF THE INVENTION Referring to FIG. 1 of the drawings, there is shown a multiple slope integrating analog-to-digital converter in which a voltage input to be measured is applied to an INPUT terminal 10-1, and then through a resistor 12-1 and closed contact A (shown open) of a switch 14-1 to a summing node 16. Other inputs to the summing node 16 include stable reference voltages +REF and -REF, which are nominally equal and of opposite polarity, applied via nominally equal-valued resistors 12-2 and 12-3 and switches 14-2 and 14-3, respectively, and reference voltage +REF applied via resistor 12-4 and switch 14-4, and will be discussed in detail later. An integrator 18 comprising an operational amplifier (op amp) A1 having an inverting (-) input connected to summing node 16 and a non-inverting (+) input connected to a common potential such as ground, and a feedback capacitor 20 connected from its output to its-input, produces output voltage ramps whose slopes are proportional to and of opposite polarity to input voltages applied to summing node 16. A slope amplifier 22 comprising an op amp A2 having a+ input connected to the output of integrator 18 and a- input connected to the junction of gain-setting resistors 24 and 26, which are serially disposed between the output of op amp A2 and ground, amplifies the ramp voltage from integrator 18 (provides a steeper slope of the same polarity) to expand the ramp when it passes through zero volts and thereby increase the sensitivity of the comparator in the next stage. A pair of diodes 28 and 30 are connected in opposite directions across resistor 26 to provide a voltage window of +0.6 volt and -0.6 volt to limit the output swing of the slope amplifier. The output of slope amplifier 22 is also connected through a resistor 32 and contact B of a switch 34 to ground during normal measurement operation, and upon reset (RST), through resistor 32 and contact A of switch 34 to the summing node 16 to zero the output prior to a measurement cycle. A comparator 36 comprising an op amp A3 having a- input connected to the output of slope amplifier 22 and a+ input connected through a resistor 38 to ground switches states and produces a digital output whenever the output ramp from the slope amplifier 22 passes through a threshold near zero volts at the comparator input. A resistor 40 is connected from the+ input to the output of op amp A3 to provide positive feedback to establish a few millivolts of hysteresis, separating the thresholds at which the positive-going ramps and negative-going ramps cause the comparator to switch, thereby preventing oscillation of the comparator due to indecision when very shallow ramps are applied to the- input. Resistor 38 in an embodiment built and tested had a value of 10 ohms, while resistor 40 had a value of 3 kilohms. The digital output of comparator 36, because the input (integrator output) is applied to the- input, is low, or CMP=0 if the input is positive with respect to ground, and high, or CMP=1 if the input is negative with respect to ground. Thus, the comparator 36 output goes low, or CMP=0 for positive-going ramps that pass through a first threshold near zero volts and goes high, or CMP=1 for negative-going ramps which pass through a second threshold near zero volts. Of course, zero volts at the comparator input is the switching threshold if resistors 38 and 40 are omitted and the+ input is connected to ground. Also, the logic would be inverted if the integrator output were applied to the+ input of the comparator. A controller 42 controls operation of the multiple slope ADC by controlling the operation of switches 14-1 through 14-4 through a measurement cycle comprising an integrate cycle and subsequent de-integrate cycle and calculating the voltage reading to be displayed on a display device 44. Controller 42 may suitably be a microprocessor, or may be an application-specific logic which performs as a state machine in accordance with either an external or an internal clock, depending on the type of controller, and programmed operating instructions which, in addition to providing instructions for determining and displaying voltage measurements, define a switching sequence algorithm for controlling the operation of the switches. The switches 14-1 through 14-2 and 34 may suitably be implemented in integrated circuit form, or may be commercially available analog switches, such as common 74HC4053 silicon-gate CMOS analog switches, in which the series and parallel switch contacts A and B, respectively, depicted in FIG. 1, connected by dashed lines, are actually transistor devices wherein one transistor is on while the other is off, that is, one switch of an A-B pair is closed while the other is open. The switches are operated by control signals applied over control lines 46-1 through 46-4 and 48, respectively, from controller 42. All of the switches in FIG. 1 are shown with their respective B contacts closed, and their respective A contacts open, so that, as shown, no current flows into summing node 16. Taking a closer look at any of the switches, for example, switch 14-2, it can be discerned that closed contact B is connected to ground, so that, in the example of switch 14-2, a constant current flows through input resistor 12-2. When a control signal arrives on line 46-2 from controller 42, contact A of switch 14-2 snaps closed while contact B snaps open (actually, the transistor represented by contact A turns on while the transistor represented by contact B turns off), and now the current that was flowing to ground is diverted into summing node 16, resulting in no change in current flow through resistor 12-2. Moreover, the stable reference voltage supply +REF will not experience any change in load or output current flow, and will thus remain stable. To further reduce error introduced by the switches themselves, the number of switches required to provide full multiple slope integration has been kept to a minimum. Also, a critical source of error in the ADC is switch charge injection. There are generally two types of charge injection. One is charge injection resulting from the switch's own control signal, and the other is charge injection resulting the from the control of an adjacent switch. The control signals sent over lines 46-1 through 46-4 and 48 from controller 42 to operate the switches are coupled via intrinsic capacitances in the switches as they are being controlled and cross-coupled to adjacent switches, and introduce charge injection current into the summing node as the positive and negative edges of the control signals are differentiated. The switching action of the controlled switches rectifies the differentiated control signals, resulting in a net positive or negative charge being injected into the summing node, depending on the switching sequence. Error introduced by the first type of switch charge injection is eliminated by operating the switches a constant number of times over a fixed integration time interval T, independent of an input voltage to be measured, for all input levels, both positive and negative, as is well known by those skilled in the art. The other type of charge injection due to cross-coupling of control signals to adjacent switches is more insidious because it occurs while one reference voltage is already on, and another reference voltage is turned on, and the differentiated edges get conducted to ground or to the summing node differently depending on the phase relationship of the reference-switch control signals. The switching scheme of the present invention solves this problem by choosing the sequence in which the switches are operated, making errors caused by charge injection a constant that can be removed like an offset. Before discussing the sequence of switching in accordance with the present invention, it is important to understand the basic operation of the multiple slope integrating ADC during an integrate cycle. FIG. 2 shows the output of integrator 18 in response to an applied negative, zero, and positive input voltages for a partial integrate cycle. An integrate cycle is one in which contact A of switch 14-1 remains closed for a fixed time period to allow an input voltage applied to input terminal 10-1 to place a charge on integrator capacitor 20, and switches 14-2 and 14-3 are operated a fixed number of times to connect negative and positive reference voltages -REF and +REF, depending on the output of comparator 36, to the integrator input for fixed periods of time T I , resulting in addition or subtraction of charge on integrator capacitor 20 as exemplified by positive and negative ramps, respectively, at the output of integrator 18 to minimize the magnitude of voltage applied to amplifier 22. It can be seen in FIG. 2 that the negative reference voltage -REF is applied for the first one-half cycle to ensure that the integrator output voltage is positive with respect to ground in order for the multiple slope integrator to work. Also, if the integrator output voltage crosses the zero-volts baseline during a time period T I , on the next time period the ramp reverses direction. On the other hand, if the integrator output voltage does not cross the zero-volts baseline during a time period T I , on the next time period the ramp continues in the same direction. Because the reference voltages and summing currents generated through resistors 12-2 and 12-3 may not be precise, the system may be calibrated so that a mismatch of summing currents will not result in an error in the measurement reading provided by the ADC system. This may easily be achieved by having separate counters within or associated with controller 42 that separately count the total length of time that the positive and negative references are turned on during an integrate cycle. In the embodiment built and tested, calibration was effected in the following manner. First, a zero input voltage is applied for one full integration cycle with both reference voltages turned off, and then any charge on the integrator is de-integrated to determine integrator offset due to drift, leakages, noise, etc. Second, both references are turned on with the input disconnected for one full integration cycle, and then any charge on the integrator is de-integrated to determine any imbalance in reference currents. This imbalance, minus integrator offset, is proportional to the ratio of +REF/-REF. Third, the ADC is operated with zero volts applied for a normal integrate cycle as shown in FIG. 2, and any charge on the integrator is de-integrated to determine integrator offset due to switch charge injection. Fourth, the ADC is operated with a known stable reference voltage applied to the input for normal integrate and de-integrate cycles, and any difference between the measurement reading and the reference voltage, minus offset, is proportional to ADC gain. The offsets, gain, and +REF/-REF ratios are stored in memory as calibration constants which can be recalled to calibrate the ADC "on the fly" for each measurement. Referring now to FIG. 3, wherein for simplicity the applied input voltage is zero volts, it can be seen that between alternate connection of the -REF and +REF voltages, there will be short periods of time T s when the -REF and +REF voltages are either both connected to the summing node 16 or both disconnected from the summing node 16. Both of these conditions will result in approximately zero current into the summing node 16 (as mentioned earlier, the reference voltages are nominally equal and of opposite polarity, and resistors 12-2 and 12-3 have nominally equal values), and hence, "flat spots" on the integrator 18 output waveform. It is during the flat spots, or simply "flats," that controller 42 looks at the output of comparator 36 to determine the status of the ADC and decide which reference voltage to apply to the summing node 16. That is, if the comparator output is a digital one (CMP=1), -REF is applied to drive the integrator output in a positive-going direction, and if the comparator output is a digital zero (CMP=0), +REF is applied to drive the integrator output in a negative-going direction. Some desired conditions to be observed during the integrate cycle are (1) the total number of transitions of switches 14-2 and 14-3 must be constant; (2) each switch operates a constant number of times; and (3) switches 14-2 and 14-3 are operated to minimize the voltage magnitude at the output of integrator 18. During the de-integrate cycle, switch 14-1 contact A is opened, and switches 14-2, 14-3 and 14-4 are operated in such a way as to effect a de-integration or removal and measurement of the remaining charge on the integrator capacitor 20. A complete measurement cycle may comprise a "two pass" integrate and de-integrate cycle, that is, two back-to-back integrate and de-integrate cycles in which the switching of resistors 14-2 and 14-3 during the integrate cycles on the two respective passes is controlled to cancel or at least minimize the effects of cross-coupled charge injection into the summing node 16. The cross-coupled charge injection is depicted in FIG. 3 as arrowheads on the switching transitions of the +REF and -REF voltages. Also, the two-pass integrate cycle is depicted as a "first pass" and "second pass" wherein on the first pass, at flat 1 both -REF and +REF are turned on (ON); at flat 2, both are off (OFF); at flat 3, both are ON; at flat 4, both are OFF; and at flat 5, both are ON. On the second pass, the order is reversed (at flat 1; both are OFF, etc.) to eliminate the effects of cross-coupled charge injection. Alternatively, a complete measure cycle may comprise single integrate and de-integrate cycles wherein during the integrate cycle the two passes are interleaved to substantially cancel the effects of cross-coupled charge injection. This is shown in FIG. 3 as a single "interleaved" pass wherein, for a zero volts input, at flat 1 both -REF and +REF are ON; at flat 2, both are OFF; at flat 3, both are OFF; at flat 4, both are ON; and at flat 5, both are ON. It can be discerned that at flat 6 both would be OFF as depicted at flat 2, and the order progresses on through the integrate cycle. It must be borne in mind, however, that this particular sequence may vary, depending upon the input voltage, or depending on the algorithm that controls the order of switching. The order in which both references are on or off may be different than those described herein, as long as at the end of a measurement cycle, both references will have sequenced an approximately equal and constant number of times for a constant integrate cycle and the direction of switch transitions will be approximately equal. It will be helpful to review the waveforms in FIGS. 4A and 4B to fully appreciate this concept. It is important that the number of times that +REF transitions ON while -REF is ON remains nearly constant for all inputs, and the number of time that -REF transitions ON with +REF ON also remains nearly constant for all inputs. Also, the number of -REF OFF transitions, while +REF is ON, is approximately equal to the number -REF ON transitions, while +REF is ON. Likewise, the number of +REF ON transitions while -REF is ON is approximately equal to the number +REF OFF transitions while -REF is ON. The operation of the multiple slope integrating ADC of FIG. 1 will be described in connection with a state machine diagram as shown in FIGS. 5A and 5B. The portion of the state machine diagram shown in FIG. 5A defines an operating algorithm associated with the programmed instructions of controller 42 for the integration portion of the measurement cycle, and the portion of the state machine diagram shown in FIG. 5B defines an operating algorithm associated with the programmed instructions of controller 42 for the de-integration portion of the measurement cycle. The state machine is driven by an internal clock of controller 42 in a conventional manner. The waveforms in FIGS. 6A and 6B, in which the states are indicated for the integrate and de-integrate cycles, respectively, should also be referred to so that a complete understanding of the operating algorithm can be attained in conjunction with circuit operation. FIG. 6A represents the operation of the circuit of FIG. 1 during an integrate cycle for a zero-volts input at input terminal 10-1. Also, in order for the integrate period to help reject power line noise, it must be an exact multiple of 16.666 milliseconds for 60 Hz operation, or 20.000 milliseconds for 50 Hz operation. In an embodiment built and tested, the integrate cycle was 100.000 milliseconds to effect noise rejection for both 50 Hz and 60 Hz operation. The clock frequency of controller 42 was chosen to be 230.4 kHz (clock period=4.3403 microseconds). This value for clock frequency will be used for the state machine clock in the following description to aid in understanding operation. Some component values used in the tested embodiment were 0.012 microfarads for integrator capacitor 20, 80 kilohms for input resistor 12-1, 40 kilohms for both reference voltage resistors 12-2 and 12-3, and 640 kilohms for the 16R resistor 12-4. INTEGRATE CYCLE State 0: At state 0 (S0), which is the idle state for the state machine of controller 42, an auto zero or reset function of the ADC is performed to ensure that the output of integrator 18 is at zero volts before a measurement is started. Controller 42 performs the auto zero function by sending a reset (RST) signal over line 48 to switch 34, closing contact A and opening contact B so that capacitor 20 has a discharge path through the summing node 16, contact A of switch 34, and resistor 32 to the output of slope amplifier 22, whose output is held near ground. As long as no command to start a measurement is received, controller 42 will continue to idle at state S0, holding switch 34 contact A in its closed position to perform the auto zero or reset function. State 1: Upon receipt of a start command signal from an external source, such as a pushbutton switch or a control circuit, the state machine of controller 42 sequences on the next clock pulse to state 1 (S1) to clear all internal registers associated with controller 42 to prepare for a new voltage measurement. If controller 42 fails to access an INTEGRATE command within a predetermined number of clock cycles, the program aborts the measurement attempt by jumping to error state 17 (S17) and thence to state 18 (S18) and back to state 0 (S0) to await a new command. State 2: The state machine sequences to state 2 (S2) when the controller 42 starts an INTEGRATE timer. On the next clock pulse, corresponding with time T 0 in FIG. 5A, a control signal from controller 42 over line 46-1 causes switch 14-1 contact B to open and contact A to close, causing current through resistor 12-1 to flow into summing node 16 as an input voltage to be measured is applied to input terminal 10-1. At the same time, a control signal from controller 42 over line 48 causes switch 34 contact A to open and contact B to close, connecting ground to the end of resistor 32. State 3: The state machine sequences to state 3 (S3) on the next clock cycle, and remains in state 3 for a predetermined time interval T2, which in embodiment tested was equal to 15 clock cycles, or 65.1 μS, during which time the only input to integrator 18 via summing node 16 is through resistor 12-1 from the input voltage applied to input terminal 10-1. Thus, the output of integrator 18 during time interval T2, plus one clock cycle for state 2, is a horizontal line for a zero volt input as shown in FIG. 5A (the integrator output is a negative-going ramp for a positive input voltage or a positive-going ramp for a negative input voltage). State 4: At the end of time interval T2 in state 3, the state machine sequences to state 4 (S4). Controller 42 immediately sends a control signal over line 46-3 to open contact B of switch 14-3 while closing contact A, connecting negative reference voltage -REF to the summing node 16. The constant current through resistor 12-3 is summed algebraically with the current through resistor 12-1, producing a positive-going ramp voltage at the output of integrator 18. The slope of the ramp is a function of the current at the summing node 16, and hence, into capacitor 20. After switch 14-3 is operated to connect voltage -REF to summing node 16, controller 42 checks its internal registers and counters to establish whether the state machine sequences to state 5 (S5) or state 8 (S8) to control the operating sequence of switching reference voltages -REF and +REF throughout the integrate cycle. Separate counters are provided to count the total length of time each of the reference voltages -REF and +REF are turned on, as discussed earlier for calibration purposes. For a two-pass integrate and de-integrate measurement cycle, a flip-flop toggles at the end of the first pass (see state 18) so that if the first pass began with both reference voltages -REF and +REF on as defined by state 5, the second pass will begin with a zero reference input (both references off) defined by state 8. This is shown in FIG. 3. State 5: When the state machine sequences to state 5 (S5), both reference voltages +REF and -REF are ON, connected via switches 14-2 and 14-3, respectively to the summing node 16, so that the net reference current into summing node 16 is nominally zero, resulting in a flat on the waveform as discussed earlier in connection with FIG. 3. Also, for two-pass measurement cycle operation, an ALTZERO flip-flop within controller 42 is toggled so that the state machine will alternate between states 5 and 8 on successive flats. That is, the state machine will sequence to state 8 on the next flat. For interleaved operation, controller 42 keeps a historical record of previous flats and the present comparator output, and from that information determines the next flat. See FIGS. 4A and 4B. Controller 42 looks at the output of comparator 36, if CMP=1, the state machine sequences to state 6 on the next clock cycle, and if CMP=0, the state machine sequences to state 7. When the end of the integrate cycle is reached as determined by the INTEGRATE timer, controller 42 causes the state machine to sequence to state 9 to begin the de-integrate cycle. State 6: When the state machine sequences to state 6 (S6), only the positive reference voltage +REF is connected to summing node 16, so that the output of integrator 18 is a negative-going ramp voltage. This can be seen in FIG. 3. As the ramp voltage progresses, a counter counts state machine clock pulses over a time interval T1 (in the embodiment built and tested, interval T1 is determined by 31 clock pulses, or 134.5 μS). At the end of interval T1, the state machine sequences to either state 5 or state 8, determined by the status of the ALTZERO flip-flop for a two-pass measurement cycle, or other controller 42 registers for an interleaved measurement cycle. State 7: When the state machine sequences to state 6 (S6), only the negative reference voltage -REF is connected to summing node 16, so that the output of integrator 18 is a positive-going ramp voltage. This can be seen in FIG. 3. As the ramp voltage progresses, a counter counts state machine clock pulses over a time interval T1 (in the embodiment built and tested, interval T1 is determined by 31 clock pulses, or 134.5 μS). At the end of interval T1, the state machine sequences to either state 5 or state 8, determined by the status of the ALTZERO flip-flop for a two-pass measurement cycle, or other controller 42 registers for an interleaved measurement cycle. State 8: When the state machine sequences to state 8 (S8), both reference voltages +REF and -REF are OFF, disconnected via switches 14-2 and 14-3, respectively from the summing node 16, so that the net reference current into summing node 16 is zero, resulting in a flat on the waveform as discussed earlier in connection with FIG. 3. Also, for two-pass measurement cycle operation, an ALTZERO flip-flop within controller 42 is toggled so that the state machine will alternate between states 5 and 8 on successive flats. That is, the state machine will sequence to state 5 on the next flat. For interleaved operation, controller 42 keeps a historical record of previous flats and the present comparator output, and from that information determines the next flat. See FIGS. 4A and 4B. Controller 42 looks at the output of comparator 36, if CMP=1, the state machine sequences to state 6 on the next clock cycle, and if CMP=0, the state machine sequences to state 7. When the end of the integrate cycle is reached, controller 42 causes the state machine to sequence to state 9 to begin the de-integrate cycle. As mentioned earlier, the system does not have to be precise since slight errors may be eliminated by use of calibration factors or constants which may be determined by operating the system with a precise zero volts input applied and monitoring the output of the integrator to locate errors as they appear or accumulate, and then entering calibration factors to resolve the errors. Once calibration constants have been determined for a system, and the system calibrated, the system should thereafter provide error-free operation. By being able to calibrate the system, the voltages, currents, resistances, and timing do not have to be exact or precise, permitting the use of readily-available and inexpensive parts and components. DE-INTEGRATE CYCLE State 9: When the integrate cycle is complete, as determined by the INTEGRATE timer, the state machine will sequence from either state 5 or state 8 to state 9 (S9) to begin the de-integrate cycle. Refer to the de-integrate waveform shown in FIG. 6B. At the end of the integrate cycle, the residual charge on capacitor 20 may be either a positive voltage +V or a negative voltage -V. To ensure that the charge on capacitor 20 for the final measurement is positive, the negative reference voltage -REF is connected via switch 14-3 and resistor 12-3 to produce a positive-going ramp at the output of integrator 18. On each clock cycle driving the state machine, the output of comparator 36 is checked. As long as CMP=1, indicating that the output of integrator 18 is negative with respect to ground, voltage -REF will remain connected. As soon as CMP=0 is detected (which may be after one clock cycle if the integrator output is already positive with respect to ground), indicating the output of integrator is positive with respect to ground, the state machine will sequence to state 10. Of course, if CMP=0 is not detected within a predetermined time T3 (which in the embodiment built and tested is 70 counts, or 303.8 μS), indicating a malfunction or an error, the state machine will sequence to state 17 and then to state 18. State 10: When the state machine sequences to state 10 (S10) upon detection of CMP=0 in state 9, the positive reference voltage +REF is connected via switch 14-2 and resistor 12-2 to the summing node 16 so that both -REF and +REF are ON for one clock cycle, resulting in a flat portion of known duration (one state machine clock cycle) on the de-integrate waveform shown in FIG. 6B. State 11: When the state machine sequences to state 11 (S11) after one clock cycle in state 10, the negative reference voltage -REF is turned off by disconnecting switch 14-3, leaving the +REF ON (connected through switch 14-2 and resistor 12-2). This causes a negative-going ramp at the output of integrator 18. On each clock cycle driving the state machine, the output of comparator 36 is checked. As long as CMP=0, indicating that the output of integrator 18 is positive with respect to ground, voltage +REF will remain connected. On the clock cycle following detection of CMP=1, indicating the output of integrator is negative with respect to ground, the state machine will sequence to state 12. Notice that the negative-going ramp will continue slightly negative, below the horizontal line representing ground in FIG. 6B. As in state 10, if CMP=1 is not detected within a predetermined time T3, indicating a malfunction or an error, the state machine will sequence to state 17 and then to state 18. State 12: When the state machine sequences to state 12 (S12) upon detection of CMP=1 in state 11, the positive reference voltage +REF is disconnected from the summing node 16, so that both +REF and -REF are OFF, resulting in a flat portion of known duration (one state machine clock cycle) on the de-integrate waveform shown in FIG. 6B before sequencing to state 13. Also, before sequencing to state 15, the state machine clock frequency is increased by a factor, such as 32, to provide a de-integrate clock having a frequency of 7.3728 MHz, which means that the period of the de-integrate clock is decreased by the same factor, providing higher resolution of the measurement. State 13: When the state machine sequences to state 13 (S13), the negative reference voltage -REF is applied via resistor 12-3 and switch 14-3 to summing node 16 to produce a positive-going ramp at the output of integrator 18. As long as the comparator 36 output is negative (CMP=1) the ramp continues in a positive-going direction; however, as soon as a zero crossing is detected (CMP=0), the ramp will terminate after one de-integrate clock cycle and the state machine will sequence to state 14. Notice in FIG. 6B that the waveform is slightly positive at the end of state 13. Here again, if the ramp continues positive-going for longer than a pre-set period of time T3, indicating a malfunction or an error, the state machine will sequence to state 17 and then to state 18. State 14: When the state machine sequences to state 14 (S14), the negative reference voltage -REF is disconnected from the summing node 16, so that nothing is connected to summing node 16 and the output of integrator 18 remains fixed until the end of predetermined period of time T3 as measured from the start of the de-integrate cycle, after which the state machine sequences to state 15. State 15: When the state machine sequences to state 15 (S15) to de-integrate the remaining charge on integrator capacitor 20 with the de-integrate clock and a less steep slope. Controller 42 sends a control signal over line 46-4 to switch 14-4 to close contact A while opening contact B, connecting positive reference voltage +REF to summing node 16 via resistor 12-4, which has a value 16 times greater than resistors 12-2 and 12-3. Accordingly, the current into summing node 16 is one-sixteenth that provided earlier through resistors 12-2 and 12-3 so that slope of the negative-going ramp at the output of integrator 18 is one-sixteenth as steep as the slopes discussed earlier. As long as the output of comparator 36 is low (CMP=0), indicating that the integrator 18 output is positive with respect to ground, the state machine will remain in state 15. The comparator output is monitored on each cycle of the de-integrate clock, and when CMP=1 is detected, indicating that the output of integrator 18 has reached zero volts and the comparator has switched, the state machine sequences to state 16. Of course, if CMP=1 is not detected within a pre-set period of time T4 (which in the embodiment tested is equal to five state machine clock cycles, or 21.7 μS), indicating a malfunction or an error, the state machine will sequence to state 17 and then to state 18. State 16: When the state machine sequences to state 16 (S16), controller 42 sends a control signal over line 46-4 to switch 14-4 to open contact A while closing contact B, disconnecting positive reference voltage +REF from summing node 16 so that nothing is connected to summing node 16 and the output of integrator 18 remains fixed until the end of the predetermined period of time T4, after which the state machine sequences to state 18. During state 16, controller 42 determines the value of the input voltage being measured by the ADC by totalling the counts in the +REF and -REF counters to determine the number of times each was ON, indicating approximately the amount of charge added or removed during the integrate cycle, adjusting by predetermined calibration factors such as offset, gain and +REF/-REF discussed earlier and algebraically adding to that the final charge measured during the de-integrate cycle. State 17: State 17 (S17) is the error state. If the state machine sequences to state 17, controller 42 is notified that an error has occurred somewhere in the measurement cycle, and so an error message may be provided to a display, or controller 42 may reset all of the ADC circuits and internal registers to begin a new measurement cycle. State 18: When the state machine sequences to state 18 (S18), controller 42 knows either that the measurement cycles has been completed or that an error has occurred. Also, an internal register is toggled so that on a next measurement cycle, or "pass," the state machine at state 4 will know to sequence to either state 5 or state 8. On the next clock cycle, the state machine sequences to state 0. It can be appreciated that component values and clock frequencies other than used for explanatory purposes herein may easily be implemented by one having ordinary skill in the art. Also, the order in which both references are on or off may be different than those described herein, as discussed earlier, as long as the general rule discussed in connection with FIGS. 4A and 4B is observed. While we have shown and described the preferred embodiment of our invention, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from our invention in its broader aspects. It is therefore contemplated that the appended claims will cover all such changes and modifications as fall within the true scope of the invention.
A multiple slope integrating analog-to-digital converter (ADC) includes many improvements and refinements which eliminate timing and non-linearity errors which accumulate due to a large number of switching operations that occur over an integrate cycle. The ADC includes an integrator and a comparator in which an input voltage to be measured is applied to a summing node at the input of the integrator during an integrate cycle, while at the same time positive and negative reference currents are selectively applied to the summing node by a controller which monitors the output of the comparator in order to limit the voltage magnitude at the output of the integrator. Thereafter, during a de-integrate cycle, the input voltage is disconnected while progressively shallower ramps are measured with a high-speed clock for greater resolution and accuracy. The comparator has a slight hysteresis built in to slightly separate the switching thresholds for positive-going and negative going ramps. The switches which control selection of the positive and negative reference currents are implemented in such a way that current surges are minimized. A method is provided to control the order in which the switches are operated to eliminate the effects of charge injection due to operation of the switches as well as signals that are cross-coupled from the control lines of adjacent switches. The length of time the respective positive and negative currents are turned on during the integrate cycle is measured, and adjustments may be made using predetermined calibration factors to resolve errors in the ADC system. Thus, circuit parameters and values need only to be stable and not be precise, permitting the use of readily-available and inexpensive off-the-shelf parts and components.
7
FIELD OF THE INVENTION The present invention relates to recycling of polycarbonates and more particularly to a process for the modifying low-molecular polycarbonate residues and production wastes to produce utilizable materials. SUMMARY OF THE INVENTION A process for making a high molecular weight (co)polycarbonate resin is disclosed. The process entails (i) obtaining at least one member selected from the group low molecular weight residue (weight average molecular weight 15,000 to 30,000) of aromatic (co)polycarbonate production, waste of (co)polycarbonate production, remainders of (co)polycarbonate production and (co)polycarbonate recyclate (ii) melting the said member in a suitable vessel to obtain a melt and (iii) feeding the melt into a reactor optionally along with at least one bisphenol or oligocarbonate having terminal OH groups and further optionally with a transesterification catalyst, and (iv) subjecting the melt to transesterification reaction at a temperature of 250 to 350° C., at a pressure below 5 mbar and residence time of 0.02-4 hours. BACKGROUND OF THE INVENTION Polycarbonates, for example from bisphenol A, are mostly amorphous technical thermoplastics with high-quality properties, such as e.g. high transparency, thermal resistance and toughness. The same applies also to aromatic copolycarbonates that are built up, for example, from bisphenol A and a cobisphenol. The production costs of such materials and the level of their properties thus also justify more demanding recycling processes, if old molded parts or production scrap are to be sent for ecologically-necessary and economically-reasonable recyling. The divide between processing costs and economy is considerably more beneficial for aromatic polycarbonates than for many other thermoplastics, so that processes consisting of more than one process step are definitely also worthwhile. However, efforts are always being made to find processes that are simpler and more economic than the known processes, in order to be able to produce more cheaply. As with other thermoplastics, the level of mechanical and physical properties of polycarbonate depends on the molecular weight. However, production waste, recyclates etc. frequently do not, or no longer, possess the required molecular weights. Direct material recycling of production waste or recyclates is therefore possible only to a very limited extent. When recycling polycarbonate residues, production wastes, remainders, recyclates and similar polycarbonate compositions, it is therefore desirable and essential to increase the molecular weight to a sufficient level for the projected new use. So, for example, low-molecular production scrap from PC production for Compact Discs could be increased to the molecular weight range required for injection molding. Or the average molecular weight of PC recyclate from the de-lamination of Compact Discs should be increased sufficiently to allow the material to be used, e.g,. as a component in the production of PC/ABS blends. There is little reference in the literature to condensation of polycarbonate molding compositions destined for chemical-material recycling. Thus EP-A 931 810 discloses a process for increasing the molecular weight of decomposed low-molecular polycondensates such as polyamides, polyesters and polycarbonates using reactive chain lengtheners. These chain lengtheners react in the plastic melt, e.g, in an extruder, under conventional compounding conditions, with the functional chain ends of the polymer. Special bisepoxides are mentioned as chain lengtheners, alone or in combination with epoxides, bisoxazolines, dicyahates, tetracarboxylic acid dianhydrides, bismaleic imides and carbodiimides amongst others. However, no example is given for the function of the process with polycarbonate. The disclosed trials showed no increase in the molecular weight of polycarbonate using the process disclosed in EP-A 931 810. DE-PS 43 26 906 provides a process for the chemical recycling of polycarbonate by transesterification with hydroxy compounds, in particular phenol, until bisphenol is obtained and the esterified carbonate unit, followed by resynthesis of polycarbonate in the melt. Although this process produces bisphenol and the carbonate unit, the polycarbonate is then completely decomposed by transesterification. In addition to the decomposition of useful bonds, which must then be built up again, the process method is also complex and expensive. DE-OS 42 40 314 differs from the above patent specification substantially by prior decomposition of the polycarbonate to oligomers, by transesterification with low-boiling monophenols. Then a higher-viscosity oligomer with a particular content of OH terminal groups is produced first from the decomposition product and optionally added diarylcarbonate by recondensation with the splitting off of the monophenol, which, in the final stage, is then polycondensed in the melt under more rigorous reaction conditions to form the desired polycarbonate. Here too the polycarbonate is first decomposed, which necessitates an additional process step. A further disadvantage is that oligomers with OH terminal groups are significantly more susceptible to thermal and oxidative loading than the corresponding polymers and rapidly become discoloured and damaged. The condensation process is therefore sensitive and must be subjected to complex controls to achieve a precise reaction that minimizes such effects. Finally, DE-OS 44 21 701 discloses a process for the chemical recycling of polycarbonates by decomposition with diaryl carbonates to form oligomers. After they have been crystallised in a particular solvent, cleaned and dried, these are re-condensed to form polycarbonate, optionally with the addition of bisphenols and a catalyst. The disadvantages of this recycling process are the same as those of the processes according to DE-PS 43 26 906 and DE-OS 42 40 314, described above. On the basis of this prior art, the object was therefore to provide a process by which the molecular weight of polycarbonates may be increased as simply and efficiently as possible. DETAILED DESCRIPTION OF THE INVENTION It was found that, surprisingly, it is possible to condense polycarbonates by simple melting in a vacuum, optionally with bisphenols or suitable oligocarbonates with OH terminal groups, to produce, directly, polycarbonates of higher molecular weights. The present invention thus relates to processes for the condensation of polycarbonate, characterised in that polycarbonates may be condensed in the melt, usefully with the addition of bisphenols or oligocarbonates with OH terminal groups to accelerate the reaction, optionally using catalysts to obtain polycarbonates, which have a higher molecular weight than the starting polycarbonate. In the process according to the invention, the polycarbonate to be condensed, preferably bisphenol A-polycarbonate, as a granulate or ground PC moulded parts, is melted in a suitable vessel and then condensed in a reactor operating batch-wise or continuously. Critical values for the reaction parameters for this are pressure, temperature and residence time. The condensation may be carried out in the presence of one or more catalysts. The reaction parameter ranges are 0.01 to 5 mbar, preferably 0.1 to 2 mbar, 250-350° C. melting temperature, preferably 280-320° C. The average residence time depends on the reaction vessel and is 0.01 to 0.3 hours for screw-type extruders and 0.2 to 4 hours for agitated tanks, kneading apparatus and disk or basket reactors. When using disk or basket reactors, residence times of 0.5 to 2 hours are preferred. With discontinuous processes, pressure and temperature may be varied in accordance with different schedules. Continuous processes are normally run constantly under the suitable temperature and pressure conditions, pressure and temperature profiles being set along the length of the reactor. Embodiments preferred, preferred in particular or most particularly preferred are those in which the parameters, definitions and explanations stated under preferred, preferred in particular or most particularly preferred, are used. However, the general definitions, parameters or explanations, or those listed in preferred ranges, given above and below may be combined arbitrarily with each other, i.e,. between the particular ranges and preferred ranges. The polycarbonate used either already has an average concentration of phenolic terminal groups of over 100 ppm OH, preferably 100-1500 ppm, in particular 400-1000 ppm, or this is adjusted in the melt by adding a bisphenol, preferably bisphenol A, or oligocarbonates having terminal OH groups. When converting in the melt to higher molecular weights, volatile portions that are split off are discharged from the reactor as vapors. The small quantities arising here are sluiced out of the process by suitable means, which simplifies the process considerably. Condensation may be carried out in agitated tanks, screw- or kneading apparatus, extruders, disk or basket reactors and in combinations of such apparatus. For continuous processes, extruders or basket or disk reactors, in particular basket or disk reactors are preferred, as disclosed in DE Appl. No. 1 011 98 51 or DE-C2 44 47 422. Basket or disk reactors are also suitable for discontinuous processing. Condensation may be accelerated by carrying it out in the presence of a condensation catalyst. Suitable catalysts and the concentrations in which to use them may be taken from the literature (Chemistry and Physics of Polycarbonates, Polymer Reviews, H. Schnell, Vol. 9, Pages 44-51, John Wiley & Sons, 1964; DE-PS 1 031 512; EP-A 360 578; EP-A 351 168; U.S. Pat. No. 3,442,854). Alkali- or earth alkali compounds with an alkaline action and ammonium- or phosphonium salts, hereinafter described as onium salts, are preferred. Phosphonium salts according to the invention are those of the formula (IV), wherein R 1-4 independently one of the others may be C 1 -C 10 -alkyls, C 6 -C 10 -aryls, C 7 -C 10 -aralkyls or C 5 -C 6 -cycloalkyls, preferably methyl or C 6 -C 14 -aryls, in particular methyl or phenyl, and X − may be an anion such as hydroxide, sulfate, hydrogen sulfate, hydrogen carbonate, carbonate, a halogenide, preferably chloride, or an alcoholate of the formula OR, wherein R may be C 6 -C 14 -aryl or C 7 -C 12 -aralkyl, preferably phenyl. Preferred catalysts are tetraphenylphosphonium chloride tetraphenylphosphonium hydroxide tetraphenylphosphonium phenolate in particular tetraphenylphosphonium phenolate. Further preferred catalysts, which may be used alone or optionally in addition to an onium salt, are compounds of alkali metals and earth alkali metals with an alkaline action, such as hydroxides, alkoxides and aryloxides of lithium, sodium, potassium, magnesium and calcium, preferably of sodium. Sodium hydroxide and sodium phenolate and the sodium bisphenolate of bisphenol A are most preferred. The polycarbonate is introduced into the condensing reactor preferably via a screw. If bisphenols or oligomers with OH terminal groups are added to increase the concentration of OH terminal groups, the screw serves as a mixing unit as well. A melting screen with or without a backwashing device may be positioned between the screw and the condensing reactor, to avoid contaminant particles having sizes that are ≧5 μm from the highly fluid melt. The melt flowing from the condensing reactor after polycondensation is discharged by means of a gear pump. Here the melt may be fed over static mixers or extruders and mixed with additives to set special formulations of the polycarbonates produced before being fed on for granulation. Suitable additives are disclosed e.g. in WO 99/55772, pg. 15-25, DE Appl. No.10122496.6 and in “Plastics Additives”, R. Gätchter and H. Müller, Hanser Publishers 1983. In principle, additives may be added at any point in the reaction, preferably before granulation. Any bisphenol or an oligocarbonate having OH terminal groups may optionally be added to the polycarbonate to be condensed. The bisphenol or the OH-containing oligocarbonate on which the polycarbonate to be condensed is based, are preferred. The dosage, in terms of parts by weight, of the bisphenol or the oligocarbonate in relation to the weight of polycarbonate used is in the range 0:100 to 10:100, preferably 0.1:100 to 5:100, in particular 0.2:100 to 1:100 for the bisphenol and in the range 0:100 to 50:100, preferably 0.5:100 to 30:100, in particular 1:100 to 10:100 for the oligocarbonate. Examples of bisphenols that may be used according to the invention or may also form the basis of the polycarbonate to be condensed may be found in WO-A1 01/05866, pg. 6-8. 4,4′-dihydroxybiphenyl, 4,4′-dihydroxydiphenyl sulphide, 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A), 2,2-bis-(3-methyl-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane, 2,2-bis-(4-hydroxyphenyl)-methane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-methane, 2,4-bis-(4-hydroxyphenyl)-2-methylbutane, 2,4-bis-(3,5-dimethyl-4-hydroxyphenyl)-2-methylbutane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, α,α′-bis-(4-hydroxyphenyl)-p-diisopropylbenzene, 2,2-bis-(3-chloro-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dibromo-4-hydroxyphenyl)-propane and 1,1-bis-(p-hydroxyphenyl) -3,3,5-trimethylcyclohexane are preferred. Diphenols preferred in particular are 4,4′-dihydroxybiphenyl, 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A) and 1,1-bis-(p-hydroxyphenyl)-3,3,5-trimethylcyclohexane. 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A) and 1,1-bis-(p-hydroxyphenyl)-3,3,5-trimethylcyclohexane are preferred most particularly, in particular 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A). Accordingly the oligomers obtained from these bisphenols may also be used according to the invention. The polycarbonate used has a weight average molecular weight (M w ) of 15,000 to 30,000, preferably 16,000 to 25,000, in particular 17,000 to 22,000, determined by measuring the relative solution viscosity in dichloromethane, calibrated by light scattering. A PC recyclate is preferred, in particular a PC recyclate from Compact Discs. The polycarbonates and copolycarbonates used may originate from the known interfacial or melt transesterification process and may therefore contain different chain stoppers. Phenol, octylphenol, cumylphenol and t-butylphenol are suitable chain stoppers. Other typical chain stoppers for polycarbonate may be taken from WO-A1 01/05866, pg. 4-6. There may also be mixtures of chain stoppers, e.g., via the mixing of different polycarbonates. Polycarbonates from the melt transesterification process preferably have the phenol of the diphenylcarbonate used for production as a chain stopper. Single polycarbonate or a mixture of various polycarbonates may be condensed. The polycarbonates may differ with regard to their average molecular weight, the bisphenol used and/or the chain stopper, branching agent etc., used. Furthermore, the polycarbonates may contain chain branching agents such as are disclosed in WO-A1 01/05866, pg. 8-9. Mixtures of polycarbonates, which are built up of the same bisphenol, in particular bisphenol A, are preferred. Mixtures occur in particular when the PC recyclates from consumption waste and process scrap to be condensed are not of the same type. The polycarbonates obtainable by the process according to the invention may be processed on conventional machinery, for example, extruders or injection molding machines, to produce any type of molded articles, for example, films or sheets, in the conventional manner. Furthermore, the polycarbonates according to the invention may also be mixed into other polymers, e.g., polyolefins, polyurethanes, polyesters, ABS and polystyrene. These materials are added preferably on conventional machines for the processing of polycarbonate, but may also be added at another stage in the production process as required. The invention also provides the polycarbonates obtainable by the process according to the invention themselves. They differ from primary material, in other words the known commercial material, by the presence of fluorescence-active centres, which fluoresce when irradiated with UV light, e.g., black light. This optical effect can be used, e.g., to aid plastic recognition in sorting processes for material recycling or to differentiate between a recyclate and a primary material. Auxiliaries and reinforcing agents may be mixed into the polycarbonates according to the invention to change or improve certain properties. Thermal—and UV stabilizers, flowing agents, mold release agents, flame-retardants, hydrolysis stabilizers, finely comminuted minerals, fibers, e.g. alkyl- and arylphosphites, -phosphates, -phosphanes, low-molecular carboxylic acid esters, halogen compounds, salts, chalk, quartz powder, glass and carbon fibers, pigments, dyes and combinations thereof, amongst others, may be considered for this purpose. Such compounds are disclosed e.g. in WO 99/55772, pg. 15-25 and in “Plastics Additives”, R. Gätchter and H. Müller, Hanser Publishers 1983. These additives may be introduced into the melting and discharge screw or directly into the melting reactor, although the discharge unit is preferred. The polycarbonates produced according to the invention may be used for many mechanically demanding applications. They are thus suitable for the production of molded articles and extrudates of the most varied character. Possible applications are Safety screens, which, as is known, are needed in many areas of buildings, vehicles and aircraft, and as visors for crash helmets, Films, in particular ski films Blown articles (see for example, U.S. Pat. No. 2,964,794), for example, 1 to 5 gallon water bottles, translucent sheets, in particular multi wall sheets, for example, for covering buildings such as stations, greenhouses and lighting installations, optical data storage units traffic signal housings or traffic signs foamed materials (see for example, DE-AS 1 031 507). thread and wire (see for example, DE-AS 1 137 167 and DE-OS 1 785 137), translucent plastics with a glass fibre content for lighting purposes (see for example, DE-OS 1 554 020), translucent plastics containing barium sulfate, titanium dioxide and/or zirconium dioxide or organic polymeric acrylate rubbers (EP-A 634 445, EP-A 269324) for the production of translucent and light-diffusing molded parts small, precision injection-molded parts, such as, for example, lens mounts (polycarbonates containing glass fibres, which optionally also contain ca 1-10 wt. % MoS 2 , in relation to the total weight, are used for this), optical instrument parts, in particular lenses for cameras and camcorders (see for example, DE-OS 2 701 173), light transmission media, in particular fiber-optic cables (see for example, EP-A1 0 089 801), electrical insulation materials for electrical conductors and for plug housings and pin-and-socket connectors, mobile telephone housings with improved resistance to perfume, after-shave and perspiration, network interface devices carrier materials for organic photoconductors, lights, e.g., headlamps, light-diffusing screens or internal lenses medical applications, e.g., oxygenators, dialyzers food applications, such as, e.g., bottles, cutlery and chocolate molds, applications in the automotive industry, where there may be contact with plastics and lubricants, such as, e.g., bumpers, optionally in the form of suitable blends with ABS or suitable rubbers, sports equipment such as, e.g., slalom poles or ski boot buckles, household articles such as, e.g., kitchen sinks and letter box housings, housings, such as, e.g., electrical distributor cases, housings for electric toothbrushes and hairdryer housings, transparent washing machines—portholes with better resistance to washing solution, protective goggles, vision-correcting spectacles, lamp covers for kitchen fittings with improved resistance to kitchen vapors, in particular, oil vapors, packaging films for medicines, chip boxes and chip carriers, as well as other applications such as e.g. stable doors or animal cages. The following examples are intended to illustrate the object of the present invention without restricting it. EXAMPLES Example 1 Ground PC from the de-lamination of Compact Discs by the process described in EP-A 537 567 (pg. 1, 2, 5, 6) was dried in the circulating air dryer (2 h/120° C.) and then melted in a twin shaft screw ZSK 25 (Werner & Pfleiderer), and continuously fed into a basket reactor operating at 300° C. A mixture containing a portion of the total polycarbonate to be condensed and bisphenol A (the amount of bisphenol A being 0.25 wt. % relative to the total weight of polycarbonate to be condensed) was introduced into the melting screw. In all, the PC feed stream (containing polycarbonate and bisphenol A) via the feed screw was 20 kg/h. No condensation catalyst was used. The condensation reactor was a drum with a melt inlet and outlet at the ends and a vacuum connection in the gas (or vapor) space, that is the volume above the melt, in which a shaft with disks, which dipped into the melt, slowly rotated. The speed of rotation was 0.8 revolutions per minute; the average residence time of the melt was ca 180 minutes. The melt temperature was 300° C., the pressure in the gas space of the reactor was 0.7 to 0.8 mbar. The condensed melt was discharged via a gear pump with attached granulating unit. The properties of the PC granulate thus obtained and the starting material are summarised in Table 1. TABLE 1 Condensation of recyclate in a disk reactor. Condensate 2) Start 1) B C Properties Units A (A + BPA) (A + BPA) Mechanical Elongation at break % 3.5 82 91 Impact strength IZOD impact kJ/m 2 28 n.b. n.b. strength, RT IZOD kJ/m 2 8b 67t notched impact 61t/17b strength, RT Content Phenolic OH ppm 600 500 600 Flowability MVR 300° C./ cm 3 /10 min 65 16 23 1.2 kg rel. solution — 1.202 1.271 1.248 viscosity 1) A: CD recyclate, recovered by de-laminating ground material from CDs 2) B: A + 0.25 wt. % BPA, 310/300° C., 0.8 mbar, 180 min average residence time C: A + 0.25 wt. % BPA, 300/290° C., 0.7 mbar, 180 min average residence time b = brittle; t = ductile; n.b. = not broken Example 2 Similarly, low-molecular PC granulate from production waste was condensed to produce a higher-molecular polycarbonate. Here Bisphenol A was used in example D and condensation catalyst were not used. The material properties are summarized in Table 2. TABLE 2 Condensation of low-molecular PC granulate for the production of Compact Discs in a disk reactor Condensate 2) Start 1) E Properties Units D (D + BPA) Mechanical Elongation at break % 60 100 Impact strength IZOD impact strength, kJ/m 2 28 n.b. RT IZOD kJ/m 2 10 60 Notched impact strength, RT Content OH ppm 130 550 Flowability MVR 300° C./1.2 kg cm 3 /10 min 71 40 rel. solution viscosity — 1.195 1.223 1) D: primary material granulate Makrolon DP 1-1265, a BPA-based homopolycarbonate, a product of Bayer. 2) E: D + 0.25 wt. % BPA, 320/310° C., 0.75 mbar, 180 min average residence time Example 3 Ground PC from the de-lamination of Compact Discs was condensed in an extruder. The extruder used was a twin shaft screw ZSK 32 (Werner & Pfleiderer) 1.4 m long with a 0.8 m long de-aerating dome, beginning 0.4 m along the screw length. Here too, melt condensation was carried out without the addition of a transesterification catalyst. Before being added the material was dried in a recirculating air dryer (2 h/120° C.). The results are summarized in Table 3. TABLE 3 Condensation of Compact Disc-recyclate in a twin shaft screw (ZSK 32, Werner & Pfleiderer) Condensate 2) Start 1) G Properties Units F (from F) Mechanical Elongation at break % 2.7 61 Impact strength IZOD impact strength, RT kJ/m 2 11b n.b. IZOD kJ/m 2 35b n.b. Notched impact strength, RT Content OH ppm 440 140 Flowability MVR 300° C./1.2 kg cm 3 /10 min 82 18 rel. solution viscosity — 1.202 1.255 Condensation of another starting material (F′) adding 0.25 wt. % BPA: OH content ppm 260 120 rel. solution viscosity — 1.198 1.265 1) F: CD recyclate, recovered from the de-lamination of ground material from CDs 2) G: F melt condensed at 320-340° C., 0.5-l mbar, 2 kg/h throughput, 100 rpm, 3-5 min average residence time b = brittle; n.b. = not broken Measuring Methods Elongation at break, modulus of elasticity to ISO 527; impact/notched impact strength to ISO 180/1C or ISO 180/4A; phenolic OH photometrically with TiCl 4 on the Ti complex; MVR to ISO 1133; rel. solution viscosity on PC solution in dichloromethane (5 g PC/I). It is clear that with the process according to the invention, the molecular weight of low-molecular polycarbonates (A, D, F) may be condensed to attain highly-viscous polycarbonates (B, C, E, G) with better mechanical properties such as elongation at break and impact/notched impact strength. Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations may be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
A process for making a high molecular weight (co)polycarbonate resin is disclosed. The process entails (i) obtaining at least one member selected from the group low molecular weight residue (weight average molecular weight 15,000 to 30,000) of aromatic (co)polycarbonate production, waste of (co)polycarbonate production, remainders of (co)polycarbonate production and (co)polycarbonate recyclate (ii) melting the said member in a suitable vessel to obtain a melt and (iii) feeding the melt into a reactor optionally along with at least one bisphenol or oligocarbonate having terminal OH groups and further optionally with a transesterification catalyst, and (iv) subjecting the melt to transesterification reaction at a temperature of 250 to 350° C., at a pressure below 5 mbar and residence time of 0.02-4 hours.
2
TECHNICAL FIELD The present invention relates to pneumatic tires for trucks and more particularly to means of preventing separation of ply turnup ends. BACKGROUND OF THE INVENTION A pneumatic vehicle tire typically includes a pair of axially separated inextensible beads. A circumferentially disposed bead filler apex extends radially outward from each respective bead. At least one carcass ply extends between the two beads. The carcass ply has axially opposite end portions, each of which is turned up around a respective bead and secured thereto. Tread rubber and sidewall rubber is located axially and radially outward, respectively, of the carcass ply. The bead area is one part of the tire that contributes a substantial amount to the rolling resistance of the tire, due to cyclical flexure which also leads to heat buildup. Under conditions of severe operation, as with truck tires, the flexure and heating in the bead region can be especially problematic, leading to separation of mutually adjacent components that have disparate properties such as the respective moduli of elasticity. In particular, the ply turnup ends are prone to separation from adjacent structural elements of the tire. More specifically, the ply is reinforced with materials such as nylon, polyester, rayon and metal which have much greater stiffness (i.e., modulus of elasticity) than does the adjacent rubber compound of which the bulk of the tire is made. The difference in elastic modulus of mutually adjacent tire elements leads to separation when the tire is stressed and deformed during use. A variety of structural design approaches have been used to manage the separation of tire elements in the bead regions of tires. For example, one method has been to provide a “flipper” surrounding the bead and the bead filler. The flipper works as a spacer that keeps the ply from making direct contact with the inextensible beads, allowing some degree of relative motion between the ply, where it turns upward under the bead, and the respective beads. In this role as a spacer, the flipper reduces the inevitable disparities of strain on the ply and on the adjacent rubber components of the tire (e.g., the filler apex, the sidewall rubber, in the bead region, and the elastomeric portions of the ply itself). The flipper is often made of a square woven cloth that is typically a textile in which each fiber, thread or cord has a generally round cross-section. When the flipper is cured in the tire, the stiffness of the fibers/cords becomes essentially the same in any direction within the plane of the textile flipper. Examples of flippers are found in U.S. Pat. Nos. 2,489,614 and 3,253,693. The latter Patent also discloses data on radial and circumferential deformations within the tire. Such deformations result in shearing stresses during normal operation of the tire, but especially during severe operating conditions. Circumferentially directed shear deformations correlate with high shearing stresses within portions of the tire where the flippers overlap the radially oriented cords that reinforce the ply. Also, given that the ply is, on each side of the tire, clamped around, or anchored to, or “turned up” about, the respective bead, there exists a “turn-up end” (as viewed in the cross section of a tire) that extends radially outward within, and circumferentially about, each sidewall. Limits on the length of the ply turnup ends are made in order to locate the ends of the ply in positions where radial deformations of the tire are relatively small. Generally the ends of the turnup ends of the ply do not extend beyond one third of the interior section height of the tire (i.e., the section height as measured from the nominal rim diameter to the inner diameter of the tire at its equatorial plane). Stresses that result in the deposition of energy (i.e., the generation of heat) in the bead region and in the region where the turnup ends terminate are frequently accompanied by strains that contribute to separation failures at the turnup ends. A balanced design for a reinforced bead assembly of a tire has stress characteristics that lead to reduced flexural energy generation (heat buildup) and to strain characteristics that can be uniformly borne by mutually adjacent tire components in the bead region, including the turnup ends. More particularly, radial-ply truck tires in which the one or more plies are reinforced with steel fibers or cords are prone to ply ending or turnup separation when exposed to severe service. Part of the cause of separation is related to the stresses described above and to the disparate moduli of elasticity of the respective metal and adjacent polymeric rubber compounds. As the tire undergoes flexure during heavy-duty use, flexure of the sidewalls in the region near to and immediately radially outward of the beads experience repeated flexural deformations in one or more directions, such as the radial and axial directions. Ply separation is especially problematic if the tire is overinflated or underinflated. Prior to the use of steel-reinforced radial ply construction, the plies were reinforced with materials having substantially lower moduli of elasticity than that of steel. Accordingly, the stresses associated with heavy-duty tire use were more easily accommodated by the respectively adjacent components, such as the ply reinforcing materials and the adjacent rubber polymeric materials. (Such tires were, of course, less durable than are those having metal reinforced plies.) Still, disparities of respective moduli of elasticity could lead to ply separation under severe conditions, especially in region near the ply endings. In addition to the use of flippers as a means by which to reduce the tendency of a ply to separate, another method that has been used involves the placement of “chippers.” A chipper is a circumferentially deployed metal or fabric layer that is disposed within the bead region in the portion of the tire where the bead fits onto the wheel rim. More specifically, the chipper lies inward of the wheel rim (i.e., toward the bead) and outward (i.e., radially outward, relative to the bead viewed in cross section) of the portion of the ply that turns upward around the bead. Chippers serve to stiffen, and increase the resistance to flexure, of the adjacent rubber material which itself is typically adjacent to the turnup ply endings. Examples of patents of prior art uses of flippers and/or chippers are as follows: U.S. Pat. No. 5,309,971 (Baker et al) U.S. Pat. No. 4,667,722 (Klepper et al) U.S. Pat. No. 4,462,448 (Kawaguchi et al) U.S. Pat. No. 4,357,976 (Mezzanotte) U.S. Pat. No. 4,289,184 (Motomura et al) U.S. Pat. No. 4,047,551 (Mezzanotte) U.S. Pat. No. 4,046,183 (Takahashi et al) U.S. Pat. No. 4,024,901 (Pogue et al) U.S. Pat. No. 3,638,705 (Devienne et al) U.S. Pat. No. 3,028,903 (Lessig) U.S. Pat. No. 2,958,360 (Mcacklem et al) U.S. Pat. No. 2,902,273 (Lessig) U.S. Pat. No. 2,501,372 (Benson) U.S. Pat. No. 2,131,636 (Nellen) U.S. Pat. No. 1,682,922 (McKone) The U.S. Pat. No. 4,319,621 (Motomura et al) discloses several embodiments for use of an inventive metal chipper composed of a reinforcing element embedded in rubber and formed of 1 to 50 helically formed metal filaments. The FIG. 4 d illustrates an embodiment using the metal chipper ( 4 3 ), constituted with reinforcing element (β) composed of the helically formed filaments ( 6 ), as a flipper folded around the bead ring ( 2 ) from the inside to the outside thereof between the bead ring ( 2 ) and the carcass ply ( 3 ) and extended upwardly over the upper end of the turn-up portion ( 3 ′) of the carcass ply ( 3 ). A chafer ( 5 1 ) reinforced with conventional steel cords and chafers ( 5 2 and 5 3 ) each reinforced with nylon cords are further arranged outside the carcass ply ( 3 ), the turn-up portion ( 3 ′) of the carcass ply ( 3 ) and the metal chipper ( 4 3 ). Each of these prior art patents can be distinguished from the present invention in that they do not include one or more of the features discussed below in the Description of the Preferred Embodiment of the present invention. OBJECTS OF THE INVENTION It is an object of the present invention to provide a bead region design that can reduce ply ending separation initiation and propagation within radial unisteel tires exposed to severe service conditions. Generally, another object of the present invention is to reduce the flexural heat buildup associated with the cyclical shearing stresses and concomitant cyclical shearing strains in the bead regions of truck tires exposed to severe operating conditions. Another object of the present invention is to employ a bead-region design feature, specifically the incorporation of a textile strip (i.e., a circumferentially disposed “patch”) over both sides of the ply turnup ends and the radially outermost portions of the chipper so as to reduce deformation and shearing stress gradients and thus improve the tire's overall resistance to initiation and propagation of ply ending separation in the bead region. It is a further object of the present invention to incorporate in the bead region of truck tires a combination of chippers, active flippers and a textile “patch” (circumferentially disposed axially outward of the ply turnup and the chipper) which operate in relation to one another in such a way as to provide spacers having such physical properties as modulus of elasticity which are intermediate between those of otherwise adjacent materials having significantly different moduli of elasticity (e.g., steel ply reinforcing wires/cords and rubber). Yet another object of the present invention is to achieve the above objectives by means of the incorporation of a smaller number of components than are used in standard tire constructions wherein gum strips are applied at the radially outermost ply and chipper endings. SUMMARY OF THE INVENTION The present invention relates to a pneumatic radial ply tire having a tread, a carcass comprising a radial ply, a belt structure located between the tread and the radial ply, two inextensible beads, and two sidewalls. The ply is reinforced with a high-modulus material, and it is wrapped around the beads with its turnup ends extending radially outward beneath the sidewalls. Nylon fabric flippers are circumferentially disposed to between the beads from the wrapped ply, separating them from direct contact. Chippers made of steel cords are disposed circumferentially between the portion of the ply that wraps around the bead in the portion of the tire bead region that makes direct contact with the wheel rim when the tire is mounted. Nylon fabric patches are circumferentially disposed over the radially outermost reaches of the axially outwardmost parts of the chippers, the ply turnup ends and the flippers, overlapping the ends of each respective part. BRIEF DESCRIPTION OF THE DRAWINGS The structure, operation, and advantages of the invention will become more apparent upon contemplation of the following description taken in conjunction with the accompanying drawings, wherein: FIG. 1 shows a cross-sectional view of a prior art tire incorporating a flipper; FIG. 2 shows a close up view of the bead region of the prior art tire shown in FIG. 1; and FIG. 3 shows a closeup cross-sectional view of the bead region of the tire according to the present invention. DEFINITIONS “Apex” or “bead filler apex” means an elastomeric filler located radially above the bead core and between the plies and the turnup plies. “Axial” and “Axially” means the lines or directions that are parallel to the axis of rotation of the tire. “Bead” or “Bead Core” generally means that part of the tire comprising an annular tensile member of radially inner beads that are associated with holding the tire to the rim; the beads being wrapped by ply cords and shaped, with or without other reinforcement elements such as flippers, chippers, apexes or fillers, toe guards and chafers. “Carcass” means the tire structure apart from the belt structure, tread, undertread over the plies, but including the beads. “Casing” means the carcass, belt structure, beads, sidewalls and all other components of the tire excepting the tread and undertread, i.e., the whole tire. “Chipper” refers to a narrow band of fabric or steel cords located in the bead area whose function is to reinforce the bead area and stabilize the radially inwardmost part of the sidewall. “Circumferential” most often means circular lines or directions extending along the perimeter of the surface of the annular tread perpendicular to the axial direction; it can also refer to the direction of the sets of adjacent circular curves whose radii define the axial curvature of the tread, as viewed in cross section. “Cord” means one of the reinforcement strands, including fibers, with which the plies and belts are reinforced. “Equatorial Plane” means the plane perpendicular to the tire's axis of rotation and passing through the center of its tread; or the plane containing the circumferential centerline of the tread. “Flipper” refers to a reinforcing fabric around the bead wire for strength and to tie the bead wire in the tire body. “Gauge” refers generally to a measurement and specifically to thickness. “Inner Liner” means the layer or layers of elastomer or other material that form the inside surface of a tubeless tire and that contain the inflating fluid within the tire. “Lateral” means a direction parallel to the axial direction. “Normal Load” means the specific design inflation pressure and load assigned by the appropriate standards organization for the service condition for the tire. “Ply” means a cord-reinforced layer of rubber-coated radially deployed or otherwise parallel cords. “Radial” and “radially” mean directions radially toward or away from the axis of rotation of the tire. “Radial Ply Structure” means the one or more carcass plies or which at least one ply has reinforcing cords oriented at an angle of between 65° and 90° with respect to the equatorial plane of the tire. “Radial Ply Tire” means a belted or circumferentially-restricted pneumatic tire in which at least one ply has cords which extend from bead to bead are laid at cord angles between 65° and 90° with respect to the equatorial plane of the tire. “Section Height” means the radial distance from the nominal rim diameter to the outer diameter of the tire at its equatorial plane. “Section Width” means the maximum linear distance parallel to the axis of the tire and between the exterior of its sidewalls when and after it has been inflated at normal pressure for 24 hours, but unloaded, excluding elevations of the sidewalls due to labeling, decoration or protective bands. “Sidewall” means that portion of a tire between the tread and the bead. “Toe guard” refers to the circumferentially deployed elastomeric rim-contacting portion of the tire axially inward of each bead. “Tread width” means the arc length of the tread surface in the plane includes the axis of rotation of the tire. “Turnup end” means the portion of a carcass ply that turns upward (i.e., radially outward) from the beads about which the ply is wrapped. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Prior Art Embodiment FIG. 1 shows in meridional cross-sectional view a prior art tire 10 having a tread 12 , a single carcass ply 14 , an inner liner 23 , belt structure 16 comprising belts 18 , 20 , carcass structure 22 , two sidewalls 15 , 17 , and bead regions 24 a , 24 b comprising bead filler apexes 26 a , 26 b and beads 28 a , 28 b . The tire 10 is suitable for mounting on a rim of a vehicle such as a truck. The carcass ply 14 includes a pair of axially opposite end portions 30 a , 30 b , each of which is secured to a respective one of the beads 28 a , 28 b . Each axial end portion 30 a or 30 b of the carcass ply 14 is turned up and around the respective bead ( 28 b , in FIG. 2) to a position sufficient to anchor each axial end portion 30 a , 30 b. The carcass ply 14 is a rubberized ply having a plurality of substantially parallel extending carcass reinforcing members made of such material as polyester, rayon or similar organic polymeric compounds. The carcass ply 14 engages the axial outer surfaces of the flippers 32 a , 32 b . Flipper 32 b is shown in FIG. 2, which shows a close-up detail view of the bead region of the prior art tire 10 . Additional prior art tires incorporating chippers and/or flippers are addressed below in relation to the present invention and their respective differences from the present invention. Summary of the Inventive Features FIG. 3 shows, in cross-sectional view, the bead region of a tire incorporating the present invention, shown mounted on a wheel rim 70 . Carcass ply 50 wraps around bead 52 b and is separated from the bead by the flipper 54 . The flipper 54 is a fabric layer disposed around the bead wire 52 b and inward of the portion of the carcass ply 50 which turns up under the bead. The flipper 54 is made of a material having physical properties (such as shearing modulus of elasticity) that are intermediate between those of the rigid metal bead material and the less rigid material of the carcass ply 50 . The flipper 54 therefore serves as an active strain-relieving layer separating the rigid metal beads from the less rigid carcass ply 50 . Carcass ply 50 is reinforced with metal as is conventional in the tire art. FIG. 3 also shows a chipper 56 . The chipper 56 consists of a narrow band of steel cloth located in the bead area for the purpose of reinforcing the bead area and stabilizing the axially inwardmost part of the sidewall 57 . The flipper 54 and the chipper 56 , along with the nylon patch 58 uniting them, are discussed separately below, and then in operational conjunction with one another. The Flipper The flipper 54 of the present invention wraps around the bead 52 b and extends radially outward into the sidewall regions of the tire. The axially inward portion 55 of flipper 54 terminates within the bead-filler apex 59 b . The axially outward portion 60 b of the flipper 54 lies radially beyond the turnup end 62 b , which itself is located radially beyond the radially outermost reach of the chipper 56 (discussed separately below). The axially outwardmost portions 62 b of the turnup ends of the ply 50 extend radially outward by a distance of between about 15 millimeters and about 30 millimeters beyond the top of a wheel rim flange 72 of the wheel rim 70 . The flipper 54 is made of nylon fabric. Nylon is defined herein as an example of thermoplastic polymers capable of extension when woven into fabrics, sheets, etc. of extreme toughness, strength and elasticity. For example, the nylon used in the present invention can have the following physical characteristics: The nylon fabric can be woven, or it can be of a monofilament or even a multifilament type of material in which all the cords run in the same direction. The nylon fabric of the flippers 54 can have a thread pitch of between about 5 and about 30 ends per inch (about 2-12 ends/cm) and an overall thickness in the range of about 0.3 to about 1.2 mm, preferably about 10 to about 20 ends per inch (about 4-8 ends/cm) and 0.5 to about 1.0 mm gauge, and most preferably between about 10 and about 20 ends per inch (about 4-8 ends/cm). The nylon cords of the flipper 54 are oriented at an angle of between about 20 degrees and about 50 degrees with respect to the radial direction, and most preferably at an angle of between 25 degrees and 35 degrees. As can be inferred from contemplation of FIG. 3, the flipper 54 is deployed about the bead 52 b which is itself circumferentially disposed within the tire. The flipper 54 disposed such that its axially inward portion 55 extends radially outward from the bead to a distance which is approximately axially adjacent to the top of the rim flange 72 of a wheel 70 . On its axially outward side, the flipper 54 extends radially outward from the bead to a location 60 b that is also approximately equal to the height of the wheel's rim flange 72 . The radialmost reach of the end 60 b of the flipper 54 extends between about 7 millimeters and about 15 millimeters beyond the radialmost reach of the ply turnup end 62 b . (The view of the elements of the bead region shown in FIG. 3 are mirror-image symmetric with the corresponding elements of the bead region on the other side of the tire.) The flipper is called “active” because it actively absorbs (i.e. during tire deflection) the differential strain between the very rigid bead 52 b and the less rigid metal reinforced ply 50 by the positioning of the flipper ends relative to the top rim flange level. This will also be the case for the “patch” outward as described later. The Chipper The chipper 56 is made of steel cords. Each chipper 56 (one for each bead, only one is shown in FIG. 3) is disposed adjacent to the portion of the ply 50 that is wrapped around the bead 52 b . More specifically, the chipper 56 is disposed on the opposite side of the portion of the ply 50 from the flipper 54 . The axially inwardmost portion of the chipper 56 lies in the portion of the bead region that, when the tire is mounted on a wheel 70 , would lie closest to the circularly cylindrical part 74 of the wheel. The axially and radially outwardmost portion of the chipper 56 lies in the portion of the bead region that, when the tire is mounted on a wheel, would lie inward of the circular portion of the wheel-rim flange 70 , being separated from the circular portion of the wheel-rim flange by tire rubber 64 . In other words, as can be seen in FIG. 3, the chipper 56 is disposed circumferentially about the radially inwardmost portion of carcass ply 50 where it turns up under the bead 52 b . The chipper 56 can extend radially outward, being more or less parallel with the turned up end 62 b of the ply 50 , for example to a distance of about 10 mm to about 30 mm beyond the radial-most reach of the turned up ends 62 b of the ply 50 , of the radial-most reach of the turnup end of the ply. There are, of course, two chippers, only one of which is shown in FIG. 3 . The disposition of the second chipper (not shown) is mirror-symmetric with respect to the bead-region elements shown in FIG. 3 . The chipper 56 protects the portion of the ply that wraps around the bead from the strains in the rubber that separates the chipper from the wheel rim 70 . The chipper 56 reinforces the bead area and stabilizes the radially inwardmost part of the sidewall 57 . In other words, the chipper 56 , being of a relatively flexible steel cords material encompassed with an elastomeric material, absorbs deformation in a way that minimizes the transmission of stress-induced shearing strains that arise inward from the wheel rim 70 , through the rubber portion 64 , to the turned up portion 62 b of the ply 50 where the chipper is most immediately adjacent to the rigid bead 52 b. In a prior art tire, the radially outermost portion of a chipper, corresponding to 68 in FIG. 3, would be exposed to high shearing stresses in the bead region. The differential shearing strains, between the chipper and the much less rigid adjacent rubber, would tend to induce separation of the chipper end 68 from the adjacent rubber 64 . The mode of separation arises from the disparity of the physical properties, in particular the disparity of the respective shear moduli of elasticity, of the chipper material and the adjacent low shear modulus of the rubber. Therefore, among the inventive features of the present invention is the use of a nylon “patch” 58 which overlays the radially outwardmost end 68 of the chipper 56 as well as the radially outermost end 60 b of the turned up end 62 b of the ply 50 . The chipper 56 of the present invention is made of steel cords having a mesh of between about 10 and about 18 ends per inch, preferably between about 12 and about 16 ends per inch. The wire cord gauge of the chipper is between about 0.6 mm and about 1.5 mm. The chipper cords are oriented at an angle of between about 25 degrees and about 35 degrees with respect to the radially oriented steel cords that reinforce the ply; most preferably it is oriented between about 27 and about 30 degrees. The Nylon Patch The nylon patch 58 shown in FIG. 3, is circumferentially disposed about the bead structure 52 b in such a way as to over lie the radially outermost regions 68 of the chipper 56 and the turned up ends 62 b of the ply 50 . The nylon patch 58 performs a function similar to that of those of the chipper 56 and the active flipper 54 . More specifically, the material of the nylon patch, because it has properties of shear modulus of elasticity that are intermediate between those of the low-modulus rubber and the much higher modulus reinforcing materials of the ply 50 and the chipper 56 , works to intermediate or absorb shearing stresses in the rubber parts which might otherwise induce separation of the flexible rubber from the less flexible material of the chipper and the ply. The nylon patch 58 is made of nylon fabric having a thread pitch of between about 5 and about 30 ends per inch (epi) and an overall thickness in the range of about 0.3 to about 1.2 mm, and 0.5 to about 1.0 mm gauge, preferably about 10 to about 20 ends per inch, and most preferably between about 10 and, about 15 ends per inch and 0.5 to 0.8 mm cord gauge. The nylon fibers of the nylon patch 58 are oriented at an angle of about 45 degrees with respect to the angle of the nylon threads of the flipper 54 . The radially outwardmost portion 67 of the patch 58 reaches to a minimum level such as extending by at least 5 mm avove the flipper 55 upper end 60 b and preferably between 10 and 15 mm. The radially inwardmost portion of the patch overlaps preferably about a minimum of 10 mm with the wire chipper 56 . Operational Dynamics of the Inventive Features The flipper 54 and the patch 58 serve to provide materials that act as strain buffers between respective tire elements which have disparate shear moduli of elasticity. More specifically, the flipper 54 introduces an intermediate material between the rigid bead 52 b and the less rigid bead wrapping portion of the steel reinforced ply 50 . The radially and axially outermost portion 60 b of the flipper 54 serves a similar strain-relieving intermediating presence between the axially inwardmost portion of the radially outermost extreme region of the turned up end 62 b of the ply 50 and the relatively less rigid (i.e., having relatively lower shear modulus of elasticity) material of the bead filler apex 59 b. The chipper 56 serves a similar, albeit more rigid, intermediating strain reliever disposed between the portion of the ply 50 that wraps around and ascends radially outward from the rigid bead 52 b. Finally, the patch 58 , which overlies the radially outer most portions of the turnup ends 62 b of the ply 50 and the radially outermost portion 68 of the chipper 56 , likewise presents a strain absorbing presence that intermediates between the high strains of the low-modulus rubber portion 64 and the relatively lower strains of the higher modulus materials respectively of the ply end 62 b and the chipper end 68 . The net effect of the incorporation of the combined inventive features of the steel cords chipper 56 and the flipper 54 and the patch 58 is a set of strain buffers that relieve or absorb the kinds of differential shearing strains that otherwise, were the chippers, flippers and patches not present, would more likely lead to separation of the adjacent materials having disparate shearing moduli of elasticity. Furthermore, this reinforced construction results in increased durability of the tire by means of the incorporation of a smaller number of components than for standard constructions with gum strips at ply and chipper ending. While the invention has been described in combination with embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing teachings. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.
The tire of the invention incorporates an active nylon flipper in each bead region. The flipper is active in the sense that it actively absorbs differential shearing strains that arise between each turnup end of the ply and each rigid metal bead during heavy-duty service. In conjunction with each of the two flippers, a chipper protects the portion of the ply lying closest to the wheel rim when the tire is mounted. A nylon patch overlaps the respective end of each chipper, the turnup end of the ply, and the radially outermost part of each flipper. The shearing modulus of the nylon material of each flippers and each patch is intermediate between the shearing moduli of the adjacent materials, which thus distributes and absorbs shearing stresses in ways that reduce the tendency of the turnup ends and the radial most part of the chippers to separate from the adjacent tire structures during heavy-duty operation.
8
BACKGROUND OF THE INVENTION The invention pertains to rotary indexing tables such as employed in the machining and fabrication arts. Rotary index tables are commonly employed with machine tools, such as milling machines and turret lathes, assembly apparatus, bottle filling machines, and the like, wherein the table is periodically indexed about its axis of rotation for sequentially presenting a station or part to a tool, or nozzle, or other similar fixture. The rotation of the index table may be manually accomplished, or power driven such as by a rotary or reciprocating motor which may be electric or fluid powered. The most conventional system for indexing an index table is to utilize a ratchet wheel having teeth defined thereon which are selectively engaged by a ratchet dog, usually pivotally mounted and often spring biased, which engages with the wheel as the dog oscillates about the table axis of rotation in the indexing direction. As the dog is oscillated in the return direction it rides over the teeth of the ratchet wheel, and adjustable means are often associated with the ratchet dog linkage to limit the angular degree of dog movement about the table axis in order to vary the extent of table rotation. Indexing devices utilizing pivoted ratchet dogs produce a positive engagement between the table ratchet wheel and dog in only the direction of rotation when the dog is rotating the wheel. Indexing tables must be indexed precisely to predetermined positions. Thus, it is necessary for the ratchet dog to move the index table to the predetermined rotational location, and no further. However, with most of the high speed machine tools and apparatus presently being utilized it is necessary to rotate the index table rapidly, and accurate location of the index table at its termination of rotation in the indexing direction becomes difficult due to the inertia of the table while rotating. The inertia of the index table tends to continue table rotation after the positive driving of the table by the ratchet dog has ceased. Such " carry-over" of the index table and ratchet wheel past the desired table location is possible because the engagement of the ratchet dog with the ratchet wheel is unidirectional, and the dog cannot prevent rotation of the table ratchet wheel past the desired location as the ratchet dog merely "rides over" the ratchet wheel teeth. In order that the index wheel and table be accurately located, a radially displaceable index pin or lock is often utilized to position and hold the index table intermediate indexing cycles. It is possible to sequence the operation of a power driven index lock such as to "catch" the index table at the end of its indexing movement to accurately locate the table. However, such an abrupt termination of the table movement as produced by an abutting relationship between table structure and a locating detent imposes undesirable and sudden shocks and impacts upon the index table and locating detent, creating high wear with the likelihood of fracturing the detent, or "peening" the table structure engaged by the locating detent. While the locating detents of the prior art are capable of accurately predetermining and maintaining the rotational position of the index table relative to its axis of rotation, such locating detents do not usually provide such a degree of interconnection between the index table and its base as to prevent vibration between the table and base, and locking means are often utilized with the table for positively locking the table with respect to its base during functioning of the apparatus mounted upon the table. For instance, if the index table supports a workpiece machined by a milling machine, it is most desirable to firmly lock the index table to its base during such machining in order to prevent inaccuracies developing in the workpiece due to slight movement and vibrations existing between the table and base. Previously utilized index table locks are often manual, requiring separate attention and operation as compared with the index table operating controls. While expansible motors have been utilized to lock index tables to their base, prior art holding means do not produce symmetric hold-down forces upon the index table, and are expensive and incapable of producing optimum holding forces in a minimum space and configuration. SUMMARY OF THE INVENTION It is an object of the invention to provide a rotary index table having an indexing detent oscillating about the table axis of rotation, and capable of engaging the index table components so as to establish a positive driving connection therewith during indexing which will prevent "overtravel" and will overcome inertial forces preventing the same from producing overtravel of the index table past its desired degree of indexing rotation. An additional object of the invention is to provide a rotary index table having a positively operated indexing detent which radially moves inwardly during rotation in the indexing direction to firmly engage a recess within the table index wheel structure to prevent play or clearance between the detent and recess during interengagement. Another object of the invention is to provide a rotary index table utilizing a positive indexing structure which is of an economical construction to produce, and is dependable in operation. Yet a further advantage of the invention lies in the provision of the incorporation of an expansible motor within the base of the index table capable of imposing an axial force upon the table to provide a high frictional engagement between the table and the base preventing vibration between the table and base. In the practice of the invention the rotary table includes a wheel portion having detent receiving recesses radially oriented and defined upon the periphery of the wheel portion. A detent support rotatable about the table axis consists of a pair of members relatively movable a limited degree with respect to each other through a lost motion linkage. These members each support a toggle link, the toggle linkages being pivotally interconnected at their central region and each linkage defining a portion of a detent. One of the detent support members is rotated by power means, and the relative movement between the support members radially displaces the detent portions of the toggle linkage into and out of engagement with the table detent receiving wheel portion. As the detent portions are positively brought into engagement with a table defined recess, and are of such configuration as to prevent disengagement of the detent with the recess at the termination of indexing, a positive interrelationship between the detent and index table occurs completely throughout the indexing movement of the detent support. Upon reversal of the direction of rotation of the detent support, the toggle linkage movement withdraws the detent from its associated recess and permits the detent to be oscillated in the reverse direction in order to initiate the next indexing cycle. Frictional engagement between the index table and its base is accomplished through an annular expansible chamber motor circumscribing the index table shaft, and the index wheel affixed to the shaft constitutes a piston member cooperating with the expansible motor chamber cylinder. A pressurized fluid source communicating with the cylinder chamber through valve means selectively permits pressurization of the chamber, and such pressurization produces an axial force upon the table shaft which creates a high frictional engagement between the index table and the table supporting surface defined upon the table base. Such engagement between the table and base is sufficient to overcome relative movement therebetween due to machining vibrations, and the like, and the incorporation of the expansible hold-down motor into the base produces uniform frictional forces on the table minimizing inaccuracies due to warpage or asymmetrical forces. BRIEF DESCRIPTION OF THE DRAWINGS The aforementioned objects and advantages of the invention will be appreciated from the following description and accompanying drawings wherein: FIG. 1 is a top elevational view of an index table in accord with the invention, FIG. 2 is a side elevational view as taken from the bottom of Fig. 1, FIG. 3 is a plan, partially sectioned view as taken along section A--A of Fig. 2, FIG. 4 is an elevational, detail, sectional view taken along right angled section B--B of FIG. 3, FIG. 5 is a plan, partially sectioned, detail view of the index wheel and detent linkage illustrating the detent at the end of the indexing motion and after initial movement of the detent support, but prior to rotation of the detent occurring, FIG. 6 is a plan, detail view of the detent linkage while being rotated in the return direction, FIG. 7 is a plan, detail view of the index wheel and detent after engagement of the detent with the index wheel and prior to rotation of the detent support in the indexing direction, FIG. 8 is a plan view of a detent toggle linkage, and FIG. 9 is a plan view of the lost motion producing link. DESCRIPTION OF THE PREFERRED EMBODIMENT The basic components of an index table in accord with the inventive concept will be best appreciated from FIGS. 1, 2 and 4. The structure includes a base 10, usually of a cast metal of relatively heavy weight, and as the disclosed index table is particularly suitable for use with machine tools, such as milling or drilling machines, the base is provided with a flat lower supporting surface and hold-down bolt receiving notches 12 whereby the base may be firmly attached to a machine tool table. The base includes a vertically disposed bore 14, FIG. 4, defining a bearing surface for the tubular table shaft 16, and the lower portion of the shaft is supported within the base bearing 18. The operating mechanism for the index table is located within a chamber 20 defined within the base, and the structure located therein will be described below. The table 22 is of a generally cylindrical configuration having an upper surface 24 provided with perpendicularly disposed T-bolt receiving grooves 26, as is conventional with machine tool index tables. The lower surface 28 of the table is flat and engages the upper flat surface 30 of the base whereby the base surface 30 is capable of supporting the weight of the table. The table 22 is firmly affixed to the upper end of the shaft 16 by pins 32 whereby the shaft and table rotate together about the shaft axis. An index wheel 34 is affixed to the shaft 16 by a key or spline and, as apparent in FIG. 4, the index wheel includes a cylindrical portion 36 and a toothed portion of greater diametrical dimension having a plurality of teeth 38 defining recesses 40 on the index wheel periphery. The recesses are formed by opposed surfaces 42 which are substantially flat and converge in an inward direction toward the axis of the shaft 16. As apparent in FIG. 4, the base 10 is provided with a cylindrical surface 44 which closely slidably receives the index wheel portion 36, and the base radial surface 46 is disposed above the upper surface of the index wheel portion whereby a chamber 48 is defined. The chamber 48 communicates with a source of pressurized fluid through a bore 50 defined in the base as represented by the dotted lines in FIG. 1. Detent support means are also mounted upon the shaft 16 and include a member 52 having an annular hub portion, FIG. 4, rotatably mounted on the shaft and maintained adjacent the index wheel 34 by a snap ring 54 received within a groove defined upon the shaft. The member 52 includes a radially extending arm 56, FIG. 3, having a pivot pin 58 located at its outer end. The hub portion of member 52 includes a cylindrical surface upon which the detent support member 60 is rotatably mounted, and positioned thereon between the hub shoulder and a snap ring 62. The member 60 is rotatably supported upon the member 52 and includes a radially extending arm 64, FIG. 3, having a pivot pin 66 located at its outer end. A friction set screw 68, FIG. 4, is threadedly received within a radial bore defined in the member 52 and engages a friction block 70 of resilient material, such as a synthetic plastic or rubber, wherein tightening of the set screw forces the friction block against the shaft 16 producing a frictional mounting of the member 52 upon the shaft which may be varied as desired. The pivot pins 58 and 66 of the detent support member arms are interconnected by a lost motion link 72, FIG. 9. The link 72 includes a hole for receiving the pivot pin 66, and the other end of the link includes an elongated slot 74 through which the pin 58 extends. The arms 56 and 64 are also interconnected by a toggle linkage consisting of a pair of links 76 and 76' identical in configuration, the shape thereof being apparent from FIG. 8. The toggle links 76 and 76' each include, at one end, a hole for receiving the associated pivot pin 58 or 66. At the other end of the toggle linkage a hole 78 is defined whereby the toggle links may be pivotally interconnected together by a pivot pin 80, FIG. 5. Also, each toggle linkage is provided with a detent projection 82 and 82' which extends radially inward toward the shaft axis and each includes a surface 84 and 84' for engagement with the index wheel recess surfaces 42, as later described. The length of the links 76 is so related to the length of the link 72 that relative rotation of movement between the members 52 and 60, as limited by the movement of the pin 58 within the slot 74, will radially displace the detent 84, collectively defined by the projections 82 and 82', between the radial positions shown in FIGS. 6 and 7. In FIG. 6 the minimum distance between the arms 56 and 64 is illustrated, wherein the pin 58 is at the rightmost portion of the slot 74, and this relationship moves the pivot pin 80 and detent 84 radially outward its maximum degree. When the pin 58 is in the leftmost portion of the slot 74 the toggle links 76 are "stretched" moving the detent 84 inwardly as in FIG. 7, whereby the detent may engage an index wheel recess 40. As will be appreciated from FIG. 7, when the detent 84 is in its innermost position the pivot pin 80 lies radially outside a line interconnecting the pivots 58 and 66 and, thus, the detent will always move radially outward upon the arms 56 and 64 moving toward each other. Rotation of the detent support member 60 is achieved by a plurality of gear teeth 86 defined thereon, as apparent in FIG. 3. The gear teeth 86 mesh with the toothed rack 88 slidably supported upon a guideway within the base 10 and operably connected to the piston 90 of an expansible motor 92, preferably air operated. Thus, reciprocation of the piston 90 and rack 88 will oscillate the support members 60 and 52 about the axis of shaft 16. When the rack 88 is moved to the right, as shown in FIG. 3, as the piston retracts, the member 60 will be rotated in a counterclockwise direction. This counterclockwise movement will cause the link 72 to move to the left locating pivot pin 58 at the right end of the slot 74 and the link 72 will then "push" the member 52 in a counterclockwise direction about the shaft 16. When the distance between the arms 56 and 64 is thus "shortened", the toggle links 76 and 76' will be pivoted outwardly, moving the detent 84 out of its associated index wheel recess, as shown in FIG. 5. When the rack 88 is moved to the left, as shown in FIG. 3, the link 72 will then "pull" the member 52 in a clockwise direction, locating the pin 58 in the left end of the slot 74, as shown in FIG. 7, and the detent 84 will radially move inward into one of the index wheel recesses 40. As the member 52 is frictionally mounted on the shaft 16 by means of the set screw 68 and friction block 70 the aforedescribed relative movement between the members 52 and 60 is dependably achieved. Accurate rotational location of the table 22 is produced by the locating detent 94 mounted in the base and radially movable into engagement with an index wheel recess 40, FIG. 5, and out of engagement with the index wheel as represented in FIG. 7. The radial displacement of the locating detent 94 is achieved by an expansible motor 96, the detent constituting an extension of the motor piston, and the detent is provided with converging surfaces 98 for corresponding intimate engagement with the recess surfaces 42. The rotational extent of oscillation of the support members 52 and 60 and, thus, the rotation of the table 22, is controlled by a threaded rod 100 rotatably mounted upon the base 10 upon suitable journals which also permit axial displacement. An abutment block 102 is provided with a threaded bore and located upon the rod 100 and partially extends into the base slot 104 whereby rotation of the rod by the knob 106 axially positions the block on the rod. Block 102 is engaged by a boss 108 defined upon the rack 88 wherein engagement of the boss with the abutment block 102, as the rack moves to the left, will displace the rod 100 to the left. Shaft movement is sensed by a valve 110 through an arm 112 mounted on rod 100 and spring biased against rod shoulder 114. Arm 112 extends through slot 104 for engaging the valve actuating plunger 116. Movement of the rack to the right is limited by the dimensions of the motor 92 itself, or other stop mechanism, not shown. The valve 110 controls the actuation of a valve 118 which controls the supply of pressurized fluid to the motor 92 and, thus, by rotation of the knob 106, the degree of index table rotation may be readily varied such that the indexing of the table 22 may vary between the distance between adjacent recesses 40 to a maximum of 90°. As appreciated from FIG. 1, conduits 120 connect the locating detent motor 96 to the control valve 118, and conduit 122 connects fitting 124 to motor 96. Fitting 124 communicates with the bore 50 for locking the table against the base, as described below. The motors 92 and 96 and valve mechanism constitute no part of the invention and may be of a conventional nature. As shown in FIG. 2, indicia 126 may be defined upon the base 10 for correlation to an indicator mark formed on the abutment block 102 wherein location of the abutment block will be readily apparent to the operator so that he may determine the degree of table indexing which will be produced each cycle. In use, assuming the table to be stationary, the locating detent 94 will be engaging a recess 40, as shown in FIG. 3, and the detent 84 will also be in engagement with a recess 40, as illustrated, since the indexing movement has been completed. Also the chamber 48 will be pressurized, forcing the index wheel "piston" portion 36 downwardly which draws the table 22 downwardly toward the base to firmly engage the table surface 28 with the base surface 30 with a high frictional force locking the table with respect to the base wherein vibrational movement between the table and base is eliminated. When it is desired to index the table 22 the valve button 128 in valve 118, FIG. 1, is depressed. Such operation of the valve button may be achieved automatically by the machine tool or other machinery associated with the index table, or the button may be manually actuated. Valve actuation pressurizes the motor 92 retracting the piston 90 and moving the rack 88 to the right, FIG. 3. The initial rotation of the member 60 by the rack 88 locates the pin 58 at the right end of the slot 74, as shown in FIG. 5, moving the detent 84 outwardly from the index wheel recess 40 previously engaged. Continued movement of the rack 88 to the right rotates both members 52 and 60 and associated detent toggle linkages and link 72 counterclockwise to the maximum extent, as determined by the retraction of the piston 90 within the motor 92. This location is predetermined to align the detent 84 with a recess 40, FIG. 6, and thereupon the motor 92 automatically reverses its direction of movement moving the rack 88 to the left, FIG. 3. Simultaneous with the pressurization of the motor 92 to reverse direction, the motor 96 is energized to withdraw the locating detent 94 from its associated recess, and the chamber 48 is depressurized. Such initial reversal of direction will cause the pin 58 to be located at the outermost part of the slot 74 pulling the detent 84 inwardly for engagement with the aligned recess 40, as shown in FIG. 7. Continued movement of the rack to the left moves the members 52 and 60 and index wheel 34 clockwise and such clockwise movement continues until the boss 108 engages the abutment block 102 to actuate the valve 110 and, at this time, the motor 92 is depressurized, the locating detent 94 is energized to engage a recess 40 and lock the index wheel and table against further rotation and, simultaneously, the chamber 48 is pressurized frictionally engaging the table and base surfaces 28 and 30, and the indexing cycle is completed. During rotation of the index wheel 34 by the detent 84 in the clockwise indexing direction the detent will be maintained in engagement with the "forward" recess surface 42 as the angle of the detent and recess surfaces constitute a "locking" angle which prevents the detent from riding out of the associated recess. Also, the fact that the detent 84 is defined by two projections 82 and 82' the circumferential distance between the inner portions of the projections will increase upon the radial position of the detent decreasing due to the fact that the toggle linkages pivot about the pivot 80. Thus, as detent 84 moves inwardly from the position of FIG. 6 with the position of FIG. 7, both the surfaces 42 of the aligned recess will be engaged by the detent projections, and no clearance or play exists relative to the detent and associated recess, which is important to assure accurate locating of the index wheel and table by the detent 84 during the indexing movement. Due to the accurate and firm engagement of the detent 84 and the recesses 40, "overtravel" of the index wheel and table is prevented regardless of how fast the table is being rotated by the motor 92 and the locating detent 94 does not engage its recess until rotation of the index wheel and table has stopped. Thus, the accuracy of indexing, as achieved by the locating detent 94, will be maintained for an extended period as little wear occurs between the locating detent and the recess surfaces 42. It will be appreciated that the aforedescribed structure and operation produces a rotary index table capable of quick and accurate indexing wherein the table may be used for close tolerance machining operations, and it is to be understood that various modifications may be apparent to those skilled in the art without departing from the spirit and scope of the invention.
A rotary index table wherein a detent oscillating about the table axis of rotation is translated radially inwardly during indexing and retracted radially outwardly during the return stroke of the detent, both actions being accomplished through a positive acting toggle link arrangement. The positive detent engagement with the table during indexing prevents table overtravel, and a locking detent is utilized to produce final table orientation. The table also includes expansible chamber motor means axially translating the table into a frictional locking engagement with its base.
8
RELATED APPLICATIONS This application claims priority from Korean Patent Application No. 10-2015-0052149 filed Apr. 14, 2015, which is herein incorporated by reference in its entirety. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a split type magazine of an air rifle, and more particularly, to a split type magazine of an air rifle which includes a pellet rotating and conveying lock unit for preventing rotation of a pellet rotating and conveying unit and of which a magazine body and a magazine fixing block are divided from each other. 2. Background Art In general, an air rifle is a kind of gun to fire a pellet with pneumatic pressure of compressed air and is mainly used for the purpose of hunting or shooting sports because it is weaker in power than guns which use gunpowder. Because the air rifles are safer than the guns which use gunpowder and require simple safety facilities which must be equipped in shooting ranges, air rifles have been relatively widely used in many countries for the purpose of leisure activities or sports. A spring type air rifle which is a kind of the air rifle adopts a method that makes compressed air by pushing a piston inside a cylinder using elasticity to return a compressed spring to its original state and fires a pellet using the power. Such spring type air rifles are mainly used in replica guns which use 6 mm BB bullets. Such a spring type air rifle has several disadvantages in that a user has to compress the spring with his or her own power whenever the user fires and in that the air rifle generates additional recoil in addition to the recoil caused by reaction of a shot while the spring returns to its original state. Next, a pump type air rifle compresses air by a pump hung on the rifle, stores the compressed air in a cylinder, and then, opens the compressed air at the time of an outburst so as to shoot a pellet with the power. Like the spring type air rifle, the pump type air rifle also has a disadvantage in that the user has to compress air by human effort using a lever whenever shooting. Before compressed air type air rifles, air rifles for competition mainly feature the pump type air rifles. Next, a carbon dioxide type air rifle shoots a pellet with pressure generated while liquid carbon dioxide is vaporized. Because a cylinder is previously charged with carbon dioxide, the carbon dioxide type air rifle is more convenient than the spring type or pump type air rifle that the user has to compress air with the hand whenever shooting. However, the carbon dioxide type air rifle has a disadvantage in that hit is not uniform because pressure generated at the time of evaporation of gas is greatly influenced by ambient temperature. Next, a compressed air type air rifle shoots a pellet by compressed air used for diving or compressed air which previously charged in the cylinder using an air compressor. The compressed air type air rifle varies little from the carbon dioxide type air rifle in appearance. Because there is no need to compress air manually whenever the user shoots a pellet, the compressed air type air rifle has convenience in use like the carbon dioxide type air rifle. However, the compressed air type air rifle is uniform in hitting differently from the carbon dioxide type air rifle. Now, air rifles for competition mainly feature the compressed air type air rifles. Differently from bullets fired by gunpowder, pellets used in the air rifle is in the form that just a warhead exists without any cartridge case, because the pellets gain momentum necessary for firing the bullets not from gunpowder contained in the pellet but from the compressed air. The tail section of the pellets used in the air rifle is made into the form of a skirt in order to effectively receive power of compressed air. In an aspect of materials of the pellet, in order to be less susceptible to wind resist, the pellets are mainly made of lead which is heavy metal. Representatively, there are pellets of 4.5 mm caliber, 5.0 mm caliber, 5.5 mm caliber and 6.35 mm caliber, and the pellets of 4.5 mm caliber are mainly used for competition, and the pellets of 5.5 mm caliber which is relatively strong in power are used for hunting. Such air rifles are divided into single-shot rifles and multi-shot rifles. Korean Patent Laid-open Publication No. 10-2001-0026459 discloses an example of the multi-shot air rifles. As shown in FIG. 1 , in order to insert a magazine 2 into a magazine combining part 3 of a rifle body 1 , after a user pushes a trigger assembly forward to back a breechblock 6 and inserts the magazine 2 into the magazine combining part 3 of the rifle body 1 , when the user pulls the trigger assembly 5 back to move the breechblock 6 forward, a single pellet is loaded in a chamber 4 . However, the conventional multi-shot air rifle has a disadvantage in that it has to fire the single pellet loaded in the chamber 4 when the user takes out the magazine 2 from the magazine combining part 3 of the rifle body 1 . PATENT LITERATURE Patent Literature 1: Korean Patent Laid-open Publication No. 10-2001-0026459 SUMMARY OF THE INVENTION Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior arts, and it is an object of the present invention to provide a split type magazine of an air rifle which includes a magazine body having a pellet rotating and conveying lock unit for preventing rotation of a pellet rotating and conveying unit and a magazine fixing block divided from the magazine body so that just the magazine body is separated even though a breechblock moves forward, thereby removing inconvenience that a user unnecessarily loads and fires a pellet. To accomplish the above object, according to the present invention, there is provided a split type magazine of an air rifle including: a magazine case which is formed in a cylindrical shape and includes an insertion groove formed in a lower end portion thereof to be fit to a magazine fixing block and a plurality of screw holes perforated at both sides; a left side plate which includes a plurality of holes to which bolts for fixing the magazine case are inserted, a magazine fixing shaft 23 formed at one side thereof, a protrusion part formed at a lower end portion of the magazine fixing shaft, a polygonal head part formed at an end of the magazine fixing shaft, a screw formed at an end portion of the magazine fixing shaft, and an inverted U-shaped groove formed at a lower end thereof; a pellet rotating and conveying unit which includes a boss part and a protrusion part inserted into the magazine fixing shaft of the left side plate, a spring support hole perforated in the boss part, a plurality of pellet insertion holes on which a plurality of pellets can be loaded and of which outer circumferential parts are opened; a right side plate which is attached by a plurality of bolts through the screw holes of the magazine case and includes a part formed at the front side thereof to cover a magazine fixing pin slide lock insertion part, an insertion groove formed at a lower end portion thereof and fit to the magazine fixing block, and a circular opening formed at the middle part thereof; a right inner plate which is inserted into the opening of the right side plate and includes a boss part formed at the left side thereof, a counter sink hole formed at the right side thereof, and an inverted ‘U’-shaped groove formed at a lower end thereof; a magazine rotary shaft fixing member which is fit to the counter sink hole of the right inner plate and includes a hole perforated at a small diameter part thereof, a spring and a ball inserted into the hole, a screw hole formed in the middle part thereof, and a recess formed in the middle part thereof to be fit to the polygonal head part of the left side plate; a spring of which one end is fixed to the spring support hole of the boss part of the pellet rotating and conveying unit and of which the other end is fixed to the hole formed in the magazine rotary shaft fixing member; a bolt for fixing the magazine rotary shaft fixing member to the screw of the magazine fixing shaft of the left side plate; and a magazine fixing block which includes balls which are respectively disposed at both sides thereof and elastically supported by a spring to be inserted into the insertion groove of the magazine case, a plurality of bolts inserted into a plurality of holes formed in a magazine fixing part of a machine part to attach the magazine fixing block to the engine part, and a pole index fixed and assembled to the middle part thereof by a pin. Furthermore, the magazine case includes a pellet rotating and conveying unit which is disposed at the front thereof and to which a pellet rotating and conveying unit fixing pin pressed by a slide lock button and a spring elastically supported by a spring and a ball is assembled. Moreover, the magazine rotary shaft fixing member includes a plurality of spring fixing holes to control elasticity of the spring. Additionally, when a breechblock pushes down the middle part of the pole index, the pole index advances in the clockwise direction so as to be in a next lock waiting state of the pellet rotating and conveying unit, and, in a case that there is a pellet, an upper wind of the magazine fixing block fixes the pellet to prevent the pellet from going over. Compared with the conventional air rifles that the magazine is separated after the user retreats the breechblock, the split type magazine of an air rifle according to the present invention allows the user to separate the magazine without moving the breechblock. Compared with the conventional air rifles which are dangerous in safety because a single pellet is loaded in the chamber when the user inserts the magazine, the split type magazine of an air rifle according to the present invention is safe because the pellet is not loaded in the chamber when the user inserts the magazine into the rifle body. Additionally, compared with the conventional air rifles which are dangerous because a single pellet is loaded in the chamber when the user inserts the magazine, the split type magazine of an air rifle according to the present invention provides a safety device doubly because it includes the lock unit of the pellet rotating and conveying unit. In addition, compared with the conventional air rifles which have to fire a pellet when the magazine is separated, the split type magazine of an air rifle according to the present invention enhances safety because the pellet rotating and conveying unit is locked when the magazine is separated. BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments of the invention in conjunction with the accompanying drawings, in which: FIG. 1 is an exploded view of an air rifle body having a magazine according to a prior art; FIG. 2 is an exploded view of a magazine body having a lock unit for preventing rotation of a pellet rotating and conveying unit of a split type magazine of an air rifle according to the present invention, and for your reference, illustrates a breechblock; FIG. 3 is an exploded view of a magazine fixing block; and FIG. 4 is a view showing a magazine combining part of a rifle body of the split type magazine of the air rifle according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Hereinafter, reference will be now made in detail to the preferred embodiment of the present invention with reference to the attached drawings. In the drawings, the same components have the same reference numerals even though they are illustrated in different figures. After studying a device that a magazine is separated even though a breechblock advances in the direction of a chamber in order to solve the problems of the conventional air rifles, the inventor of the present invention has invented a split type magazine whose a magazine body could be separated from a magazine fixing block even in a state where the breechblock is inserted into a pellet insertion hole by forming a lower end part of the pellet insertion hole of a pellet rotating and conveying unit to be opened. FIG. 2 is an exploded view of a magazine body having a lock unit for preventing rotation of a pellet rotating and conveying unit of a split type magazine of an air rifle according to the present invention, and for your understanding, illustrates a breechblock, which does not fall into the category of the present invention, FIG. 3 is an exploded view of a magazine fixing block, and FIG. 4 is a view showing a part where the magazine fixing block of the present invention is attached to a magazine combining part of a rifle body. The split type magazine 10 of an air rifle according to the present invention is greatly divided into two parts: one being a magazine body 10 and the other being a magazine fixing block 50 . Hereinafter, the split type magazine 10 of an air rifle according to the present invention will be described in more detail. First, the magazine body is as follows. A magazine case 11 is formed in a cylindrical shape and a plurality of screw holes 12 are formed at both ends. A pellet rotating and conveying lock unit which has a pellet rotating and conveying fixing pin 17 pressed by a slide lock button 15 and a spring 16 elastically supported by a spring 13 and a ball 14 is assembled to a space part formed at the front. The spring 13 and the ball 14 clicks when the slide lock button 15 moves from side to side to be locked. An insertion groove 18 which is inserted into a ball 51 of the pellet fixing block 50 is formed at a lower end portion. A left side plate 20 has a plurality of holes 22 formed to be joined to the left side of the magazine case 11 by a plurality of joining bolts 21 . A magazine fixing shaft 23 is formed at one side of the left side plate 20 , and a protrusion part 24 is formed at a lower end portion of the magazine fixing shaft 23 . A polygonal head part 25 is formed at an end of the magazine fixing shaft 23 , and a screw 26 is formed at the right end of the magazine fixing shaft 23 . An inverted U-shaped groove 27 is formed at a lower end of the left side plate 20 . A breechblock 28 can advance into the inverted U-shaped groove 27 and retreat from the inverted U-shaped groove 27 . Moreover, the left side plate 20 has a slide lock unit covering part 29 . The left side plate 20 is attached to the magazine case 11 by the bolts 21 . The dotted circle in FIG. 2 is a cross sectional view of a pellet rotating and conveying unit 30 . The pellet rotating and conveying unit 30 includes: a boss part 32 and a protrusion part 38 which are fit and inserted into the magazine fixing shaft 23 of the left side plate 20 ; and a spring support hole 33 perforated in the boss part 32 . The first part of a spring 48 is fit into the spring support hole 33 . A plurality of pellet insertion holes 34 to which a plurality of pellets can be loaded are formed in the outer circumferential surface of the pellet rotating and conveying unit 30 , and outer circumferential parts 35 of the pellet insertion holes 34 are opened. A right side plate 31 is attached to the right of the magazine case 11 by the bolts 21 through the screw holes 12 of the magazine case 11 . The right side plate 31 includes a slide lock unit covering part 29 formed at the front side thereof for covering the pellet rotating and conveying lock unit, and an insertion groove 18 which is formed at a lower end portion thereof to be inserted into the pellet fixing block 50 . A right side inner plate 36 is assembled to an opening 37 of the right side plate 31 . The right side inner plate 36 is inserted into the opening 37 of the right side plate 31 , and includes: an inverted ‘U’-shaped opening part 39 formed at a lower end portion thereof; a boss part 40 formed at the left side thereof; and a counter sink hole 41 formed at the right side thereof. The boss part 40 is fit into a right end hole of the pellet rotating and conveying unit 30 . A pellet rotating shaft fixing member 44 has a screw hole 43 formed at an end portion of a middle part thereof and a recess formed at the other end portion thereof to be fit to the polygonal head part 25 of the left side plate 20 . The magazine rotary shaft fixing member 44 has a hole 45 perforated at a small diameter part thereof, and a spring 46 and a ball 47 are inserted into the hole 45 . The ball 47 pressed to the spring 46 serves as a bearing. The magazine rotary shaft fixing member 44 is fit to the counter sink hole 41 of the right inner plate 36 and is fixed by a bolt 49 . An end of the spring 48 is fixed to the spring support hole 33 of the boss part 32 of the pellet rotating and conveying unit 30 , and the other end is fixed to a spring support hole 42 formed in the magazine rotary shaft fixing member 44 . A plurality of spring support holes 42 are formed in the magazine rotary shaft fixing member 44 to control elasticity of the spring 48 . The spring 48 serves to make the pellet rotating and conveying unit 30 rotate with elasticity. In this instance, when the pellet rotating and conveying unit 30 rotates, the protrusion part 38 formed on the pellet rotating and conveying unit 30 and the protrusion part 24 formed on the left side plate 20 come into contact with each other so that the pellet rotating and conveying unit 30 rotates just at a predetermined angle. When the pellet rotating and conveying unit 30 rotates, the right inner plate 36 rotates together with the pellet rotating and conveying unit 30 . In this instance, the magazine rotary shaft fixing member 44 does not rotate because the polygonal head part 25 of the left side plate 20 is combined with the recess of the magazine rotary shaft fixing member 44 and the bolt 49 is fixed to the screw 26 . The bolt 49 fixes the magazine rotary shaft fixing member 44 to the screw 26 of the magazine fixing shaft 23 of the left side plate 20 . Hereinafter, the magazine fixing block 50 will be described as follows. The magazine fixing block 50 has balls 51 which are respectively disposed at both sides thereof and are elastically supported by a spring to be inserted into the insertion groove 18 of the magazine case 11 . The ball 51 is mounted to slightly protrude out from the side wall of the magazine fixing block 50 . When the user presses down the magazine case 11 , the insertion groove 18 presses the ball 51 , and the ball 51 is elastically retreated by the spring. When the user presses more down the magazine case 11 , the ball 51 is fit into the insertion groove 18 to support the insertion groove 18 . The magazine fixing block 50 has a plurality of holes 53 formed to be attached to a magazine fixing part of a machine part 61 using a plurality of bolts 52 . The magazine fixing block 50 has a pole index 55 which is fixed by a pin 54 and is assembled to a middle part thereof. The pole index 55 has an oval-shaped hole 56 . A spring 59 is supported in a hole, which is transversely formed in the magazine fixing block 50 , by a fixing bolt 57 , and one end of the spring 59 elastically supports the pole index 55 in the transverse direction. The pole index 55 is elastically supported by the spring 58 in the upward direction. The pole index 55 fixed by the pin 54 is assembled to the middle part of the magazine fixing block 50 . When the breechblock 28 pushes down the middle part of the pole index 55 , the pole index 55 advances in the clockwise direction so as to be in a next lock waiting state of the pellet rotating and conveying unit 30 . In this instance, in a case that there is a pellet, an upper wind 71 of the magazine fixing block 50 serves to fix the pellet to prevent the pellet from going over. The split type magazine is operated by repeating the above movements. In order to fix the magazine fixing block 50 , the machine part 60 has two screw holes 61 , and the magazine fixing block 50 is fixed when the bolts 52 are inserted into the screw holes 61 . The machine part 60 has a pellet loading hole 62 , and the pellet is loaded on the pellet loading hole 62 by the breechblock 28 . An assembling process of the components of the split type magazine for the air rifle according to the present invention will be described. In a state where the left side plate 20 gets in contact with the right side of the magazine case 11 , the four bolts 21 are inserted and fixed in order. The first part of the spring 48 is fit into the spring hole 33 of the pellet rotating and conveying unit 30 , and then, the pellet rotating and conveying unit 30 and the spring 48 are fit to the magazine fixing shaft 23 of the left side plate 20 . Next, the spring 13 is put into the hole formed in the front side of the magazine case 11 and the ball 14 is put into the hole, and then, the slide lock button 15 is pushed into the groove sideways. The pellet rotating and conveying fixing pin 17 pressed by the spring 16 is assembled. In the above state, the right side plate 30 is fixed to the holes 12 of the magazine case 11 using the four bolts 21 . Next, the right inner plate 36 is adjusted to the magazine case 11 , and then, is fixed by the four bolts 21 . At the same time, the boss part 40 of the right inner plate 36 is fit into the hole of the pellet rotating and conveying unit 30 . Continuously, after the spring 46 and the ball 47 are put into the hole 42 of the magazine rotary shaft fixing member 44 , one end portion of the spring 48 is fit into the hole 42 , and then, is inserted into the hole of the right inner plate 36 . After that, the bolt 49 is coupled to the screw 26 formed on the magazine fixing shaft 23 of the left side plate 20 . Then, the assembly of the split type magazine is finished. After that, an assembling process of the magazine fixing block 50 will be described. The springs and the balls 51 are inserted into the transverse holes formed at both ends of the magazine fixing block 50 , and then, are fit into the holes not to get out of the holes by making entrances of the transverse holes get narrower. The balls 51 partly protrude from both sides of the magazine fixing block 50 . When the user presses down the magazine case 11 , the insertion groove 18 of the magazine case 11 presses the balls 51 so that the balls 51 moves inwardly by elasticity of the spring. When the user presses down the magazine case 11 more, the balls 51 are elastically supported to the insertion groove 18 so that the magazine case 11 is snap-fixed to the magazine fixing block 50 . After the pin 54 is inserted into the hole formed at the side of the magazine fixing block 50 , the pole index 55 having the oval-shaped hole 56 is rotatably fixed, and then, the spring 59 is put into a hole 70 and the bolt 57 is assembled to the hole. The spring 58 is inserted into the bottom side of the pole index 55 . The assembled magazine fixing block 50 is inserted into a recess of the machine part 60 , and then, is firmly fastened in the recess of the machine part 60 by the bolt 52 . A method to insert a pellet into the magazine will be described. First, put the slide lock button 15 at a lock position. Second, rotate the right inner plate 36 in the clockwise direction to the finish. Third, in the above state, insert pellets into the pellet insertion holes 34 one by one while rotating the right inner plate 36 in the counter clockwise direction. Fourth, insert and fix into the magazine fixing block 50 . Fifth, put the slide lock button 15 at a lock release position. Sixth, retreat the breechblock 28 , and then, push the breechblock 28 forward so that a single shot of the pellet is loaded in a chamber. In this instance, when the breechblock 28 pushes down the middle part of the pole index 55 , the pole index 55 advances in the clockwise direction so that the pellet rotating and conveying unit 30 is in the next lock waiting state. In this instance, in the case that there is a pellet, the upper wind 71 of the magazine fixing block 50 serves to fix the pellet to prevent the pellet from going over.
A split type magazine of an air rifle includes a lock unit to prevent the rotation of a pellet rotating and conveying unit, A magazine body and a magazine fixing block of the split type magazine are divided from each other. The split type magazine allows the user to separate the magazine without moving the breechblock. It is safe because the pellet is not loaded in the chamber when the user inserts the magazine into the rifle body. Further, the lock unit of the pellet rotating and conveying unit enhances safety because the pellet rotating and conveying unit is locked when the magazine is separated.
5
BACKGROUND OF THE INVENTION (1) Field of the Invention The present invention relates to a humidity conditioner for humidity-conditioning a room by dehumidifying the room at a time of high humidity by absorbing moisture therefrom and condensing the moisture for passage through a moisture absorber and discharge outwardly of the room, and releasing moisture from the moisture absorber to the room at a dry time, and to a novel humidity-conditioning apparatus for a storeroom which utilizes the above humidity conditioner for humidity-conditioning the storeroom while effecting mildew-proofing and preventing dew drop formation. (2) Description of the Prior Art An example of a known, commercially available dehumidifying is disclosed in Japanase Patent Publication Kokai No. 55-159827. This dehumidifier has a large-scale construction comprising a filter formed of a corrugated asbestos sheet or the like impregnated with a hydroscopic filler, the filter being exposed to hot air flows thereby to collect high-humidity air. Although the above dehumidifier has an excellent dehumidifying capability, it is not suited for use in a closet or a storeroom since air must be recirculated and the mechanical noise is produced. Dehumidifying agents are also commercially available but they cannot be regenerated and therefore require the trouble of periodic replacements. Further, the above dehumidifier has the disadvantage that it is incapable of effecting humidity conditioning by humidifying a room when the room becomes excessively dry. On the other hand, Japanese Patent Publication Kokai No. 60-103909 discloses a known example of storerooms having a dehumidifying function without using a rotational drive. This storeroom utilizes the Peltier effect but has the following disadvantages. The construction of this storeroom comprises peripheral walls and a door with a heat insulating treatment, and a thermoelectric cooler disposed at an upper position for dehumidifying the storeroom by utilizing the Peltier effect. Air is cooled through contact with a cooling member, thereby to form dew drops which flow down to be collected and discharged outwardly of the storeroom. Only a minor dehumidifying effect is produced during wintertime since there is a small difference between air temperature and cooling member temperature and since dew drops are formed on the cooling member. Consequently, dew drops are formed on the wall of the storeroom facing north. During summer, on the other hand, the storeroom produces a dehumidifying effect while in operation, but the temperature in the storeroom will fall when the storeroom is cooled with the dehumidifying function stopped. As a result, the relative humidity will increase to produce moist atmosphere since moisture is trapped due to the moisture-insulating layers. Thus, the known storeroom could result in mildew formation and dampen articles stored therein, as distinct from a known wooden storeroom whose side plates themselves have a humidity-conditioning function. SUMMARY OF THE INVENTION The present invention has been made having regard to the state of the art noted above. A primary object of the present invention is to provide a compact humidity conditioner having a simple construction and yet excellent moisture absorbing and desorbing capabilities, allowing regeneration of a hygroscopic filler, and continuously usable over a long period of time. The humidity conditioner condenses absorbed moisture within a panel for discharge through a back surface of a moisture absorber by a heating element disposed on the back surface thereof and, when the room is excessively dry, absorbs moisture from a water holder and releases the moisture through the moisture absorber to the room. In order to achieve the above primary object, a dehumidifying apparatus according to the present invention comprises a moisture absorber including a porous material formed of laminated fiber and having continuous fine interstices, and a hygroscopic filler filling the interstices, the moisture absorber having at least one laminar section acting as a moisture absorbing face, and a heating element integrated with another face of the moisture absorber for allowing release of moisture from the moisture absorber. A secondary object of the present invention is to provide a storeroom having a dehumidifying function without necessitating a drive therefor. The storeroom has proper humidity conditioning function even when at rest regardless of seasons and without being influenced by cooling and heating of its interior space. In order to achieve the secondary object, a storeroom according to the present invention comprises a humidity-insulated box defining a moisture absorbing opening in part of four peripheral sides thereof, a moisture absorber including a porous material formed of laminated fiber and having continuous fine interstices, and a hygroscopic filler filling the interstices, the porous material having laminar surface acting as a moisture absorbing face opposed to the moisture absorbing opening, a heating element integrated with another laminar surface acting as a moisture desorbing face of the moisture absorber, and a moisture release opening defined in a peripheral position of the box for communicating with the moisture desorbing face of the moisture absorber. How the present invention functions will now be described. Moisture absorbed by the moisture absorber tends to move to a position in the moisture absorber having a low moisture content gradient and a low steam pressure gradient. At this time, the presence of the hygroscropic filler in the interstices enables a moisture absorption twice to several tens of times the moisture absorption without the hygroscropic filler, and promotes the moisture movement even with very small differences in the moisture content and steam pressure. The moisture movement has a directional characteristic since, in the porous material formed of laminated fiber, the fiber has a two-dimensional expanse chiefly parallel to the laminates. Consequently, when the front face of the moisture absorber is exposed to a highly humid room, the moisture absorbed moves along the laminates to spread throughout the moisture absorber. At this time, the heating element provided on the other face opposite the moisture absorbing face is operated, whereby the moisture adjacent the heating element is released in water vapor from the other face. As a result, the moisture content adjacent the heating element is decreased, thereby regenerating the hygroscopic filler adjacent the heating element. The moisture released from the back surface of the moisture absorber through heating forms dew drops on the cover member to be collected in the water holder below. Conversely, at a time of low humidity in the room to which the front face of the moisture absorber is exposed, the water in the water holder is evaporated to be absorbed by the moisture absorber. The absorbed moisture is caused by the steam pressure gradient to move toward the front face and to be released from the front face to the room. As a result, the humidity in the room is maintained within a certain range. How the storeroom utilizing the above humidity conditioner functions will be described next. When the storeroom is highly humid, moisture absorbed therefrom spreads throughout the moisture absorber. Thereafter the heating element provided on a laminar face (acting as the moisture desorbing face) of the moisture absorber outside the storeroom is operated for a predetermined time, whereby the moisture adjacent the heating element is released in water vapor outwardly of the storeroom. As a result, the moisture content adjacent the heating element is decreased, thereby regenerating the hygroscopic filler adjacent the heating element. In order to effectively use the above moisture absorber without necessitating a large space therefor, the storeroom defines a moisture absorbing opening in part of the four peripheral walls for attaching the moisture absorber. This construction secures a large moisture absorbing area. The storeroom performs the humidity-conditioning function even when at rest. Thus, there is no possibility of forming dew drops on the inside walls of the storeroom in winter, or humidifying the storeroom interior due to an increase in the relative humidity in the storeroom during a cooling operation in summer. The above humidity conditioning mechanism realizes an effective humidity conditioning not only during a dehumidifying operation but during a rest period, thereby forming no dew drops or mildew with environmental changes. The advantages produced by the present invention are as follows: In the present invention, the moisture absorber includes a porous material formed of laminated fiber and having continuous fine interstices, and a hygroscopic filler filling the interstices, the moisture absorber having at least one laminar section acting as a moisture absorbing face, and a heating element integrated with another face of the moisture absorber for allowing release of moisture from the moisture absorber. Moisture movement has a directional characteristic since, in the porous material formed of laminated fiber, the fiber has a two-dimensional expanse chiefly parallel to the laminates. Consequently, the moisture is readily allowed to move toward the face with which the heating element is integrated. This permits the moisture absorbing face and moisture desorbing face to be oriented in selected direction, thereby enabling effective dehumidification. Thus, dehumidification and regeneration are possible without recirculation of air. This feature provides an advantage of low running cost with minimal energy application. The humidity conditioner according to the present invention has little influence on room temperature, and therefore is suited for dehumidifying a closet or a storeroom. The moisture absorbed into the moisture absorber is released in water vapor from the heating face of the absorber by the action of the heating element. Thus, no outflow of the hygroscopic filler occurs, enabling a high moisture absorbing function to be maintained over a long period of time. This feature has a further advantage of avoiding fouling, damage and deterioration of peripheral equipment due to outflow of the hygroscopic filler. In addition, the moisture absorber per se requires no air recirculating device or the like. This allows the peripheral equipment to be simplified and the installation to be compact. As a result, this humidity conditioner may be incorporated into an air-conditioner or a wall of a building to provide a dehumidifying method entirely different from conventional dehumidifying methods. According to the present invention, the apparatus is operable in response to the relative humidity, such that the moisture absorber absorbs moisture when a room is highly humid, and releases the moisture to the room when the latter is excessively dry. Thus, the apparatus of the present invention can humidity-condition the room as distinct from the known dehumidifier. This apparatus, therefore, is effective for maintaining environment in a room such as a storeroom for fur, books or antiques. The moisture in the storeroom is absorbed by the moisture absorber and is released outwardly through the moisture releasing opening defined in the box, thereby significantly reducing the humidity in the storeroom. The storeroom dehumidification is carried out very quietly since no drive is involved at this time. In addition, the use of the heating element for releasing moisture does not produce dew drops or frost on the desorbing face of the moisture absorber, as in the dehumidification utilizing the Peltier effect, when the room is heated in winter time. The storeroom is humidity-conditioned even when a dehumidifying operation is not taking place, and effective humidity conditioning is continuously provided for the storeroom through all seasons. Other advantages of the present invention will be apparent from the following description of the preferred embodiments to be had with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS The drawings show humidity conditioners and storerooms having a humidity conditioning function according to the present invention, in which: FIG. 1 is a sectional perspective view of a principal portion of a humidity conditioner, FIG. 2 is a schematic perspective view of a principal portion of the humidity conditioner, FIG. 3 is a schematic perspective view of another humidity conditioner, FIG. 4 is a schematic view in vertical section of a further humidity conditioner, FIG. 5 is a schematic sectional view of a principal portion of the above embodiments, FIG. 6 is a schematic sectional view of a principal portion of a modified humidity conditioner, FIG. 7 is a view in vertical section of the above embodiment, FIG. 8 is a section taken on line X--X of FIG. 7, and FIGS. 9 and 10 are graphs illustrating performance comparisons. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention as embodied will be described in detail hereinafter with reference to the drawings. A moisture absorber 4a according to the present invention may be formed of a porous material having fine interstices, such as; (1) rock fiber, glass fiber or other inorganic fiber bound together with a binder, or (2) nonwoven cloths or fiber plates as above laminated in an appropriate thickness. As shown in FIG. 5, the laminated porous material may have one of opposite laminar face bent in a selected direction. Alternatively, as shown in FIG. 6, the material may have adjacent laminar faces acting as a moisture absorbing surface and a moisture desorbing surface for desorbing moisture in a right-angle direction. The porous material should preferably have a moisture permeability not less than 1×10 -3 g/m·h·mmHg, and a resistance of heat conduction not less than 2.0 m·h·°C./kcal since the greater the temperature difference is between a front surface and a back surface when heated, moisture movement to the back surface is the more promoted. In order to promote capillary flows, and in order to retain a hygroscopic filler, which will be described later, the porous material should preferably have a good distribution of interstice sizes in the range of 0.1 to 100 micrometers. In the case of laminated porous material, an interstice size distribution of 1 micrometer and upward is well suited for moisture movement. Further, the porous material needs to have a thickness of at least 5 mm, preferably 20 mm or more, since the thicker the material is, the greater is its moisture retention and the slower is the heat conduction to the front surface when the back surface is heated, thereby facilitating formation of a temperature gradient and a moisture holding gradient. In the present invention, the hygroscopic filler comprises (1) a deliquescent material such as calcium chloride, lithium chloride or the like, (2) a water-soluble high polymer such as diethylene glycol, triethylene glycol, glyceline, sodium polyacrylate, PVA or the like, (3) an inorganic hygroscopic material such as bentonite, sepiolite, zeolite, activated alumina, zonotolite, activated carbon, molecular sieves or the like, and (4) a water-insoluble high polymer hygroscopic material such as graft starch, isobutylene maleic anhydride or the like, which are used alone or in combination. The porous material is filled with the hygroscopic filler by a method in which the filler is applied together with the binder and fiber at the time of integrating these components, or a method in which, after the porous material is obtained, the porous material is made hydrophilic by means of a surface active agent or the like, impregnated with the hygroscopic filler dissolved in water, and dried. A heater 2 used in the present invention comprises a metal wire, or an etched metal or a conductive coating material applied to a gas-permeable sheet, with a suitable moisture-proofing and short-circuit-proofing treatment. The heater may include a heat distributing sheet such as a metal netting laid thereon to uniformalize heat. The heating temperature may be set so that the material temperature becomes 60° to 140° C., although the higher the temperature is, the moisture desorption is the more promoted and the shorter becomes the moisture desorbing time. A moisture sealing door may be provided for preventing absorption of external moisture at a moisture absorbing time, which door is opened at a heating time. The heater may effectively be used to heat the moisture absorber for several hours after the absorber is allowed to absorb moisture for a predetermined time and becomes moist. This operation may be controlled by means of a timer or a temperature sensor. (First Embodiment) FIG. 1 shows a first embodiment of the present invention, in which the moisture absorber 1 comprises the porous material formed by laminating fibers containing the hygroscopic filler. The moisture absorber 1 is bent in advance so that laminar faces are at right angles to each other. Number 2 indicates the heating wire, and number 3 indicates a cover member overlying the moisture absorber 1. The moisture absorber 1 is used as mounted on a wall or the like, with a moisture absorbing face 4a exposed to a room interior and a moisture desorbing face 5 connected to a duct or the like disposed on a back surface of the wall. Moisture absorbed by the moisture absorber 1 is guided by the moisture absorber 1 and cover member 3 and is released through the moisture desorbing face 5. According to the above construction, a long distance is secured in a limited space between the moisture absorbing face and the moisture desorbing face. Thus, the heat generated by the heating wire 2 is not readily conducted to the moisture absorbing face, thereby preventing release of the moisture from the moisture absorbing face to the room interior. The duct extends outwardly of the system and is ventilated. Moisture is then absorbed through the moisture absorbing face, and is released through the moisture desorbing face and outwardly of the system. Referring to FIG. 2, the cover member 4 according to the present invention comprises a plastic plate or a metal plate which is moisture imperpeable and waterproof, and has excellent heat conduction to readily form dew drops. The moisture absorber 1 is mounted so that a spacing is formed between the cover member 4 and the back bottom of the moisture absorber 1. A water holding device 6 is placed below the cover member 4. The water holding device 6 serves to hold dew drops flowing down inside the cover member 4. This water holding device 6 is removable, to throw away water accumulating therein and to replenish water at a humidifying time. Number 10 indicates a moisture content sensor. As shown in FIG. 3, the water holding device 6 may include a heater 7 which is operable under a low humidity condition to promote evaporation of water in the cover member 4. As a result, the moisture absorber 1 becomes highly moist from the back surface, and release moisture from its front surface to the room interior, thereby quickly effecting moisture control of the room. Further, as shown in FIG. 3, a ventilating fan 8 may be attached to the cover member 4, which fan is selectively operable when the heater 7 is operated. Thus, the moisture released from the back surface of the moisture absorber 1 may be released outwardly of the cover member 4 with the operation of the heater 9, whereby dehumidification is effected quickly. Automatic running of the apparatus may be achieved by controlling, in an interlocked manner, the moisture content sensor 10 which detects equilibrium moisture content of the moisture absorber 1, the heating wire 2 of the moisture absorber 1, the heater 7 of the water holding device 6, and the fan 8 in response to a relative humidity of the room environment. The control of these components may be effected by means of a humidity sensor 11 provided on the moisture absorber 1 opposed to the room interior. The heater 7 of the water holding device 6 is operated when the humidity in the room falls below a predetermined humidity. FIG. 4 shows a box 12 of high moisture insulation used in the present invention. This box 12 is formed of a plastic plate, a metal plate, a plywood board having moisture-insulating front and back surfaces with PVC sheets or polyester resin coatings applied thereto, or a flush panel including an adhesive such as vinyl acetate resin or the like having low moisture permeability applied over entire opposed surface of two plywood boards which are rigidly interconnected by crosspieces. A front door 13 is hinged for opening and closing a front opening of the box 12, and a packing 14 is disposed at a position of contact between the front door 13 and an edge of the box 12 defining the opening. In the embodiment of FIG. 4, the box 12 includes a bottom plate 15 defining a moisture absorbing opening 16, and the moisture absorber 1 shown in FIG. 5 is mounted therein through a dust filter 17 to seal the interior of the box 12. The moisture absorber 1 is housed in a casing 23 including a moisture releasing door 18 at a front of the casing 23. The door 18 opens to expose the moisture desorbing face of the moisture absorber 1 at a heating time. A moisture releasing opening 19 is provided outside the moisture releasing door 18, and the box 12 includes a fan 20 for releasing moisture through a louver 22 at the front of a caster 21. The moisture absorber 1 includes a heater 2 on the moisture desorbing face. FIGS. 7 and 8 show another embodiment of the present invention for humidity conditioning a room. In this embodiment, the box 12 has a side plate defining a moisture releasing opening 16, the moisture absorber 1 has a heater 2 disposed on a bottom surface acting as the moisture desorbing face, and the moisture desorbed is collected in a removable water vessel 24 for disposal. In this embodiment too, a moisture releasing door 18 is hinged to open and close the moisture desorbing face. An excellent moisture conditioning effect is produced where the moisture absorber 1 has an exposed surface area not less than 100 cm 2 , preferably 500 to 2,000 cm 2 , for 1 m 3 of the storeroom volume. (Specific Construction of the Moisture Absorber -1) A laminar moisture absorber 1 was prepared by impregnating a rock fiber board (specific gravity: 0.25, average interstice diameter: 55 micrometers, and void ratio: 90.6%) having phenol resin sized 200×150×50 mm as the binder, with 15% by weight of calcium chloride acting as the hygroscopic filler. Three of this moisture absorber 1 were stacked one upon another with one laminar face overlying another through 1.5 mm thick plastic plates acting as guides and reinforcements. The resulting product was placed in a cover member with one end thereof bent 90 degrees. Further, a cable heater (length 1.5 m, 100V, and 30W) is integrated with one end face, thereby completing a three-layer product (150×150×200 mm, and space thickness: 50 mm). This device was placed in an atmosphere of 90% absolute humidity, and was electrified for 30 minutes a day, whereby about 7 grams of water was obtained per day. (Experiment -1) Incidentally, a commercially available, disposable moisture absorber placed in a closet or the like produces about 100 ml of water per month. The moisture absorber according to the present invention produces a dehumidifying effect of a much higher level. A commercially available dehumidifier for indoor use produces 100 mg of water per hour. The above embodiment becomes comparable to this dehumidifier by increasing the size of its moisture absorbing area to 60×60 cm. The water thus produced was dried but no solid was found. This proved that the hygroscopic filler did not flow out of the moisture absorber. Thus, the performance of the moisture absorber does not deteriorate over a long time of use. (Experiment -2) Sheets of felt impregnated with 20% by weight of calcium chloride acting as the hygroscopic filler was stacked to produce a moisture absorber 50×50×150 mm. A cable heater (100V and 22.5W) was secured to the back surface of the moisture absorber, and a water holder was attached to the apparatus. A cable heater was applied also to the bottom of the water holder. A moisture content sensor is mounted in the moisture absorber, and a humidity sensor was attached to a surface of the moisture absorber. When the room humidity was above 50% RH and the moisture content of the moisture absorber increased correspondingly, the moisture content sensor would detect it and turn on the cable heater of the moisture absorber. On the other hand, when the humidity fell below 0.40% RH, the humidity sensor attached to the absorber surface would detect it and turn on the heater in the water holder. This apparatus was placed in an atmosphere of 25° C. and 80%, whereby 10 ml of water accumulated in the water holder in a day. When the dehumidifying apparatus of the present invention was placed in an atmosphere of 25° C. and 30% with water stored in the water holder, 5 ml of the water was exhausted per day. (Specific Construction of the Moisture Absorber -2) A laminar moisture absorber 1 was prepared by impregnating a rock fiber board (specific gravity: 0.25, average interstice diameter: 55 micrometers, and void ratio: 90.6%) having phenol resin of 50 mm thickness and 20×50 cm (1,000 cm 2 ) moisture control area as the binder, with 15% by weight of calcium chloride acting as the hygroscopic filler. Three of this moisture absorber 1 were stacked one upon another with one laminar face overlying another through 1.5 mm thick plastic plates acting as guides and reinforcements. The resulting product was placed in the casing 18 with one end thereof bent 90 degrees. Further, a cable heater 5 (length 1.5 cm, 100V, and 30W) is integrated with one end face acting as the moisture desorbing face, thereby completing a three-layer product (150×150×200 mm, and space thickness: 50 mm). This moisture absorber was placed in the humidity-insulating box 12 which was lined with vinyl chloride, and the following experiments were conducted. (Experiment -1) A moisture conditioning and drying test was carried out with a highly humid ambient atmosphere of 8° C. and 90% RH. Further, a comparative test was carried out on a Peltier type dehumidifier placed in the same box as the box 12 used in the Specific Construction of Moisture Absorber -1. Temperature variations in an empty storeroom were measured, the results of which are shown in FIG. 9. In the case of the Peltier type dehumidifier which dehumidifies through formation of dew drops due to cooling, no temperature decrease occurred probably because its cooling section was frosted. With the apparatus according to the present invention, a marked temperature decrease occurred and an equilibrium was reached upon laps of about 150 minutes. (Experiment -2) Wet shirts as set out in Table 1 were placed in the storeroom, and clothing dehumidifying tests were carried out. The box 12 used was lined with vinyl chloride as in Experiment -1. Internal temperature variations are shown in FIG. 10. TABLE 1______________________________________ Moisture AbsorptionShirts Weight (g) Absortion (g) Rate (%)______________________________________Cotton -1 202 14 6.9Cotton -2 215 16 7.4Cotton & 163 8 4.9Poly -1Cotton & 172 8 4.7Poly -2______________________________________ It has been confirmed that, with the present invention, the temperature in the storeroom fell and moisture was removed from the clothing. With the comparative example, there occurred no change in the weights of the clothing and the absolute humidity changed little. The absolute humidity of 5 mmHg corresponds to a relative humidity of 50 to 60%. Thus, fur coats wet with snow in wintertime, for example, may be placed in the box according to the present invention for moisture control. Thus, the storeroom to which the invention is applied is well suited for storing clothing, cameras and other articles without damage for unlimited periods of time.
A humidity conditioner comprising a moisture absorber and a heating element attached to or embedded in the moisture absorber. The moisture absorber includes a porous material having continuous fine interstices, and a hygroscopic filler filling the interstices.
5
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a differential apparatus provided with a differential limiting function or a differential locking function. [0003] 2. Description of the Related Art [0004] The Japanese Patent Application Laid-open No. 50(1975)-20331 discloses a differential apparatus with a differential limiting function including a cone clutch, a cam mechanism, an actuator, a stop mechanism and the like. [0005] In the differential apparatus, the differential operation is mechanically limited by the actuator, the stop mechanism and the like. Therefore, a wheel needs to spin at high speed to lock the differential operation, whereby the differential operation cannot be controlled while the vehicle is moving. Specifically, the differential operation cannot be locked or the lock cannot be released in dependence on conditions of vehicle speed, steering, a road surface, or the like. [0006] The actuator and the stop mechanism are composed of a number of parts, such as balances and weights, coil springs of three types, or the like, which are difficult to adjust weight or spring constants thereof, causing unstable motion and variation of products. [0007] Generally, a fluid pressure actuator, such as a pneumatic actuator and a hydraulic actuator or an actuator using an electromagnet, is employed to control the differential operation in dependence on conditions of vehicle speed, steering, and the road surface. Particularly, the fluid pressure actuator is employed because it is capable of generating a large differential limiting force required to lock the differential operation. [0008] However, the fluid pressure actuator needs a pressure source (pump) and a pressure line (piping). Modification or alteration of a casing or a vehicle body for accommodating the differential apparatus is required to make space for arrangement of the pressure source and line. Moreover, it is difficult to unitize, package or modularize the differential apparatus, the pressure source, the pressure line, and the like. [0009] The fluid pressure actuator has low reliability because of possible leak from each portion of the pressure source and line, which causes loss of function. For preventing the leak, seals need to be enforced, thus leading to cost increase. [0010] Meanwhile, in the case of the actuator using an electromagnet, it is difficult to obtain enough differential limiting force to lock the differential operation. SUMMARY OF THE INVENTION [0011] The object of the present invention is to provide a differential apparatus using an electromagnet, in which enough differential limiting force can be obtained to lock differential operation. [0012] Another object of the present invention is to provide a unitized differential apparatus having a differential limiting function, making modification and alteration of a casing or a vehicle body minor or unnecessary. [0013] An aspect of the present invention is a differential apparatus comprising: a rotary input member; a rotary output member within the input member, rotatable relative to the input member; a clutch mechanism for interconnecting the input member and the output member, the clutch mechanism including a first clutch member rotatable together with the input member and a second clutch member rotatable together with the output member, the second clutch member to be axially displaced to engage with the first clutch member; an actuator for limiting rotation of the second clutch member relative to the input member to angularly displace the second clutch member relative to the output member; and a cam mechanism provided between the second clutch member and the output member for engaging the first and second clutch members, the cam mechanism including a first cam face to be rotated together with the second clutch member and a second cam face to be rotated together with the output member, wherein the first and second cam faces cooperate to axially displace the second clutch member away from the output member, as the second clutch member is angularly displaced relative to the output member by the actuator, whereby the second clutch member is axially displaced to engage with the first clutch member. BRIEF DESCRIPTION OF THE DRAWINGS [0014] The invention will now be described with reference to the accompanying drawings wherein: [0015] [0015]FIG. 1 a is a sectional view of a differential apparatus according to a first embodiment of the present invention. [0016] [0016]FIG. 1 b is an explanatory view of a cam mechanism of the differential apparatus in FIG. 1 a. [0017] [0017]FIG. 2 is an enlarged sectional view showing a clutch mechanism of a differential apparatus according to a second embodiment of the present invention. [0018] [0018]FIG. 3 is an enlarged sectional view showing a clutch mechanism of a differential apparatus according to a third embodiment of the present invention. [0019] [0019]FIG. 4 is a sectional view of a differential apparatus according to a fourth embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0020] Embodiments of the present invention will be explained below with reference to the drawings, wherein like members are designated by like reference characters, and members without reference characters are not illustrated in the drawings. Left/right in the following description corresponds to left/right in FIGS. 1 a to 3 , respectively. [0021] First Embodiment [0022] As shown in FIG. 1 a , a differential apparatus 1 (a first embodiment of the present invention) is composed of a differential case 3 (input member), a bevel gear type differential mechanism 5 (output member), an actuator 8 including a frictional force generation mechanism 7 and a transmission mechanism 9 , a cone clutch 11 (clutch mechanism), a cam 13 (cam mechanism), a return spring 15 , a controller, and the like. [0023] The differential case 3 includes a casing body 19 in the right side of FIG. 1 a and a cover 17 fixed on a left opening of the casing body 19 with bolts. The differential case 3 is arranged within a differential carrier. [0024] A boss portion 21 of the cover 17 and a boss portion 23 of the casing body 19 are individually supported on the differential carrier with bearings. An oil reservoir is formed within the differential carrier. [0025] On the differential case 3 , a ring bevel gear is fixed with bolts to be engaged with an output bevel gear of a propeller shaft of a power train. The propeller shaft is connected to a transmission. A driving force from an engine is transmitted to the differential case 3 via the transmission and the propeller shaft to rotate the differential case 3 . [0026] The differential mechanism 5 within the differential case 3 , which is rotatable relative to the differential case 3 , is composed of pinion shafts 25 , pinion gears 27 , left and right side gears 29 and 31 , and the like. [0027] Each pinion shaft 25 is engaged with a through hole 33 at both ends thereof provided in the casing 19 , and fixed to the casing 19 with a spring pin. Each pinion gear 27 is rotatably supported on the pinion shaft 25 . The left side gear 29 and the right side gear 31 are engaged with the pinion gear 27 on the left and right thereof, respectively. [0028] Between the casing body 19 and each pinion gear 27 , a spherical washer 35 is interposed. The spherical washer 35 receives a centrifugal force of the pinion gear 27 when the differential case 3 is rotating and a reaction force which is applied to the pinion gear 27 by engagement of the left and the right side gears 29 and 31 . [0029] A hub portion 37 of the left side gear 29 is rotatably supported by a bearing portion 39 of the cover 17 and connected to a left wheel through an axle spline-connected to the hub portion 37 . A hub portion 41 of the right side gear 31 is rotatably supported by a bearing portion 43 of the casing body 19 and connected to a right wheel through an axle spline-connected to the hub portion 41 . [0030] Between the hub portion 37 of the left side gear 29 and the boss portion 21 of the cover 17 , and between the hub portion 41 of the right side gear 31 and the boss portion 23 of the casing body 19 , thrust washers 45 are individually arranged. The thrust washers 45 receive reaction forces applied to the left and right side gears 29 and 31 by engagement of the pinion gears 27 and the left and the right side gears 29 and 31 , respectively. [0031] The driving force from the engine is distributed to the left and the right side gears 29 and 31 from the differential case 3 via the pinion shafts 25 and the pinion gears 27 , and transmitted to the left and the right wheels via the axles thereof. [0032] For example, when a difference of drive resistance occurs between the left and the right wheels while a vehicle is moving on a rough road, each pinion gear 27 rotates about an axis of the pinion shaft 25 , and thus the driving force from the engine is distributed to the left and right sides. [0033] The actuator 8 is composed of the frictional force generation mechanism 7 , the transmission mechanism 9 , and the like. [0034] The frictional force generation mechanism 7 is composed of a right ring gear 47 (armature) made of a magnetic material, a friction clutch 49 (pilot clutch) formed between the right side surface of the right ring gear 47 and the inner surface of the right side wall of the casing body 19 , an electromagnet 51 , and the like. [0035] The right ring gear 47 is supported on the outer circumferential surface of the hub portion 41 of the right side gear 31 so as to be displaceable in an axial direction and rotatable relative to the hub portion 41 , and is centered. [0036] A core 53 of the electromagnet 51 is connected to the differential carrier through a support member, and fixed thereto so as not to rotate. Moreover, the core 53 is supported on the outer circumferential surface of the boss portion 23 with a bearing interposed therebetween and is centered. The inner diameter of the core 53 is smaller than the outer diameter of the right ring gear 47 , and projections of the core 53 and the right ring gear 47 in the axial direction are overlapped each other. A moderate air gap is provided between a left side face of the core 53 and the outer surface of the right side wall of the casing body 19 in the vicinity thereof. A lead wire of the electromagnet 51 is drawn out of the differential carrier through a grommet and connected to a battery on the vehicle. [0037] The core 53 , the right side wall of the casing body 19 , and the right ring gear 47 constitutes a magnetic path of the electromagnet 51 . The right side wall of the casing body 19 is radially divided into an inner wall and an outer wall by a ring 55 made of stainless steel of a non-magnetic material. The ring 55 is embedded in the casing body 19 at a radial position corresponding to the electromagnet 51 . The ring 55 prevents a short circuit of magnetic flux on the magnetic path. [0038] The transmission mechanism 9 is composed of a gear portion 47 a (first gear portion) formed in the right ring gear 47 , a gear portion 57 a (second gear portion) formed in a left ring gear (clutch member) 57 , left and right pinion gears 61 and 63 , small-diameter shafts (shaft member) 59 connecting the left and right pinion gears 61 and 63 , and the like. [0039] The left ring gear 57 is supported on the outer circumferential surface of the hub portion 37 of the left side gear 29 so as to be movable in the axial direction and angularly displaceable, and is centered. The left ring gear 57 can rotate together with the left side gear 29 and rotates relative to the cover 17 . The left ring gear 57 is the same as the right ring gear 47 in diameter. [0040] The shafts 59 are arranged along the axial direction between the pinion gears 27 outside the left and right side gears 29 and 31 in the radial direction within the casing body 19 . Both ends of each shaft 59 are rotatably supported by left and right bearing portions 65 and 67 , which are formed in the cover 17 and the right side wall of the casing body 19 , respectively. [0041] The right pinion gear (first pinion gear) 61 is formed on the right end side of the shaft 59 and engaged with the right ring gear 47 . The left pinion gear (second pinion gear) 63 is formed on the left end side of the shaft 59 and engaged with the left ring gear 57 . [0042] The left and right pinion gears 61 and 63 and the left and right ring gears 47 and 57 are spur gears in order that an engagement reaction force is not generated in the axial direction when the pinion gears 61 and 63 and the ring gears 47 and 57 rotate in engagement with each other. [0043] Therefore, the rotation of the left ring gear 57 is transmitted to the right ring gear 47 at equal speed via the left pinion gear 63 , the shafts 55 , and the right pinion gear 61 . [0044] The cone clutch 11 is operated to interconnect the cover 17 and the left ring gear 57 . The cone clutch 11 includes a cone portion 69 integrally formed on a left sidewall of the left ring gear 57 and a conical friction surface portion 70 increasing in diameter toward the right. The friction surface portion 70 is provided on the inner surface of the sidewall of the cover 17 and rotates with the cover 17 . [0045] The cam 13 is provided between a right side surface of the left ring gear 57 and a left side surface of the left side gear 29 . As shown in FIG. 1 b , the cam 13 includes a cam face 13 a rotating together with the hub portion 37 of the left side gear 29 and a cam face 13 b rotating together with the left ring gear 57 and engaging with the cam face 13 a . These cam faces 13 a and 13 b are inclined in the circumferential direction at a certain distance from the rotation axis. If differential torque is applied between the left side gear 29 and the left ring gear 57 by the actuator 8 , a circumferential direction force F 1 acts on the cam faces 13 a and 13 b , and then slip restrained by the engaging faces thereof is produced to generate a thrust force F 2 in the axial direction, which is called a cam thrust force. The left side gear 29 and the left ring gear 57 are displaced in the axial direction so as to separate from each other by this thrust force F 2 . [0046] The cone clutch 11 and the cam 13 are arranged on the left side of the differential mechanism 5 in the axial direction, and the friction clutch 49 and the electromagnet 51 are arranged on the right side of the differential mechanism 5 in the axial direction, which are substantially symmetrically arranged. [0047] The return spring 15 is arranged between the left ring gear 57 and a snap ring 71 attached on the outer circumferential surface of the hub portion 37 of the left side gear 29 . The return spring 15 presses the left ring gear 57 rightward, that is, in a direction of releasing coupling of the cone clutch 11 , or in a direction of engaging the cam 13 . [0048] The controller detects the vehicle moving in a curve from detection signals of a vehicle speed, a steering angle, a lateral gravity, and the like. The controller excites the electromagnet 51 , controls an exciting current, stops excitation, and so on in dependence on road conditions. [0049] When the electromagnet 51 is excited, a magnetic flux loop 73 is formed in the above described magnetic path, and the right ring gear 47 is attracted rightward to be pressed against the casing body 19 . Accordingly, the friction clutch 49 is engaged to generate a frictional force. The frictional force brakes rotation of the right ring gear 47 relative to the casing body 19 . Furthermore, the braking force is transmitted to the left ring gear 57 via the right ring gear 47 , the right pinion gear 61 , the shafts 59 , and the left pinion gear 63 of the transmission mechanism 9 to brake rotation of the left ring gear 57 relative to the cover 17 . [0050] If differential rotation is generated within the differential mechanism 5 in this state, relative angular displacement is generated between the left ring gear 57 and the left side gear 29 , and thus differential torque is applied to the cam 13 provided therebetween. The differential torque causes the cam 13 to generate the cam thrust force to displace the left ring gear 57 and the cone portion 69 thereof leftward in the axial direction against the return spring 15 . Accordingly, the cone portion 69 is engaged with the friction surface portion 70 to engage the cone clutch 11 and a differential limiting force is generated. [0051] As described above, the cam 13 is actuated using the differential torque of the left side gear 29 to amplify the engaging force of the cone clutch 11 , so that a large differential limiting force can be obtained. Furthermore, a wedge effect (self-lock function) by an angle of the conical friction surface of the cone clutch 11 amplifies the differential limiting force. Therefore, the electromagnet 51 can be employed, obtaining the differential limiting force enough to lock the differential operation. [0052] When the differential limiting force thus obtained is larger than differential lock torque of the differential mechanism 5 , the differential operation is locked. When the differential limiting force is smaller than the differential lock torque, the cam thrust force of the cam 13 is increased or decreased in dependence on variation in the differential torque, so that a differential limiting function similar to that of a torque sensitive type can be obtained. [0053] Furthermore, if slip of the friction clutch 49 is adjusted by controlling the exciting current of the electromagnet 51 , the braking force by the frictional force, differential torque, and the cam thrust force of the cam 13 vary, and the differential limiting force can be freely controlled. [0054] When the excitation of the electromagnet 51 is stopped, the friction clutch 49 is disengaged, and the cam thrust force of the cam 13 disappears. Then, the left ring gear 57 is returned rightward by the pressing force of the return spring 15 , and the cone clutch 11 is disengaged. Accordingly, the differential rotation of the differential mechanism 5 becomes free. [0055] Note that, even if the friction clutch 49 is activated by the excitation/non-excitation and the current control of the electromagnet 51 as described above, a moderate air gap is always maintained between the outer surface of the right sidewall of the casing body 19 and the electromagnet 51 . The air gap prevents the rotation of the casing body 19 from being interfered by contacting the electromagnet 51 and receiving sliding resistance. [0056] When the friction clutch 49 and the cone clutch 11 are disengaged as described above, the left ring gear 57 , the shafts 59 , the left and right pinion gears 61 and 63 , and the right ring gear 47 rotate in conjunction with the rotation of the left side gear 29 to generate relative rotation (sliding rotation) between the right ring gear 47 and the right side gear 31 . [0057] The thrust washer 45 on the left end of the left side gear 29 receives a reaction force which is applied to the left side gear 29 by engagement of the pinion gears 27 and the left side gear 29 and resists the leftward movement of the left side gear 29 relative to the casing body 19 . The return spring 15 presses the left ring gear 57 rightward relative to the left side gear 29 . Therefore, a moderate gap is secured within the cone clutch 11 , thus preventing the cone clutch 11 from being inadvertently engaged and generating the differential limiting force. [0058] The controller excites the electromagnet 51 , controls the exciting current, and stops the excitation at arbitrary timing to perform differential lock, adjustment of the differential limiting force, release of the lock, and the like in dependence on conditions of a vehicle speed, steering, a road surface, or the like. Such operations improve a starting ability, an acceleration ability, a turning ability, a steerability, stability, an off-road ability of the vehicle and the like. [0059] The differential case 3 is provided with an opening, and on the inner circumferential surfaces of the boss portions 21 and 23 , spiral oil grooves are formed. [0060] The lower half of the differential apparatus 1 is immersed in oil of the oil reservoir. In accordance with the rotation of the differential case 3 and the ring gears thereof, the oil flows into/out of the differential case 3 through the opening and the spiral oil grooves, and sufficiently lubricates and cools the engaging portions of the gears 27 , 29 , and 31 (the differential mechanism 5 ), the sliding portions between the outer circumferential surfaces of the pinion shafts 25 and the pinion gears 27 , the thrust washers 45 and 45 , the spherical washer 35 , the support portions 39 and 43 of the left and right side gears 29 and 31 , the friction clutch 49 , the engaging portions of the gears 47 , 61 , 63 , and 57 of the transmission mechanism 9 , the sliding portions between the ring gears 47 and 57 and the hub portions 41 and 37 of the side gears 29 and 31 , the cam 13 , the cone clutch 11 , and so on. [0061] Moreover, the electromagnet 51 is cooled by the oil which is splashed over by the rotation of the differential case 3 and the ring gears as well as the lower half thereof is immersed in the oil reservoir. Accordingly, the capability (magnetic force) thereof is stabilized, so that the function of the friction clutch 49 and the differential limiting force of the cone clutch 11 are stabilized. [0062] In the differential apparatus 1 structured as described above, the pressure source, the pressure line and the space for arrangement thereof become unnecessary unlike the differential apparatus using the fluid pressure actuator. Accordingly, the differential apparatus becomes simple in structure and compact, thus enhancing mountability on the vehicle. Moreover, installation of the pressure line becomes unnecessary, so that assembly of the device is facilitated and the assembly costs are reduced. [0063] Moreover, function is not lost by pressure leak, so that high reliability can be obtained. It becomes unnecessary to enforce the seals of the pressure line for preventing leak, which saves the costs. [0064] The differential apparatus land the electromagnet 51 can be easily unitized, packaged, or modularized. Accordingly, the impact to the differential carrier and the vehicle body is minimized and the modification and the alteration thereof become minor or unnecessary. [0065] The frictional force generation mechanism 7 (friction clutch 49 ) for generating frictional force between the differential case 3 and the right ring gear 47 is a pilot clutch for activating the cam 13 . As described above, the cone clutch 11 for the differential limiting force is engaged by the cam 13 . Accordingly, the electromagnet 51 only needs a magnetic force in amount enough to engage the friction clutch 49 , and the electromagnet 51 is not required to have a particularly large amount of magnetic force (excitation power). [0066] Therefore, the electromagnet 51 becomes small and lightweight, and accordingly the differential apparatus 1 is made to be small and lightweight. Furthermore, burdens on the in-vehicle battery and an alternator for charge of the battery are reduced, thus reducing fuel consumption of the engine which drives the alternator. [0067] The cone clutch 11 and the cam 13 are arranged on the left side of the differential mechanism 5 and the friction clutch 49 and the electromagnet 51 are arranged on the right side of the differential mechanism 5 . Accordingly, the deferential device 1 is balanced in weight with respect to the differential center, and factors of generating vibration can be restrained. Moreover, the burden on the bearing supporting the differential apparatus 1 on the differential carrier is reduced, thus enhancing durability. [0068] With respect to the dimensional center of the differential mechanism 5 , the differential mechanism 5 is balanced in the axial direction, so that the axles connected to the side gears 29 and 31 can be designed to have equal dimensions. Therefore, it is possible to share the axles and reduce the costs. Moreover, since the modification and the alteration of the differential carrier or the vehicle body for compensating imbalance in the lengths of the left and right axles and the weight are avoided, the costs are further reduced. [0069] Since the cone clutch 11 can generate a large differential limiting force with a comparatively small area of the friction surface, the differential apparatus 1 is structured to be compact. [0070] Since the cone clutch 11 has a friction surface of a small area, drag torque owing to oil viscosity is small. Therefore, the differential limit and lock are easily released, thus maintaining good steerability without the remaining differential limit torque and keeping the engine fuel-efficient. [0071] Moreover, if the gear ratio of the right pinion gear 61 , the right ring gear 47 , the left pinion gear 63 , and the left ring gear 57 is changed, for example, the diameter of the right pinion gear 61 is designed to be larger than that of the left pinion gear 63 and the diameter of the right ring gear 47 is designed to be smaller than that of the left ring gear 57 , the braking force of the friction clutch 49 is amplified to be transmitted to the left ring gear 57 . Accordingly, the capacity of the electromagnet 51 can be reduced. [0072] Furthermore, if the right pinion gear 61 and the ring gear 47 , or the left pinion gear 63 and the left ring gear 57 are helical gears, the positions thereof in the axial direction can be controlled by utilizing the engagement reaction force generated in rotation of the right pinion gear 61 and the ring gear 47 , or the left pinion gear 63 and the left ring gear 57 in engagement with each other. [0073] Second Embodiment [0074] As shown in FIG. 2, a differential apparatus 101 (a second embodiment of the present invention) is composed of a differential case 3 , a bevel gear type differential mechanism 5 , an actuator 8 including a frictional force generation mechanism 7 and a transmission mechanism 9 , a multiple plate clutch 103 (clutch mechanism), a cam 13 , a return spring 15 , a controller, and the like. [0075] The differential apparatus 101 has a structure in which the cone clutch 11 in the differential apparatus 1 of the first embodiment is substituted with the multiple plate clutch 103 . [0076] Next, description will be made on differences from the differential apparatus 1 of the first embodiment. [0077] The multiple plate clutch 103 is provided between the inner surface of the sidewall of the cover 17 and the left side surface of the left ring gear 57 . In the radially inside portion of the left ring gear 57 , a hub portion 109 is formed extending leftward in the axial direction along the outer circumferential surface of the hub portion 37 of the left side gear 29 . Outer plates 105 are connected to a spline portion 107 so as to be slidable in the axial direction, the spline portion 107 being formed on the inner circumferential surface of the cover 17 . Inner plates 111 are connected to a spline portion 113 so as to be slidable in the axial direction, the spline portion 113 being formed on the outer circumferential surface of the hub portion 109 of the left ring gear 57 . [0078] When the electromagnet 51 is excited, the right ring gear 47 is attracted rightward to engage the friction clutch 49 . The frictional force thereof brakes rotation of the left ring gear 57 via the transmission mechanism 9 . If differential rotation is generated in the differential mechanism 5 in such a state, the cam 13 is activated by differential torque between the left ring gear 57 and the left side gear 29 to engage the multiple plate clutch 103 . [0079] When the differential limiting force thus obtained is larger than the differential lock torque of the differential mechanism 5 , the differential operation is locked. When the differential limiting force is smaller than the differential lock torque, a differential limiting force similar to that of a torque sensitive type can be obtained by the cam thrust force of the cam 13 . [0080] When the slip of the friction clutch 49 is adjusted by controlling the exciting current of the electromagnet 51 , the differential limiting force can be freely controlled. [0081] When the excitation of the electromagnet 51 is stopped, the multiple plate clutch 103 is disengaged by the pressing force of the return spring 15 , and the differential rotation of the differential mechanism 5 becomes free. [0082] The multiple plate clutch 103 generates differential limiting force enough to lock the differential operation because of the wide area of the friction surfaces between a number of plates 105 and 111 . [0083] Moreover, in the multiple plate clutch 103 , the differential limiting force can be easily adjusted by changing the number of plates 105 and 111 . Therefore, the differential apparatus 101 can be applied to the wide range of different vehicle types. [0084] Third Embodiment [0085] As shown in FIG. 3, a differential apparatus 201 (a third embodiment of the present invention) is composed of a differential case 3 , a bevel gear type differential mechanism 5 , an actuator 8 including a frictional force generation mechanism 7 and a transmission mechanism 9 , a multiple plate clutch 203 (clutch mechanism), a cam 13 , a return spring 15 , a controller, and the like. [0086] Next, description will be made on differences from the differential apparatus 1 of the first embodiment. [0087] The multiple plate clutch 203 includes inner plates 211 and the outer plates 105 , which are provided between the inner surface of the sidewall of the cover 17 and the left side surface of the left ring gear 57 , and the left ring gear 57 as a pressing member for pressing the inner and outer plates 211 and 105 for displacement in the axial direction to engage the inner and outer plates 211 and 105 . In the radially inside portion of the left ring gear 57 , a hub portion 209 is formed. The hub portion 209 extends rightward in the axial direction along the outer circumferential surface of the hub portion 37 of the left side gear 29 . The outer plates 105 are connected to the spline portion 107 , which is formed on the inner circumferential surface of the cover 17 , so as to be slidable in the axial direction. The inner plates 211 are connected to a spline portion 213 , which is formed on the outer circumferential surface of the hub portion 37 of the left side gear 29 , so as to be slidable in the axial direction. [0088] The snap ring 71 is attached to the outer circumferential surface of the hub portion 37 of the left side gear 29 on the right side of the multiple plate clutch 203 and stops the return spring 15 . [0089] When the multiple plate clutch 203 is engaged by excitation of the electromagnet 51 , the differential limiting force thereof is transmitted directly to the left side gear 29 via the inner plate 211 of the multiple plate clutch 203 , without passing through the cam 13 . Accordingly, the capacity of the cam 13 can be reduced. [0090] Fourth Embodiment [0091] As shown in FIG. 4, a differential apparatus 301 (a fourth embodiment of the present invention) is composed of a differential case 3 , a bevel gear type differential mechanism 5 , an armature 303 , a cam 305 (cam mechanism), a multiple plate pilot clutch 309 (clutch mechanism), a return spring 307 , an electromagnet 51 (actuator), a controller, and the like. [0092] Next, description will be made on differences from the differential apparatus 1 of the first embodiment. [0093] The differential case 3 includes the cover 17 , the casing body 19 of a non-magnetic material, and a rotor 311 of a magnetic material. The cover 17 is fixed on the left opening of the casing body 19 with bolts. The rotor 311 is welded on a right opening of the casing body 19 to constitute the right side wall of the differential case 3 . [0094] The differential case 3 is arranged within the differential carrier. The boss portion 23 of the cover 17 and a boss portion 313 of the rotor 311 are supported by the differential carrier with bearings interposed therebetween. The oil reservoir is formed within the differential carrier. [0095] The hub portion 37 of the left side gear 29 is supported by the support portion 39 of the cover 17 and connected to the left wheel via the axle spline-connected to the hub portion 37 . The hub portion 41 of the right side gear 31 is connected to the right wheel via the axle spline-connected to the hub portion 41 . [0096] Between the hub portion 41 of the right side gear 31 and the boss portion 313 of the rotor 311 , a thrust washer 45 is arranged. The thrust washer 45 receives a reaction force which is applied to the right side gear 31 by engagement of the right side gear 31 and the pinion gears 27 . [0097] The armature 303 is composed of a disk-shaped flange portion 349 and a hub portion 347 integrally formed so as to extend rightward in the axial direction from the radially inside portion of the flange portion 349 along the outer circumferential surface of the hub portion 41 of the right side gear 31 . The armature 303 is supported on the outer circumferential surface of the hub portion 41 of the right side gear 31 . [0098] The cam 305 is provided between the left surface of the flange portion 349 of the armature 303 and the right side surface of the right side gear 31 . The return spring 307 is provided on the outer circumferential surface of the hub portion 41 of the right side gear 31 between a left end surface of the boss portion 313 of the rotor 311 and a right end portion of a hub portion 347 of the armature 303 . The return spring 307 presses the armature 303 Leftward with respect to the differential case 3 , that is, in the direction of engaging the cam 305 . [0099] The pilot clutch 309 is provided between the left side surface of the rotor 311 and the flange portion 349 of the armature 303 inside the casing body 19 . Outer plates 351 thereof are connected to a spline portion 353 so as to be slidable in the axial direction, the spline portion 353 being formed on the inner circumferential surface of the casing body 19 . Inner plates 355 thereof are connected to a spline portion 357 so as to be slidable in the axial direction, the spline portion 357 being formed on the outer circumferential surface of the hub portion 347 of the armature 303 . [0100] The core 53 of the electromagnet 51 is supported on the rotor 311 with a bearing interposed therebetween and is centered. The inner diameter of the core 53 is smaller than the outer diameter of the flange portion 349 of the armature 303 , and the projections of the core 53 and the armature 303 in the axial direction are overlapped each other. A moderate air gap is provided between the left side surface of the core 53 and the right side surface of the rotor 311 in the vicinity thereof. [0101] The core 53 , the rotor 311 , the pilot clutch 309 , and the armature 303 constitute a magnetic path of the electromagnet 51 . [0102] The rotor 311 is radially divided into an inner wall and an outer wall by the ring 55 of stainless steel as a non-magnetic material. The ring 55 is embedded in the rotor 311 at the radial position corresponding to the electromagnet 51 . Each of plates 351 and 355 of the pilot clutch 309 is circumferentially provided with notches 359 at a plurality of positions and bridge portions between the notches 359 in a radial position corresponding to the ring 55 . The bridges connect the radially inside and the outside of each of the plates 351 and 355 . The ring 55 and the notches 359 prevent a short circuit of magnetic flux on the magnetic path. [0103] When the electromagnet 51 is excited, a magnetic flux loop 373 is formed on the above described magnetic path, and the armature 303 is attracted and displaced rightward in the axial direction. The armature 303 presses and engages the pilot clutch 309 between the armature 303 and the rotor 311 to generate pilot torque (frictional force). Therefore, the relative rotation of the armature 303 with respect to the differential case 3 is limited. [0104] When differential rotation is generated in the differential mechanism 5 in the state where the pilot torque is generated, relative angular displacement is generated between the armature 303 , which is connected to the differential case 3 via the pilot clutch 309 , and the right side gear 31 , and the differential torque is applied to the cam 305 provided therebetween. With the differential torque, the cam 305 generates the cam thrust force and moves the armature 303 rightward against the return spring 307 . The engaging force of the pilot clutch 309 is thus amplified. [0105] The above described self-lock function of the pilot clutch 309 by the cam 305 allows a large differential limiting force to be obtained. When the differential limiting force thus obtained exceeds the differential lock torque of the differential mechanism 5 , the differential operation is locked. As described above, the actuator using the electromagnet 51 can generate enough differential limiting force to lock the differential operation. [0106] When the differential limiting force is smaller than the differential lock torque, the differential limiting force of the torque sensitive type can be obtained by the cam thrust force of the cam 305 , which varies in dependence on variation in the differential torque. [0107] Furthermore, if slip of the pilot clutch 309 is adjusted by controlling the exciting current of the electromagnet 51 , the pilot torque of the pilot clutch 309 and the cam thrust force of the cam 305 vary, and the differential limiting force can be freely controlled. [0108] When the excitation of the electromagnet 51 is stopped, the armature 303 is returned leftward by the pressing force of the return spring 307 , and the pilot clutch 309 is disengaged. Accordingly, the pilot torque and the cam thrust force of the cam 305 disappear, and the differential rotation of the differential mechanism 5 becomes free. [0109] In the embodiment, as described above, the pilot clutch 309 serves as a main clutch for locking the differential operation with the engaging force amplified by the cam 305 . In other words, the clutch mechanism serves as the pilot clutch and the clutch for limiting the differential operation. [0110] Moreover, the thrust washer 45 on the right end of the hub portion 41 of the right side gear 31 receives a reaction force which is applied to the right side gear 31 by engagement of the right side gear 31 and the pinion gears 27 , and resists the rightward movement of the right side gear 31 relative to the rotor 311 . The return spring 307 presses the armature 303 leftward relative to the rotor 311 . Therefore, a moderate gap is secured between the armature 303 and the pilot clutch 309 , thus preventing the pilot clutch 309 from being inadvertently engaged and generating the differential limiting force. [0111] The differential case 3 is provided with an opening, and spiral oil grooves are formed on the inner circumferential surfaces of the boss portions 21 and 313 . [0112] The lower half of the differential apparatus 301 is immersed in the oil of the oil reservoir. In accordance with the rotation of the differential case 3 , the oil flows into/out of the differential case 3 through the opening and the spiral oil grooves, and sufficiently lubricates and cools the engaging portions of the gears 27 , 29 , and 31 , the sliding portions between the outer circumferential surfaces of the pinion shafts 25 and the pinion gears 27 , the thrust washer 45 , the spherical washer 35 , the support portion 39 of the left side gear 29 , the sliding portion between the hub portion 347 of the armature 303 and the hub portion 41 of the right side gear 31 , the cam 305 , the pilot clutch 309 , the both ends of the return spring 307 , and so on. [0113] Moreover, the electromagnet 51 is cooled by the oil which is splashed over by the rotation of the differential case 3 and the ring gears thereof, thus stabilizing the capability (magnetic force) thereof. Accordingly, the operating function of the pilot clutch 309 is stabilized. [0114] The invention may be practiced or embodied in still other ways without departing from the spirit or essential character thereof. For instance, the engine in the present invention can be an electric motor converting electric energy into torque. [0115] The clutch mechanism for use in the differential apparatus may be a clutch mechanism of another type. For example, the clutch mechanism used in the differential apparatus of the fourth embodiment may be a cone clutch. As shown in the third embodiment, the multiple plate clutch having the inner plate attached to the side gear may be used. [0116] The differential mechanism is not limited to the bevel gear differential mechanism, but may be a planetary gear type differential mechanism, a differential mechanism including a pair of output side gears connected to a pinion gear, which is accommodated in a housing hollow of the differential case so as to be freely slidable and rotatable, a differential mechanism using a worm gear, and so on. [0117] Moreover, the cam mechanism may be a ball cam, which is composed of a curved surface rotating together with the side gear, a curved surface rotating together with the ring gear or the armature, and a ball interposed therebetween. The ball cam displaces the curved surfaces so as to separate from each other in the direction of the rotation axis when relative angular displacement between the surfaces is generated. [0118] The differential apparatus can be used as any one of a front differential (differential apparatus for distributing the driving force from the motor into the left and the right front wheels), a rear differential (differential apparatus for distributing the driving force from the engine into the left and the right rear wheels), and a center differential (differential apparatus for distributing the driving force from the engine into the front wheels and the rear wheels). [0119] The preferred embodiments described herein are therefore illustrative and not restrictive, the scope of the invention being indicated by the claims and all variations which come within the meaning of claims are intended to be embraced therein. [0120] The present disclosure relates to subject matters contained in Japanese Patent Application No. 2001-397602, filed on Dec. 27, 2001, and Japanese Patent Application No. 2002-33043, filed on Feb. 8, 2002, the disclosure of which are expressly incorporated herein by reference in its entirety.
Differential apparatus which includes input and output members rotatable relative to each other, a clutch mechanism for interconnecting them, an actuator and a cam mechanism. The clutch mechanism includes first and second clutch members rotating with the input and output members, respectively. The actuator limits rotation of the second clutch member relative to the input member to angularly displace the second clutch member 1o relative to the output member. The cam mechanism is provided between the second clutch member and the output member, and includes first and second cam faces rotating with the second clutch member and the output member, respectively. When the actuator operates, these cam faces cooperate to axially displace the second clutch member away from the output member, whereby the second clutch member is axially displaced to engage with the first clutch member.
5
FIELD OF THE INVENTION The present invention relates to a rotary actuator with taiored torque output and, more particularly, to a rotary actuator wherein a rod formed of a shape memory alloy such as 55-Nitinol, is formed into an initial shape, subsequently twisted about its longitudinal axis, and may be selectively heated to cause the rod to rotate about its longitudinal axis to return to the initial shape. BACKGROUND OF THE INVENTION A group of metals known as shape memory alloys exhibit a property that when a member formed from such a metal is deformed while below a martensite finished temperature and then is heated to above an austenite temperature, the member returns to the shape existing before the deformation. A well-known shape memory alloy is 55-Nitinol, which is an alloy of nickel and titanium. The use of Nitinol in a heat engine is described in Ginell et al., Nitinol Heat Engines for Low-Grade Thermal Energy Conversion, Mechanical Engineering (May 1979), pp. 28-33. Other applications of shape memory alloys have been disclosed in issued patents. For example, U.S. Pat. No. 4,700,541 issued to Gabriel et al. discloses an electrically-controlled shape memory alloy actuator wherein a wire made of shape memory alloy has its ends constrained against movement and is caused to rotate by the selective application of voltages to different sections of the wire. U.S. Pat. No. 4,010,455 issued to Stange discloses a thermally-powered rotary actuator that is used for positioning a rotatable shaft in first and second positions disposed 180° apart. The actuator incorporates heat extensible springs formed from 55-Nitinol to apply clockwise or counterclockwise torque to a shaft upon the selective heating of one or the other of the springs. A mechanical actuator employing Nitinol is also disclosed in U.S. Pat. No. 4,553,393 issued to Ruoff. The actuator of Ruoff is an electro-mechanical servo control system wherein a combination of parallel elements formed from Nitinol may be selectively, electrically heated under digital control to regulate the degree of actuating force provided by the Nitinol actuators. U.S. Pat. No. 4,665,334 issued to Jamieson describes the use of a shape memory alloy, such as Nitinol, in an actuator to produce rotary motion in the manner of a stepper motor. The memory metal element is employed to impart a drive motion to a spring clutch that is positioned about a shaft. The alternate heating and cooling of the memory metal element causes the spring clutch to tighten and loosen, respectively, to rotate the shaft through a small angle. The memory actuator is selectively, electrically heated. While the use of shape memory alloys, such as Nitinol, to provide rotary actuators is known, the prior art devices have primarily relied upon electricity to heat the Nitinol above the austenite temperature. In addition to the actuator, a source of electricity is required as well as a control system for selectively applying the electricity to the Nitinol elements. These requirements complicate the construction of the actuator and cause it to be more expensive to manufacture and less reliable to operate. In addition, if an actuator is provided for a single use, the requirement for an electrical control system may make the actuator unnecessarily expensive. Moreover, if a Nitinol actuator is used in a spacecraft or missile to release latches or to provide rotary power for mechanisms therein, the actuator must be lightweight, dependable, and operate with a high degree of precision. SUMMARY OF THE INVENTION An object of the present invention is a rotary actuator made from a shape memory alloy in a manner to provide torque in a pre-selected manner when activated. Another object of the present invention is a lightweight, inexpensive rotary actuator that uses a Nitinol member to provide rotary power. Still another object of the present invention is a rotary actuator that uses a Nitinol torsion member that is selectively heated by the burning of chemical grains provided around the Nitinol to cause rotation of one end of the member. Yet another object of the present invention is a rotary actuator that uses a Nitinol member that is heated by the burning of chemical grain to provide rotary power in a stepped operation. A further object of the present invention is a rotary actuator that can be tailored to produce motion at any desired speed, torque or angular excursion. These and other objects are accomplished by a rotary actuator for delivering torque through a selected angle of rotation comprising a torsion member having a longitudinal axis and being made from a shape memory alloy, the torsion member having a 0° rotation about the longitudinal axis when the member is heated to a temperature above a predetermined temperature and a predetermined angular rotation about the longitudinal axis when the member is at a temperature below the predetermined temperature, and heat generating material being of variable, predetermined burn rate surrounding or enclosed within the torsion member to selectively heat successive portions of the member to a temperature above the predetermined temperature to cause the member to rotate about the longitudinal axis. BRIEF DESCRIPTION OF THE DRAWING The manner by which the above objects and other objects, features, and advantages of the present invention are obtained will be fully apparent from the following detailed description when considered in view of the drawing figure that shows a partial cross section of the rotary actuator of the present invention. DETAILED DESCRIPTION In the figure, a rotary actuator 1 includes an elongated member 11, such as a rod or a tube, formed of shape memory alloy such as 55-Nitinol. The member 11 is fixed at a first end 13 to a mounting block 15. The mounting block 15 may be secured to a support (not shown) by appropriate fasteners 17. The purpose of the mounting block 15 and the fasteners 17 is to retain the end 13 of the member 11 fixed against rotation. The member 11 has a second end 19 rotatably mounted in a bearing block 21. The end 19 is adapted to be connected to an element that is to be rotatably driven. As formed, the member 11 has 0° rotation about its longitudinal axis. When fixed to the mounting block 15 at a temperature below the martensite finished temperature, the member 11 is malleable and may be twisted, i.e., rotated about the longitudinal axis through a selected angle. As long as the member 11 is not heated to a temperature above the austenite temperature, it will remain in the twisted shape. The member 11 is enclosed within a casing 23. The casing 23 may be made of stainless steel and is used to enclose a chemical grain 25 that is provided, e.g., packed, around the member 11. The chemical grain may constitute a propellant as commonly used in a solid propellant motor and burned to produce gas and heat. The chemical grain could also be selected from grains used in ordnance devices. The chemical grain may be mixed to form a slurry and then poured around the member 11 (and inside the member 11 if it is tubular) inside of the casing 23. Other chemical grains are known which are machinable to fit around the member 11. A two step actuator can be built by dividing the chemical grain into two or more sections separated by appropriate nonflammable separator elements 27. Each separator element 27 includes a chemical timer connecting adjacent sections of the chemical grain. As shown in the figure, a chemical timer comprises a bore 29 formed in the separator 27 and packed with the chemical grain. Assuming that the chemical grain is first ignited near the end 19 of the member 11, it will burn in the direction of the separator 27 and then ignite the chemical grain in the bore 29. After the chemical grain in the bore 29 has been burned, the lower portion of the chemical grain 25 will be ignited and the chemical grain will continue to burn in the direction of the end 13 of the member 11, thus initiating the second step of the actuation. A suitable vent 31 is provided near the end 19 of the member 11 to enable the gas generated by the burning of the chemical grain to be discharged and prevent pressurization within the casing 23. Also shown in the figure is an electrically-activated squib 33 provided to ignite the chemical grain. The squib 33 is preferably provided if the chemical grain 25 is not easily ignited by the direct application of a small electrical current. The chemical grain 25 is first preferably ignited at the end that will rotate. The portion of the member 11 located at the burn location of the chemical grain 25 will pass above the austenite temperature and that portion of the member 11 will return to the state of zero rotation about the longitudinal axis of the member 11. Thus, as the chemical grain burns from the vent 31 toward the fixed end 13 of the member 11, rotation of the shape memory alloy member 11 will occur at the location of the burn point and not within the chemical grain 25 between the burn point and the fixed end 13. It is preferable that the chemical grain not be disturbed by the rotation of the member to prevent a gap from being formed between the member 11 and the chemical grain 25 and also that the chemical grain 25 not be disturbed by rotation of the member 11 which would cause the burn rate of the chemical grain to become less predictable. It is possible, however, that the chemical grain could be ignited at the fixed end 13 and burn toward the rotatable end 19 if a sheath were provided between the member 11 and the chemical grain 25 such that the member 11 could rotate without disturbing the chemical grain. Moreover, a vent would be required in the casing 23 near the end 13 of the member 11. In operation, the squib 33 is electrically activated to ignite the chemical grain 25 in the upper portion of the stainless steel casing 23. As the chemical grain 25 burns, it causes localized heating of the member 11 and causes the local heated portion of the member to resume the shape existing before the deformation of the member caused by longitudinal twisting. As the local area of the member 11 resumes its original orientation a spline 35 will be rotated accordingly. The rotation of the spline 35 continues as the burn area of the chemical grain 25 proceeds in a direction away from the rotatable end 19 of the member 11. When the chemical grain above the separator 27 is fully consumed, rotation of the member 11 will cease until the burn front has passed through the chemical timer grain provided in the bore 29. This provides a delay between the first and second stage of actuation (if desired). The chemical grain 25 in the lower portion of the casing 23 will then be ignited and the spline 35 will be caused to rotate again until the chemical grain is fully consumed. If the burn rate of the chemical grain 25 in the upper and lower portions of the casing 23 are different the member 11 will rotate at different rates. As embodied herein, a Nitinol torsion member (rod or tube) is plastically deformed to some angle after having been set at a 0° deflection. When the member is heated to its activation temperature, i.e., above the austenite temperature, the member returns to the initial position to provide torque to a spline that may be used to actuate a latch or an electrical switch, drive a gear train, etc. The Nitinol member is heated by the burning of a chemical grain that is packed around or within the member. The rate of release of the rotary energy stored in the deformed member can be controlled by selecting the burn rate of the chemical grain and by incorporating appropriate chemical timers and inflammable separators to separate contiguous portions of the grain. It is also possible to reduce the burn rate of the grain by mixing inert material with the grain. The torque-displacement output of the Nitinol member can be altered by changing its outer (and inner) diameter(s) because the greater the diameter of the rod or tube the greater the torque that can be produced. The length of the member is selected according to the desired travel angle. Moreover, the actuator can be reused by reassembly of the Nitinol member and chemical grain within the appropriate casing. While a preferred embodiment of the present invention has been described above, it should be understood that numerous modifications can be made to the invention without departing from the spirit and scope thereof. Accordingly, it is intended that the scope of the present invention be defined by the following claims and the equivalents thereof.
A rotary actuator with tailored torque output comprises a shape memory alloy rod or tube encased within or filled with a burnable chemical grain. In its initial state, the rod or tube has zero degree rotation about its longitudinal axis. The rod or tube is then rotated or twisted about its longitudinal axis when the shape memory alloy is in a malleable state. The rod or tube may be progressively, selectively heated by the burning of the chemical grain to cause the shape memory alloy to return locally to its original shape with the consequence that a free end of the rod or tube is rotated.
5
FIELD OF THE INVENTION This invention relates to polymer compositions comprising a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon. More particularly, the invention relates to compositions comprising a major proportion of such linear alternating polymer and a minor amount of one or more additives, the composition having improved processing properties. BACKGROUND OF THE INVENTION The class of linear alternating polymers of carbon monoxide and at least one ethylenically unsaturated hydrocarbon has been known for some time. These polymers were produced by Nozaki, e.g., U.S. Pat. No. 3,694,412, employing as catalyst arylphosphine complexes of palladium moieties and certain inert solvents. More recent methods for the production of such polymers, now known as polyketones or polyketone polymers, are illustrated by a number of published European Patent Applications including Nos. 121,965, 181,014, 213,671 and 257,663. These processes involve the use of catalyst compositions produced from a compound of palladium, nickel, or cobalt, an anion of a strong non-hydrohalogenic acid and a bidentate ligand of phosphorus, arsenic, antimony or nitrogen. The resulting polymers are relatively high molecular weight materials having established utility as premium thermoplastics. For example, the polyketone polymers are processed by techniques conventional for thermoplastics into a variety of shaped articles including containers for food and drink. Although the polymers have many attractive properties such as yield stress, tensile strength, impact strength and flex modulus, the processing of the polymers is often more difficult than desired, particularly if the polyketone polymer has a relatively high molecular weight, as reflected in a relatively high limiting viscosity number, LVN, as measured in m-cresol at 60° C. Yet, the polymers of relatively high LVN are more attractive as engineering thermoplastics. In published European Patent Application 326,224 the use of fatty acid amides as lubricating additives for polyketone polymers is disclosed. In U.S. Pat. No. 4,857,570 the use of carboxylic acids having from 1 to 2 alkyl side chains as melt stabilizers for polyketone polymers is disclosed. In copending U.S. patent application Ser. No. 674,991, filed Mar. 26, 1991, the use of certain polar materials of a wide variety of structures as lubricating additives for polyketone polymers is disclosed. It would be of advantage, however, to provide polyketone compositions containing polar additives of improved processing properties. SUMMARY OF THE INVENTION The present invention provides compositions comprising linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon having improved processing properties. More particularly, the invention provides such compositions comprising a major proportion of the linear alternating polymer and a minor proportion of one or more of certain lubricating additives having at least two hydrocarbyl groups of substantial carbon number. The invention also relates to a method of improving the processing properties of the linear alternating polymer by the incorporation therein of a minor proportion of one or more of the lubricating additives. DESCRIPTION OF THE INVENTION The present invention relates to compositions of improved processing properties which comprise a major proportion of a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon. The ethylenically unsaturated hydrocarbons useful as precursors of the linear alternating polymer have up to 20 carbon atoms inclusive, preferably up to 10 carbon atoms inclusive, and are aliphatic including ethylene and other α-olefins such as propylene, butylene, isobutylene, 1-hexene, 1-octene and 1-dodecene, or are arylaliphatic having an aryl substituent on an otherwise aliphatic molecule, particularly an aryl substituent on a carbon atom of the ethylenic unsaturation. Illustrative of this latter class of ethylenically unsaturated hydrocarbons are styrene, p-methylstyrene, p-ethylstyrene and m-isopropylstyrene. The preferred copolymers employed in the compositions of the invention are copolymers of carbon monoxide and ethylene and the preferred terpolymers are terpolymers of carbon monoxide, ethylene and a second ethylenically unsaturated hydrocarbon of at least 3 carbon atoms, particularly an α-olefin such as propylene. When the preferred terpolymers are employed, there will be at least two units incorporating a moiety of ethylene for each unit incorporating a moiety of the second ethylenically unsaturated hydrocarbon. Preferably, there will be from about 10 to about 100 units incorporating a moiety of ethylene for each unit incorporating a moiety of the second hydrocarbon. The polymeric chain of the preferred polyketone polymers is therefore represented by the repeating formula --CO--CH.sub.2 --CH.sub.2)].sub.x [CO--G)].sub.y (I) wherein G is the moiety of the second ethylenically unsaturated hydrocarbon of at least 3 carbon atoms polymerized through the ethylenic unsaturation thereof and the ratio of y:x is no more than about 0.5. When the preferred copolymers are employed in the compositions of the invention there will be no second hydrocarbon present and the copolymers are represented by the above formula I wherein y is zero. When y is other than zero, i.e., terpolymers are employed, the --CO--CH 2 CH 2 -- units and the --CO--G-- units are found randomly throughout the polymer chain and the preferred ratios of y:x are from about 0.01 to abot 0.1. The end groups or "caps" of the polymer chain will depend upon what materials were present during polymerization and what and whether the polymer has been purified. The precise nature of the end groups is of little significance so far as the overall properties of the polymer are concerned so that the polyketone polymers are fairly represented by the formula for the polymeric chain as depicted above. Of particular interest are the linear alternating polymers of number average molecular weight from about 1,000 to 200,000, particularly those polymers of number average molecular weight from about 20,000 to about 90,000, as determined by gel permeation chromatography. The physical properties of the polymers will be determined in part by the molecular weight, whether the polymer is a copolymer or a terpolymer and, in the case of terpolymers, the nature of and the proportion of the second hydrocarbon present. Typical melting points for such polymers are from about 175° C. to about 300° C. but more often are from about 210° C. to about 270° C. Such polymers will typically have limiting viscosity numbers (LVN), as measured in a standard capillary viscosity measuring device in m-cresol at 60° C., of from about 0.4 dl/g to about 10 dl/g, preferably from about 0.8 dl/g to about 4 dl/g. The compositions of the invention are particularly usefully produced from polyketone polymers of LVN from about 1.5 dl/g to about 4 dl/g. The polyketone polymers are produced by the general processes illustrated by the above published European Patent Applications. Although the scope of the polymerization process is extensive, a preferred catalyst composition is formed from a compound of palladium, particularly palladium acetate, the anion of a non-hydrohalogenic acid having a pKa below 2, e.g., trifluoroacetic acid or p-toluenesulfonic acid, and a bidentate ligand of phosphorus such as 1,3-bis(diphenylphosphino)propane or 1,3-bis[di(2-methoxyphenyl)phosphino]propane. The polymerization process is conducted by contacting the monomers under polymerization conditions in the presence of the catalyst composition and a polar reaction diluent such as methanol. Typical polymerization conditions will include a polymerization temperature from about 20° C. to about 150° C. but preferably from about 30° C. to about 135° C. The suitable reaction pressures will be from about 5 bar to about 200 bar but pressures from about 10 bar to about 100 bar are more often employed. Reactant and catalyst contacting during polymerization is facilitated by some means of agitation, e.g., shaking or stirring, and subsequent to reaction the polymerization is terminated by cooling the reactor and contents and releasing the pressure. The polymer product is customarily obtained as a material substantially insoluble in the reaction diluent and is recovered by conventional techniques such as filtration or decantation. The polymer is used as such or is purified as by contacting the polymer with a solvent or complexing agent selective for catalyst residues. The compositions of the invention comprise a major proportion of the linear alternating polymer and a minor proportion of at least one polar compound lubricating additive containing at least two hydrocarbyl groups of substantial carbon number, i.e., at least two hydrocarbyl groups of from 5 to 30 carbon atoms, attached to polar moieties of the compound. Such polar lubricating additives are represented by the formula Y(ZR).sub.n (II) wherein Y is a n-valent alkyl, including cycloalkyl, group of up to 6 carbon atoms substituted with up to 2 polar groups selected from --OR', --CO 2 R' and --O--COR', wherein R' independently is hydrogen or alkyl of up to 4 carbon atoms inclusive, Z independently is selected from --O--, --CO--O--, --CONR'-- or R'--CO--N< wherein R' has the previously stated meaning, n is 2 or 3 and R independently is a hydrocarbyl group of from 5 to 30 carbon atoms inclusive attached to Y through a polar group Z. Each R group is aliphatic or aromatic or contains moieties of both and more suitably has from 10 to 30 carbon atoms. Illustrative of aromatic R groups are those derived from benzene or naphthalene and cycloaliphatic R groups are illustrated by those derived from cyclohexane, cycloheptane and norbornane. Preferred R groups are aliphatic and particularly preferred are primary, straight-chain alkyl groups such as those found in myristic acid, stearic acid, palmitic acid and montanic acid. Illustrative of the lubricating additives of the invention are esters such as trimyristyl 1,3,5-cyclohexanetricarboxylate, bis(4,6,8-trimethylnon-2-yl) suberate, 1,3-(2,2-dimethylpropyl) dilaurate, 1-montanoxyloxy-1,3-didecanoyloxypropane and dibornyl 2-methoxy-1,3-propandioate. Preferred among such ester additives are di- and tri-esters of glycol such as glycerol 1,2-dioleate, glycerol 1,2-dioctanoate, glycerol 1,3-disterate, glycerol 1,2-dioleate 3-stearate, glycerol tripalmate and glycerol tristearate. Illustrative of lubricating additives containing amide linkages are N,N'-dimethyl-N,N'-dimyristoyltrimethylenediamine, N,N'-distearoylmethylenediamine, N-docosyl-2-(4'-hexylbenzoylamino)propionamide, N,N'-dilinoleylsuccinamide, N,N'-didocosanoylethylenediamine, N,N-dilaurylethylenediamine and N,N'-distearoylethylenediamine. Preferred among the amide lubricating additives are diamides of ethylenediamine wherein the acid moiety is R. The lubricating additive is employed in a minor proportion in the compositions of the invention. Suitable amounts of lubricating additive are from about 0.01% by weight to about 5% by weight based on total composition. Preferred quantities of lubricating additive are from about 0.1% by weight to about 3% by weight on the same basis. The polyketone polymer and the lubricating additive are combined by procedures conventional for producing such compositions including dry blending and extruding. The compositions may suitably contain other additives which are conventionally employed to provide thermal or UV stabilization including hindered phenols and aromatic amines. Such additives are introduced into the composition prior to, together with or subsequent to the mixing of the polyketone polymer and the lubricating additive. The compositions of the invention demonstrate improved processing properties as compared with other additives including similar polar compounds having only a single hydrocarbyl group of substantial carbon number. The compositions are processed as in an extruder using less torque for a given feed rate or alternatively the use of a higher feed rate is possible at constant torque. The compositions showed lower increases in viscosity when processed by methods which apply mechanical stress. The compositions are thermoplastic as previously stated and are processed by such techniques conventional for thermoplastics. Specific applications are in the production of containers for food and drink and parts and housings for automotive applications. The invention is further illustrated by the following Comparative Examples (not of the invention) and the Illustrative Embodiments which should not be regarded as limiting. ILLUSTRATIVE EMBODIMENT (IE) I Comparative Examples (CE) I and II A granular linear alternating polymer of carbon monoxide, ethylene and propylene having a linear viscosity number of 1.36 dl/g (measured in m-cresol at 60° C.) and a melting point of 222° C. contained 0.5% by weight of n-octadecyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate and 0.5% by weight of 2,6-di-t-butyl-4-methylphenol (commercially available antioxidants). Sample of the terpolymer were mixed with various additives by dry blending and tumbling in air for 85 minutes. Samples of the blends were transferred to a commercial torque rheometer designed for operation with polyvinyl chloride and equipped with two spindles. The rheometer was operated at 240° C. The torque of each blend was measured at speeds of 60 rpm of one spindle and 40 rpm of the other spindle. The results are shown in Table I. TABLE I______________________________________ Initial Torque, Rate of Increase ofAdditive % wt. Nm Torque, Nm/min______________________________________IE I 3.6 0.06N,N'-distearoylethylenene-diamine, 1.0CE I 4.7 5.1None 4.5 5.3CE II 2.2 0.13Stearamide, 1.0 2.8 0.10______________________________________ ILLUSTRATIVE EMBODIMENTS II AND III Comparative Examples III and IV A linear alternating terpolymer of carbon monoxide, ethylene and propylene had a limiting viscosity number of 1.84 dl/g (measured in m-cresol at 60° C.) and a melting point of 218° C. This polymer, in powdered form, was mixed with samples of various additives by dry blending and tumbling in air for 5 minutes. Samples of each mixture were then extruded in air in a 15 mm twin-screw extruder operated at 275° C. The relative feed rates were calculated while maintaining a constant torque of 300 rpm. Plaques of each material of 0.75 mm thickness were compression molded by pressing the extrudates at 240° C. for 1.5 minutes. The plaques were used in dynamic viscosity measurements over 30 minutes residence time at 275° C. and 1 rad/s using a parallel plate rheometer. The results of these tests are shown in Table II. TABLE II______________________________________ Rate of Initial Viscosity Relative Viscosity, IncreaseAdditive, % wt. Feed Rate 10.sup.3 Pa · s Pa · s/min______________________________________IE II 1.6 1.7 570Glycerol 1,3-distearate, 0.3IE III 1.9 1.7 540Glycerol tristearate, 0.3CE III 1.0 2.5 1000None (defined)CE IV 1.5 2.0 710Glycerol 1-monostearate, 0.3______________________________________
Compositions comprising linear alternating polymers of carbon monoxide and at least one ethylenically unsaturated hydrocarbon and certain polar additives containing at least two groups of substantial carbon number show improved processing properties. A method of improving the processing properties of the linear alternating polymer comprises incorporating therein at least one of the polar additives.
2
The present invention relates generally to a control linkage for a device which is substantially resistant to adverse environments. BACKGROUND AND BRIEF SUMMARY OF THE INVENTION The actuation and control of environmentally sensitive equipment, whether it be electronic or mechanical or the combination, has always been of great interest. There is great need for economical, secure and reliable control linkage for an environmentally sensitive device. For example, as shown in the preferred embodiment, if water or steam should enter the radio's inner workings, great harm may be caused. The novel and unique application of elastomeric washers between the control linkage handles prevents external elements from entering the device yet allowing ample versatility in control. The novel and unique application of elastomeric washers are supported and retained in place by shoulders formed in grooves on the device. Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the preferred embodiment of the invention, from the claims and from the accompanying drawings, in which like numerals are employed to designate like parts throughout the same. BRIEF DESCRIPTION OF THE DRAWINGS A fuller understanding of the foregoing may be had by reference to the accompanying drawings, wherein: FIG. 1 is a front elevation of the water resistant control linkage of the present invention embodied in a sound emitting device; FIG. 2 is an exploded perspective view of the water resistant control linkage of the present invention as shown in FIG. 1; FIG. 3 is a view of the present invention taken along line 3--3 of FIG. 1; and FIG. 4 is a view of the present invention taken along line 4--4 of FIG. 1. DETAILED DESCRIPTION OF THE INVENTION While the invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention. It should be understood, however, that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the spirit and scope of the invention and/or claims to the embodiment illustrated. Referring now to FIG. 1, the numeral 10 indicated generally the water resistant control linkage of the present invention embodied in an associated sound emitting device such as a radio. A grooved face 20 is shown with guide handle 52 and toothed guide handle 73 positioned upon face 20 with guide retainer plate 80 overlying the face. FIG. 2 is an exploded perspective view of the present invention 10 depicting base 30 with gear 75 and linear slide control 65 positioned thereon. Gear 75 is fashioned to control a conventional rotary potentiometer or other device (not shown). Yoke 60 is fashioned to be complementary with slide control 65. Slide control 65 may be a potentiometer or other conventional device. Grooved face 20 is shown with guide groove 59 in which inner and outer guide shoulders 57 & 58 respectively are fashioned therein. Guide groove 79 is shown on grooved face 20 with inner and outer guide shoulders 77, 78 fashioned therein. Elastic washers 40 of varying diameters are shown sized and postioned to fit into corresponding grooves 59 and 79 and are supported and retained by inner and outer shoulders 57, 78, 58, 77 respective. Linkage ring 50 is shown with guide handle 52 affixed thereto and guide yoke adapter 55 protruding therefrom. Guide yoke adapter 55 is dimensioned to connect with yoke 60. Linkage ring 70 is shown with toothed guide handle 73 affixed thereto in which teeth 72 are configured therein. Teeth 72 are fashioned to complement the teeth of gear 75. Guide retainer plate 80 controls the travel of retainer ring 50 by restricting the movement of handle 52 between stops at each of its ends. Likewise handle 73 is restricted between stops at each of its ends. Between retainer plate 80 and cover plate 90 is a tension spring 92 and elastic washer (not shown) in order to seal opening 95 in face 20. Cover plate 90 protrudes through opening 95 to engage a conventional push button switch 97 mounted on base 30. FIG. 3 is a cross-sectional view along line 3--3 of FIG. 1 in which cover plate 90 of the present invention 10 is positioned onto guide retainer plate 80 and tensioned by spring 92 and washer 19 to engage push button switch 97. Toothed guide handle 73 is shown affixed to linkage ring 70 in which teeth 72 are fashioned therein to complementary engage gear 75. Elastic washers 40 are shown in frictional proximity to linkage ring 70 and supported along shoulders 77, 78. Linkage ring 50 is shown in frictional proximity to elastomeric washers 40 in which washers 40 are supported by guide shoulders 57, 58. Base 30 is shown in complementary engagement of grooved face 20. FIG. 4 is a cross-sectional view of the present invention 10 along line 4--4 of FIG. 1. Cover plate 90 is shown affixed to guide retainer plate 80 in which linkage ring 50 is shown set into grooved face 20. Elastic washers 40 are positioned on shoulders 57, 58 as set in guide groove 59. Guide-yoke adapter 55 is affixed to linkage ring 50 in which adapter 55 is dimentioned to engage yoke 60 which is in moveable complimentary engagement to slide control 65. Linkage ring 70 is fashioned into guide groove 79 of face 20 in which elastomeric washers 40 are a frictional proximity to and supported by guide shoulders 77, 78. Guide handle 52 shown in outline, is retained and constrained for travel by guide retainer plate 80. Base 30 is in complementary engagement to grooved face 20. The operation and use of the present invention 10 is effectively and simply described as follows. In the preferred embodiment shown, for a radio which may be used out of doors, in bath or shower or other wet applications, the water control resistant linkage is used to control either volume or tuned frequency adjustment. Handle 52 being affixed to circular linkage ring 50 which is positioned in guide groove 59 is substantially hermetically sealed from water and resistant to particulate matter by the use of elastomeric washers 40. The washers 40 of varying appropriate sizes are supported by shoulders 57, 58 (as shown in FIGS. 2-4) in which guide-yoke adapter 55 is affixed to engage yoke 60 and is complementary positioned to moveably engage slide control 65 in order to vary a potentiometer to other device. Linkage ring 70 is shown with teeth 72 protruding along its outer circular circumference in which operation of toothed guide handle 73 causes linkage ring 70 to rotate, and in turn, teeth 72 engage gear 75 to likewise vary a conventional frequency tuning device. Linkage ring 70 is positioned within guide groove 79 and is in frictional proximity with washers 40 to create a hermetic seal which is also resistant to particulate matter. Washers 40 are supported by guide shoulders 77, 78 fashioned within guide groove 79. The use of shoulders 57, 58 in groove 59 and shoulders 77, 78 in groove 79, to support the varying diameter elastic washers 40 in frictional proximity to linkage rings 50 and 70 and grooves 59 and 79, respectively, allows for the inventive water and particulate matter resistant nature of the present invention 10. Guide retainer plate 80 is superimposed concentrically upon linkage rings 50 and 70 as placed into grooves 59 and 79 in order to retain linkage rings 50 and 70 therein retainer plate 80 also maintains elastic washers 40 in frictional proximity to linkage rings 50 and 70 in order to abutt shoulders 57, 58 and 77, 78 respectively. Guide retainer plate 80 also controls the semi-arcuate travel of the tuning and frequency adjustment handles 52 and 73 respectively. Cover plate 90 is affixed over and is retained by guide retainer plate 80 and grooved face 20 and is tensioned away from guide retainer plate 80 by spring 97 in which the cover plate 90 protrudes into opening 95 so that when cover plate 90 and spring 97 is compressed into grooved face 20, push button switch 97 or other convention device is activated. It is understood that the present invention is not to be limited to the embodiment shown but may use with more or less number of concentric guides based upon the principal of obtaining fluid and particulate matter resistance for a control linkage by the use of grooves with inner and outer internal shoulders in order to support elastic washers or other sealing means. It is further understood that not only may toothed gears and slidable knobs with moveable yokes be used, but also other conventional physical connections be applicable. It is further contemplated that the inventive features shown and described in the preferred embodiment may also be obtained by the use of a single concentric shoulder within one of said grooves as an individual sealing means or that the material from which the housing is formed be sufficiently resilient to provide the sealing function without the need for separate sealing rings. While the foregoing has presented certain specific embodiments of the present invention, it is to be understood that these embodiments have been presented by way of example only. It is expected that others will perceive differences which, while bearing from the foregoing, do not depart from the spirit and scope of the invention herein described and claimed.
A fluid resistant control linkage assembly having a housing with interior and exterior sides. The control linkage has a circular groove defined in the exterior side of the housing. A ring is rotatably disposed with the groove. A handle is affixed to the ring and located outside the housing to input rotational motion to the ring. An opening is defined in the groove to provide access to the interior of the housing. An array of gear teeth or a yoke or a post is affixed to the ring at the opening. The groove may be fitted with at least one elastromeric washer which is supported by at least one concentric shoulder along said groove.
6
CROSS-REFERENCE TO RELATED APPLICATIONS The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/591,851, filed on Jan. 27, 2012, which is hereby incorporated by reference in its entirety. BACKGROUND As medical science has progressed, it has become increasingly important to provide non-human interactive formats for teaching patient care. Non-human interactive devices and systems can be used to teach the skills needed to successfully identify and treat various patient conditions without putting actual patients at risk. Such training devices and systems can be used by medical personnel and medical students to learn the techniques required for proper patient care, including those techniques used in war or combat zones where time is often of the essence in successful to both patient and medical personnel survival. In that regard, the training of medical personnel and patients is greatly enhanced through the use of realistic hands-on training with devices and systems, such as those of the present disclosure, that mimic characteristics of natural human and, in particular, allow training of procedures commonly performed in war and/or combat zones. In view of the foregoing, there remains a need for devices, systems, and methods appropriate for use in combat medical training. BRIEF DESCRIPTION OF THE DRAWINGS The present disclosure can be better understood from the following detailed description when read with the accompanying figures. FIG. 1 is a perspective view of a patient simulator according to one embodiment of the present disclosure. FIG. 2 is a perspective view of a neck mechanism of the patient simulator of FIG. 1 according to an embodiment of the present disclosure. FIG. 3 is a front view of a neck support of the neck mechanism of FIG. 2 according to one embodiment of the present disclosure. FIG. 4 is a front, exploded view of the neck support of FIG. 3 . FIG. 5 is a perspective front view of a mounting structure of the neck mechanism of FIG. 2 according to one embodiment of the present disclosure. FIG. 6 is a perspective rear view of the mounting structure of FIG. 5 . FIG. 7 is a perspective view of the mounting structure of FIGS. 5 and 6 attached to a head portion of the patient simulator of FIG. 1 . FIG. 8 is a front view of a neck portion of the patient simulator of FIG. 1 according to an embodiment of the present disclosure. FIG. 9 is a top view of components of a trachea device of the neck portion of the patient simulator of FIG. 1 according to an embodiment of the present disclosure. FIG. 10 is a perspective view of a trachea housing according to an embodiment of the present disclosure. FIG. 11 is a top view of the trachea housing of FIG. 10 . FIG. 12 is a perspective view of a trachea box according to an embodiment of the present disclosure. FIG. 13 is a perspective view of supports of the trachea box of FIG. 12 according to an embodiment of the present disclosure. FIG. 14 is a side view of a trachea insert according to an embodiment the present disclosure. FIG. 15 is a side view of components of the trachea insert of FIG. 14 according to an embodiment the present disclosure. FIG. 16 is an end view of the components of the trachea insert shown in FIG. 15 . FIG. 17 is an end view of the components of the trachea insert similar to that of FIG. 16 , but showing the trachea insert mated with the supports of the trachea box shown in FIG. 13 . FIG. 18 is a top view of the trachea insert of FIG. 14 positioned within the trachea box of FIG. 12 . FIG. 19 is an end view of the trachea insert of FIG. 14 positioned within the trachea box of FIG. 12 . FIG. 20 is an end view of the trachea insert of FIG. 14 positioned within the trachea box of FIG. 12 similar to that of FIG. 19 , but from an opposing end. FIG. 21 is a perspective view of the trachea insert of FIG. 14 positioned within the trachea box of FIG. 12 positioned within the trachea housing of FIG. 10 . FIG. 22 is a top view of the trachea insert of FIG. 14 positioned within the trachea box of FIG. 12 positioned within the trachea housing of FIG. 10 . FIG. 23 is an end view of the trachea insert of FIG. 14 positioned within the trachea box of FIG. 12 positioned within the trachea housing of FIG. 10 , where only portions of the trachea box and trachea housing are illustrated. FIG. 24 a is a perspective, cross-sectional view of the trachea insert of FIG. 14 positioned within the trachea box of FIG. 12 positioned within the trachea housing of FIG. 10 . FIG. 24 b is a perspective view of trachea tube positioned through an opening created in the trachea device. FIG. 25 is a top view of a chest cavity of the patient simulator of FIG. 1 illustrating support structures and a pneumothorax simulation system according to an embodiment of the present disclosure. FIG. 26 is a perspective view of the chest cavity of FIG. 25 , but illustrating an intraosseus simulation component mounted on a support structure along with the pneumothorax simulation system. FIG. 27 is a perspective view of the support structures and portions of the pneumothorax simulation system of FIGS. 25 and 26 . FIG. 28 is a perspective, exploded view of the support structures and portions of the pneumothorax simulation system of FIG. 27 . FIG. 29 is a perspective view of a portion of the pneumothorax simulation system according to an embodiment of the present disclosure. FIG. 30 is a perspective, exploded view of the portion of the pneumothorax simulation system of FIG. 29 . FIG. 31 is a bottom view of a portion of a pneumothorax simulation system according to an embodiment of the present disclosure. FIG. 32 is a perspective view of a mounting support structure according to an embodiment of the present disclosure. FIG. 33 is a perspective, exploded view of the mounting support structure of FIG. 32 . FIG. 34 is a perspective view of a mounting support structure for an intraosseus device according to an embodiment of the present disclosure. FIG. 35 is a perspective view of an intraosseus device according to an embodiment of the present disclosure. FIG. 36 is a cross-sectional side view of an intraosseus device according to an embodiment of the present disclosure. FIG. 37 is a front view of an upper arm assembly according to an embodiment of the present disclosure. FIG. 38 is a front cross-sectional view of the upper arm assembly of FIG. 37 . FIG. 39 is a side view of a shoulder joint assembly of the upper arm assembly of FIGS. 37 and 38 according to an embodiment of the present disclosure. FIG. 40 is a side cross-sectional view of the shoulder joint assembly of FIG. 39 . FIG. 41 is a perspective, exploded view of the shoulder joint assembly of FIGS. 39 and 40 . FIG. 42 is an end view of a component of the shoulder joint assembly of FIGS. 39-41 according to an embodiment of the present disclosure. FIG. 43 is a front view of an upper leg assembly according to an embodiment of the present disclosure. FIG. 44 is a perspective cross-sectional view of the upper leg assembly of FIG. 43 . FIG. 45 is a side view of a hip joint assembly of the upper leg assembly of FIGS. 43 and 44 according to an embodiment of the present disclosure. FIG. 46 is a side cross-sectional view of the hip joint assembly of FIG. 45 . FIG. 47 is a perspective, exploded view of the hip joint assembly of FIGS. 45 and 46 . FIG. 48 is a top view of a portion of the patient simulator of FIG. 1 illustrating portions of the hip joint assembly of FIGS. 45-47 assembled with a torso of the patient simulator. FIG. 49 is a perspective side view of the upper leg assembly of FIG. 43 , but illustrating inner components received within the upper leg assembly according to an embodiment of the present disclosure. FIG. 50 is a perspective view of a reservoir holder of the upper leg assembly of FIG. 43 according to an embodiment of the present disclosure. FIG. 51 is a perspective, exploded view of the reservoir holder of FIG. 50 . FIG. 52 is a perspective view of a pump and valve system of the upper leg assembly of FIG. 43 according to an embodiment of the present disclosure. FIG. 53 is a perspective, exploded view of the pump and valve system of FIG. 52 . FIG. 54 is a perspective view of the reservoir holder and the pump and valve system of the upper leg assembly, connected to corresponding tubing and electrical connections outside of the upper leg assembly. FIG. 55 is a perspective view of the upper leg assembly of FIG. 43 with the reservoir holder and the pump and valve system positioned therein FIG. 56 is a perspective view of an upper arm assembly according to an embodiment of the present disclosure. FIG. 57 is a perspective, exploded view of a mold system for forming the upper arm assembly of FIG. 56 according to an embodiment of the present disclosure. FIG. 58 is a perspective, assembled view of the mold system of FIG. 57 . FIG. 59 is a side view of the upper arm assembly of FIG. 56 attached to a torso of the patient simulator of FIG. 1 having a wound according to an embodiment of the present disclosure. FIG. 60 is a perspective, transparent view of a mold for forming a portion of the wound of the upper arm assembly of FIG. 59 according to an embodiment of the present disclosure. FIG. 61 is a perspective, transparent view of a mold for forming another portion of the wound of the upper arm assembly of FIG. 59 according to an embodiment of the present disclosure. FIG. 62 is a perspective, transparent view of a mold for forming yet another portion of the wound of the upper arm assembly of FIG. 59 according to an embodiment of the present disclosure. FIG. 63 is a top view of the mold of FIG. 60 . FIG. 64 is a top view of the mold of FIG. 61 . FIG. 65 is a top view of the mold of FIG. 62 . FIG. 66 is a perspective view of the structure of a wound created using the molds of FIGS. 60-65 . FIGS. 67-71 illustrate a series of steps to enhance the realism of the wound based on the wound structure of FIG. 66 created using the molds of FIGS. 60-65 according to an embodiment of the present disclosure. FIG. 72 illustrates the attachment of tubing to the wound structure of FIGS. 66-71 according to an embodiment of the present disclosure. FIG. 73 is a perspective view of an arm tourniquet housing according to an embodiment of the present disclosure. FIG. 74 is a perspective, exploded view of a mold system for forming the tourniquet housing of FIG. 73 according to an embodiment of the present disclosure. FIG. 75 is a perspective, side view of an upper leg assembly according to an embodiment of the present disclosure. FIG. 76 is a perspective, bottom view of the upper leg assembly of FIG. 75 . FIG. 77 is a perspective view of a mold system for forming the upper leg assembly of FIG. 76 according to an embodiment of the present disclosure. FIG. 78 is a perspective view of a mold of the mold system of FIG. 77 according to an embodiment of the present disclosure. FIG. 79 is a perspective view of another mold of the mold system of FIG. 77 configured to mate with the mold of FIG. 78 according to an embodiment of the present disclosure. FIG. 80 is a perspective side view of an upper leg assembly manufactured using the mold system of FIGS. 77-79 . FIG. 81 is a perspective, transparent view of a mold for forming a portion of the wound of the upper leg assembly of FIG. 80 according to an embodiment of the present disclosure. FIG. 82 is a perspective, transparent view of a mold for forming another portion of the wound of the upper leg assembly of FIG. 80 according to an embodiment of the present disclosure. FIG. 83 is a perspective, transparent view of a mold for forming yet another portion of the wound of the upper leg assembly of FIG. 80 according to an embodiment of the present disclosure. FIG. 84 is a top view of the mold of FIG. 81 . FIG. 85 is a top view of the mold of FIG. 82 . FIG. 86 is a top view of the mold of FIG. 83 . FIG. 87 is a perspective view of a wound structure created using the molds of FIGS. 81-86 . FIGS. 88-97 illustrate a series of steps to assemble a wound structure based on the components created using the molds of FIGS. 81-86 according to an embodiment of the present disclosure. FIGS. 98-103 illustrate a series of steps to enhance the realism of the wound structure of FIGS. 87 and 97 according to an embodiment of the present disclosure. FIG. 104 illustrates the attachment of tubing to the wound structure of FIGS. 87-103 according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It is nevertheless understood that no limitation to the scope of the disclosure is intended. Any alterations and further modifications to the described devices, systems, and methods, and any further application of the principles of the present disclosure are fully contemplated and included within the present disclosure as would normally occur to one skilled in the art to which the disclosure relates. In particular, it is fully contemplated that the features, components, and/or steps described with respect to one embodiment may be combined with the features, components, and/or steps described with respect to other embodiments of the present disclosure. For the sake of brevity, however, the numerous iterations of these combinations will not be described separately. Referring initially to FIG. 1 , shown therein is a patient simulator 100 . In the illustrated embodiment, the patient simulator 100 is a full body patient simulator. To that end, the patient simulator 100 includes a torso 102 , legs 103 and 104 , arms 105 and 106 , a neck 107 , and a head 108 . The various anatomical portions of the patient simulator 100 are sized, shaped, and formed of a suitable material to mimic natural human anatomy. The patient simulator 100 can be either a male simulator or a female simulator and will include appropriate anatomical features based on the simulated gender. Further, in some instances, the patient simulator 100 includes a simulated circulatory system, a simulated respiratory system, and/or other simulated aspects. In that regard, the patient simulator 100 is in communication with a control system configured to control the circulatory system, respiratory system, and/or other aspects of the patient simulator. For example, in some instances, the control system is configured to adjust parameters associated with the circulatory system, respiratory system, and/or other aspects of the patient simulator 100 in accordance with a simulation scenario and/or a user's application of treatment to the patient simulator 100 based on the simulation scenario. Accordingly, in some instances, the patient simulator 100 includes one or more features as described in In some instances, aspects of the present disclosure are configured for use with the simulators and the related features disclosed in U.S. patent application Ser. Nos. 13/223,020, 13/031,116, 13/031,087, 13/031,102, 12/856,903, 12/708,682, 12/708,659, 11/952,606, 11/952,669, 8,016,598, U.S. Pat. Nos. 7,976,313, 7,976,312, 7,866,983, 7,114,954, 7,192,284, 7,811,090, 6,758,676, 6,503,087, 6,527,558, 6,443,735, 6,193,519, 5,853,292, 5,472,345, each of which is hereby incorporated by reference in its entirety. Further, in some instances, the patient simulator 100 includes one or more features as provided in medical simulators provided by Gaumard Scientific Company, Inc. based out of Miami, Fla., including but not limited to the following models: S 1000 Hal®, S 1020 Hal®, S 1030 Hal®, S 3000 Hal®, S 2000 Susie®, S 221 Clinical Chloe, S 222 Clinical Chloe, S 222 . 100 Super Chloe, S 303 Code Blue®, S 304 Code Blue®, S 100 Susie®, S 100 Simon®, S 200 Susie®, S 200 Simon®, S 201 Susie®, S 201 Simon®, S 203 Susie®, S 204 Simon®, S 205 Simple Simon®, S 206 Simple Susie®, S 3004 Pediatric Hal®, S 3005 Pediatric Hal®, S 3009 Premie Hal®, S 3010 Newborn Hal®, S 110 Mike®, S 110 Michelle®, S 150 Mike®, S 150 Michelle®, S 107 Multipurpose Patient Care and CPR Infant Simulator, S117 Multipurpose Patient Care and CPR Pediatric Simulator, S157 Multipurpose Patient Care and CPR Pediatric Simulator, S 575 Noelle®, S 565 Noelle®, S 560 Noelle®, S 555 Noelle®, S 550 Noelle®, S 550 . 100 Noelle, and/or other patient simulators. Referring now to FIGS. 2-4 , shown therein are aspects of a neck mechanism having a neck support structure 110 according to an embodiment of the present disclosure. In that regard, FIG. 2 is a perspective view of the neck mechanism illustrating the support structure; FIG. 3 is a front view of a neck support structure 110 according to one embodiment of the present disclosure; and FIG. 4 is a front, exploded view of the neck support structure 110 . As shown the neck support structure 110 comprises a spring 112 that threadedly mates with two threaded tubular structures 114 and 116 . In that regard, the ends of the tubular structures 114 and 116 that are not threadingly engaged with the spring 112 are configured to be fixedly secured to a mount within a portion of the head 108 of the patient simulator 100 and a mount within a portion of the torso 102 of the patient simulator, respectively. The resulting neck support structure 100 provides realistic range of motion to the patient simulator's neck 107 and head 108 , while also acting as a shock absorber to prevent unwanted damage to the patient simulator's head and inner components during rough handling. Referring now to FIGS. 2 and 5 - 7 , shown therein are aspects of a neck mechanism having a mounting structure 120 according to an embodiment of the present disclosure. In that regard, FIG. 2 is a perspective view of the neck mechanism illustrating the mounting structure 120 ; FIG. 5 is a perspective front view of the mounting structure 120 ; FIG. 6 is a perspective rear view of the mounting structure 120 ; and FIG. 7 is a perspective view of the mounting structure 120 attached to a head portion 108 of the patient simulator. Generally, the mounting structure 120 includes two platforms 122 and 124 connected by a variable length support 126 . The platform 124 is configured to be fixedly secured to the head 108 of the patient simulator 100 . In some instances, the platform 124 also interfaces with the end of the tubular structure 114 connected to the spring 112 of the neck support structure 110 that is to be fixedly secured to the head 108 . The platform 122 is configured to allow a trachea device 150 (discussed in greater detail below) to be mounted thereto, as shown in FIG. 2 , for example. In that regard, the mounting structure 120 is adjustable such that the position of the platform 122 can be adjusted longitudinally and rotationally (see series of locking screws 128 along length of tube extending between platforms that allow such movement when loosened and prevent such movement when tightened) as well as pivotally (see locking screw 130 at pivot point of platform 122 ). Accordingly, a specifically desired orientation and/or position of the platform 122 can be selected and achieved for any number of reasons (e.g., simulate a specific condition, simulator manufacturing tolerance, different size trachea devices, etc.). Referring now to FIGS. 8-24 b , shown therein are aspects of a trachea device 150 according to an embodiment of the present disclosure. In that regard, FIG. 8 is a front view of a neck portion 107 of the patient simulator 100 containing the trachea device 150 ; FIG. 9 is a top view of components of the trachea insert; FIG. 10 is a perspective view of a trachea housing according to an embodiment of the present disclosure. FIG. 11 is a top view of the trachea housing; FIG. 12 is a perspective view of a trachea box according to an embodiment of the present disclosure; FIG. 13 is a perspective view of supports of the trachea box according to an embodiment of the present disclosure; FIG. 14 is a side view of a trachea insert according to an embodiment the present disclosure; FIG. 15 is a side view of components of the trachea insert; FIG. 16 is an end view of the components of the trachea insert; FIG. 17 is an end view of the components of the trachea insert similar to that of FIG. 16 , but showing the trachea insert mated with the supports of the trachea box; FIG. 18 is a top view of the trachea insert positioned within the trachea box; FIG. 19 is an end view of the trachea insert positioned within the trachea box; FIG. 20 is an end view of the trachea insert positioned within the trachea box similar to that of FIG. 19 , but from an opposing end; FIG. 21 is a perspective view of the trachea insert positioned within the trachea box, which is positioned within the trachea housing; FIG. 22 is a top view of the trachea insert of positioned within the trachea box, which is positioned within the trachea housing; FIG. 23 is an end view of the trachea insert positioned within the trachea box, which is positioned within the trachea housing; FIG. 24 a is a perspective, cross-sectional view of the trachea insert positioned within the trachea box, which is positioned within the trachea housing; and FIG. 24 b is a perspective view of trachea tube positioned through an opening created in the trachea device. The trachea device allows training of combat medics on proper tracheostomy procedures, including insertion of a trachea tube. In that regard, the trachea device includes a trachea housing 152 , a trachea box 154 , a surgical cricoid insert 156 with anatomical landmarks, and a skin cover 158 . As shown in FIGS. 10 and 11 , the housing 152 includes a recess 160 sized and shaped to receive the trachea box 154 . As shown in FIG. 12 , the trachea box 154 includes a recess 162 sized and shaped to receive the cricoid insert 156 . In that regard, the trachea box 154 includes projections 164 that are configured to mate with corresponding recesses in the cricoid insert 156 . To this end, the trachea box 154 includes support structures 166 each having a projection 164 over which a suitable flexible material is overmolded/injected around to form the trachea box 154 . In that regard, the support structures 166 are formed of a more rigid material than the overmolded/injected material. As shown in FIG. 14 , two pieces 170 and 172 of the cricoid insert are connected by a silicon layer 174 that simulates human cartilage. Piece 170 of the cricoid insert 156 includes recesses 176 for engaging with the projections 164 of the trachea box 154 when positioned within the recess 162 of the trachea box. The surgical cricoid insert 156 is formed of sufficiently durable materials to be repeatedly subjected to a tracheostomy hook. In that regard, in typical use the combat medic will make two incisions (one medial, one lateral) through the trachea skin cover 158 over the surgical cricoid 156 . Then the medic will insert the tracheostomy hook into the cricoid cartilage at the intersection of the incisions and lift upward towards a 45 degree position. The tracheostomy hook is utilized to hold the trachea steady during the tracheostomy procedure. As shown in FIG. 24 b , once the opening has been created, the combat medic inserts a tracheostomy tube 180 thru the cricoid cartilage such that oxygen can be provided to the wounded soldier. As shown, each of the components of the trachea device are replaceable and easily assembled. Referring now to FIGS. 25-36 , shown therein are various aspects of a chest cavity of a patient simulator according to embodiments of the present disclosure. In that regard, FIG. 25 is a top view of a chest cavity of the patient simulator illustrating support structures and a pneumothorax simulation system according to an embodiment of the present disclosure; FIG. 26 is a perspective view of the chest cavity of FIG. 25 illustrating an intraosseus simulation component mounted on a support structure; FIG. 27 is a perspective view of the support structures and portions of the pneumothorax simulation system; FIG. 28 is a perspective, exploded view of the support structures and portions of the pneumothorax simulation system; FIG. 29 is a perspective view of a portion of the pneumothorax simulation system according to an embodiment of the present disclosure; FIG. 30 is a perspective, exploded view of the portion of the pneumothorax simulation system of FIG. 29 ; FIG. 31 is a bottom view of a portion of a pneumothorax simulation system according to an embodiment of the present disclosure; FIG. 32 is a perspective view of a mounting support structure according to an embodiment of the present disclosure; FIG. 33 is a perspective, exploded view of the mounting support structure; FIG. 34 is a perspective view of a mounting support structure for an intraosseus device according to an embodiment of the present disclosure; FIG. 35 is a perspective view of an intraosseus device according to an embodiment of the present disclosure; and FIG. 36 is a cross-sectional side view of an intraosseus device according to an embodiment of the present disclosure. As shown in FIG. 25 , the chest cavity includes a spring system 200 to facilitate the performance of chest compression on the patient simulator. In some implementations, the spring system 200 is an energy and/or air harvesting system as disclosed in U.S. Provisional Patent Application No. 61/757,137, titled “MEDICAL SIMULATORS WITH ENERGY HARVESTING POWER SUPPLIES,” filed on Jan. 26, 2013, which is hereby incorporated by reference in its entirety. The chest cavity also includes a pneumothorax simulation system 202 . The chest cavity of the patient simulator also includes a mounting structure 204 for a device 206 (see FIG. 26 , for example) that is positioned where the sternum would be located. Further, the patient simulator breathes in accordance with a respiratory pattern. In that regard, the patient simulator has chest rise and fall corresponding to the respiratory pattern. To simulate some scenarios, one or both of the left and right lungs can be disabled to simulate pneumothorax. To that end, the patient simulator includes the pneumothorax simulation system 202 in some instances that allows training of pneumothorax procedures. In particular, in some instances the patient simulator facilitates training of needle chest decompressions using a 3¼ inch long and 14 gauge needle, or other suitable needles, at the 2nd intercostal space bilaterally. In that regard, proper insertion of the needle is detectable by the pneumothorax system such that the respiratory pattern of the patient simulator can be adjusted accordingly. In this regard, FIGS. 27-33 illustrate aspects of the pneumothorax system and associated mounting components. As shown, mounting brackets 210 and 212 are coupled together by components 214 and 216 . Each side of the patient simulator includes switch mechanisms 218 to which plates 220 are mounted. As described below, depression of the plate 220 in response to a proper needle puncture actuates the associated switch mechanism 218 such that the controller or processing system is alerted and the corresponding respiratory pattern of the patient simulator can be adjusted. As shown, the mounting structure 204 for device 206 is also coupled to the mounting bracket 210 . The mounting structure 204 includes a spring 222 , a threaded tubular member 224 , and a mount 226 . The mount 226 is sized and shaped to mate with the device 206 such that the device 206 is fixedly secured to the mounting structure 204 via mount 226 . FIGS. 29-31 illustrate additional aspects of the switch mechanism 218 . As shown, the switch mechanism 218 includes support arms 230 to which the plate 220 are secured. The supports arms 230 (and plate 220 ) pivot about rod 232 such that when the plate 220 is depressed a switch 234 is activated. More specifically, as the plate 220 is depressed a movable contact piece 236 of the switch 234 comes into contact with a base portion 238 of the switch 234 , thereby activating (or deactivating) the switch. The rotational orientation of the switch relative to the plate 220 is adjustable in some instances such that the amount of travel of the plate necessary to activate/deactivate the switch 234 is selectable. The support members 230 , rod 232 , and switch 234 are mounted to a support structure 240 . Springs 242 and washers 244 are utilized in some embodiments to couple the components together. Springs 242 are utilized in some instances to bias the plate 220 back to the original starting position (non-depressed position). The skin of the patient positioned over the pneumothorax locations is durable with respect to needle punctures such that these procedures can be performed multiple times without needing to change the skin of the patient simulator. Sensors detect the needle insertion and communicate the action to the controller or control system that controls the respiratory pattern of the patient simulator. Accordingly, the controller or control system adjusts the respiratory pattern based on the treatment administered to the patient simulator in some instances. The device 206 , shown in FIGS. 26 , 35 , and 36 , is configured to accept fluids and can be used multiple times without needing to replace the device such that the device 206 can be utilized for the infusion of medication. In that regard, referring to FIG. 36 , in some instances the device 206 has a housing 250 with a reservoir 252 that is configured to accept fluids. Further, the reservoir 252 is in communication with tubing 254 that allows drainage of the received fluids from the reservoir 252 of the device 206 . In some instances, the device 206 is configured to be used with the FAST-1 intraosseous device. In some instances, the device 206 is positioned on a mounting structure, such as mounting structure 204 that includes a spring 222 , threaded tubular member 224 , and mount 226 . The mount 226 is sized and shaped to mate with the device 206 such that the device 206 is fixedly secured to the mounting structure 204 via mount 226 . Referring now to FIGS. 37-42 , shown therein are aspects of an upper arm assembly 300 according to an embodiment of the present disclosure. In that regard, FIG. 37 is a front view of an upper arm assembly 300 according to an embodiment of the present disclosure; FIG. 38 is a front cross-sectional view of the upper arm assembly 300 ; FIG. 39 is a side view of a shoulder joint assembly 302 of the upper arm assembly 300 according to an embodiment of the present disclosure; FIG. 40 is a side cross-sectional view of the shoulder joint assembly 302 ; FIG. 41 is a perspective, exploded view of the shoulder joint assembly 302 ; and FIG. 42 is an end view of a component of the shoulder joint assembly according to an embodiment of the present disclosure. As shown, in some instances the shoulder connections of the arms are configured to provide natural motion/flexibility, yet provide strength and durability sufficient to allow the simulator to be dragged by the arms. In some embodiments, the shoulder connections include openings extending therethrough to allow passage of communication cables and/or tubing for introduction of fluids (e.g., simulated blood). Further, still, in some instances the shoulder connections allows arm range of motion to a natural range (e.g., approximately 270 degrees), but prevents full rotation of the arm to prevent unwanted kinking and/or damage to the communication cables and/or tubing going through the shoulder connection and into the arm. To this end, in some implementations the arm assembly 300 includes a shoulder joint 302 that includes a spring 304 and mounting structures 306 and 308 for securing the shoulder joint 302 to the arm assembly 300 and torso 102 of the patient simulator 100 , respectively. As shown, mounting structure 306 includes a component 306 having tapered outer surfaces and an internal passage that receives a portion of the spring 304 . The spring 304 threadingly engages an end piece 310 that mechanically secures the spring 304 to the component 306 . The mounting structure 308 includes components 312 , 314 , and 316 along with a pin system 318 . In that regard, the pin system 318 extends through an opening 320 in component 314 such that the rotation of the pin system 318 along the length of the opening 320 allows rotation of the shoulder joint in a manner that simulates the natural rotation of a human shoulder, including limiting total range of motion to approximate 270 degrees. Component 312 provides pivoting motion to the shoulder joint 302 . The spring 304 engages a threaded opening within component 316 as shown in FIG. 40 . Referring now to FIGS. 43-48 , shown therein are aspects of an upper leg assembly 350 according to an embodiment of the present disclosure. In that regard, FIG. 43 is a front view of an upper leg assembly 350 according to an embodiment of the present disclosure; FIG. 44 is a perspective cross-sectional view of the upper leg assembly 350 ; FIG. 45 is a side view of a hip joint assembly 352 of the upper leg assembly according to an embodiment of the present disclosure; FIG. 46 is a side cross-sectional view of the hip joint assembly 352 ; FIG. 47 is a perspective, exploded view of the hip joint assembly 352 ; and FIG. 48 is a top view of a portion of the patient simulator illustrating portions of the hip joint assembly 352 assembled with a torso 102 of the patient simulator 100 . As shown, in some instances the hip connections of the legs 103 and 104 of the patient simulator 100 are configured to provide natural motion/flexibility, yet provide strength and durability sufficient to allow the simulator to be dragged by the legs. In some embodiments, the hip connections include openings extending therethrough to allow passage of communication cables and/or tubing for introduction of fluids (e.g., simulated blood). Further, still, in some instances the connections limit range of motion to a natural range, but prevents full rotation of the legs to prevent unwanted kinking and/or damage to the communication cables and/or tubing going through the shoulder connection and into the arm. As shown in FIGS. 45-47 , the hip joint assembly 352 includes a spring 354 that is threadingly engaged with an inner portion of a component 356 . A locking ring 358 having locking pin 360 clamps onto an outer portion of the component 356 . Collectively, the component 356 and locking ring 358 are utilized to secure the spring 354 to the torso 102 of the patient simulator. The hip joint assembly 352 also includes a threaded member 362 that extends through components 364 and 366 and engages a locking ring 368 having locking pin 360 . The locking ring 368 clamps onto an outer portion of the member 362 . The spring 354 threadingly engages an inner portion of the member 362 . Component 366 provides pivoting motion to the hip joint 302 in some instances. Referring now to FIGS. 49-55 , shown therein are aspects of inner components of the upper leg assembly 350 according to an embodiment of the present disclosure. In that regard, FIG. 49 is a perspective side view of the upper leg assembly 350 illustrating components received within the upper leg assembly according to an embodiment of the present disclosure; FIG. 50 is a perspective view of a reservoir holder of the upper leg assembly according to an embodiment of the present disclosure; FIG. 51 is a perspective, exploded view of the reservoir holder; FIG. 52 is a perspective view of a pump and valve system of the upper leg assembly according to an embodiment of the present disclosure; FIG. 53 is a perspective, exploded view of the pump and valve system; FIG. 54 is a perspective view of the reservoir holder and the pump and valve system of the upper leg assembly connected to corresponding tubing and electrical connections outside of the upper leg assembly; and FIG. 55 is a perspective view of the upper leg assembly with the reservoir holder and the pump and valve system positioned therein. A fluid reservoir houses the blood that is utilized to simulate the bleeding of the wounds is contained in one or both of the legs in some instances. In some instances, the reservoir contains 1.5 liters or more of simulated blood that is utilized to cause simulated bleeding of axilla wound, groin wound, amputation arm, and/ amputation leg. In that regard, in some instances the patient simulator bleeds at a rate of approximately 0.25 liters per minute. Accordingly, in some instances the reservoir holder includes a sensor to monitor the amount of blood within the reservoir so that a user or instructor can be aware when the simulator is running low on blood and replenish the reservoir as needed. The valves and pumps are configured to supply blood to the appropriate wound(s) in response to control system and/or actions by the user. As shown in FIG. 49 , the upper leg assembly 350 includes a collection of components 400 configured to facilitate operation of these bleeding features. For example, FIGS. 50 and 51 show a reservoir mounting system 402 according to an embodiment of the present disclosure. The reservoir mounting system 402 includes a tray 404 configured to receive the fluid reservoir (such as rigid or flexible fluid container) that is pivotally mounted to a mounting support 406 by pivot joint 408 . A sensor 410 is provided to monitor the amount of the fluid present in the reservoir (e.g., by monitoring changes in weight/pressure imparted on the sensor 410 by the fluid reservoir and the tray 404 ). FIGS. 52 and 53 show a pump and valve system 420 configured to interface with the fluid reservoir held by the reservoir mounting system 402 . The pump and valve system 420 includes pumps 422 and associated mounts 424 , 426 , and 428 . The pump and valve system 420 also includes one or more valves 432 and an associated mount 430 . The pumps 422 , valves, 432 , and fluid reservoir(s) are connected via a plurality of tubes or other fluid passageways as necessary to facilitate the desired bleeding functionalities of the patient. In that regard, the controller or processing system controls operation of the pumps 422 and/or valves 432 in some instances to simulate desired bleeding scenarios (including the user's responses thereto in some implementations). FIG. 55 shows the reservoir mounting system 402 and the pump and valve system 420 mounted within the upper leg assembly 350 with a reservoir 434 according to an implementation of the present disclosure. Referring now to FIGS. 56-74 , shown therein are aspects of an upper arm assembly 300 and corresponding manufacturing components and techniques according to embodiments of the present disclosure. In that regard, FIG. 56 is a perspective view of an upper arm assembly 300 according to an embodiment of the present disclosure. FIG. 57 is a perspective, exploded view of a mold system 500 for forming the upper arm assembly according to an embodiment of the present disclosure, while FIG. 58 is a perspective, assembled view of the mold system. As shown, the mold system 500 includes a plate 502 , portion 504 , and portion 506 that are to be assembled together. To that end, a spacer 508 is utilized to separate a section of portion 506 from the plate 502 . The mold system 500 also includes plugs 510 and 512 that are positioned within openings in the portion 506 , as shown. FIG. 59 is a side view of the upper arm assembly 350 attached to the torso 102 of the patient simulator having a wound 520 positioned within a recess of the arm assembly according to an embodiment of the present disclosure. To that end, FIGS. 60-65 illustrate aspects of mold systems for forming various arm wounds and/or arm blanks according to embodiments of the present disclosure. More specifically, FIG. 60 is a perspective, transparent view of a mold 530 for forming a portion of the wound of the upper arm assembly according to an embodiment of the present disclosure. As shown, the mold 530 includes a recess 532 configured to receive a material that is to form at least a portion of the wound and a plurality of members 534 . The plurality of members 534 are configured to define passages through the resulting wound structure that can be utilized to pass fluid in a manner that simulates bleeding. FIG. 61 is a perspective, transparent view of a mold 540 for forming another wound and/or another portion of a wound of the upper arm assembly according to an embodiment of the present disclosure. Likewise, FIG. 62 is a perspective, transparent view of a mold 550 for forming yet another wound and/or another portion of the wound of the upper arm assembly according to an embodiment of the present disclosure. FIG. 63 is a top view of the mold 530 of FIG. 60 ; FIG. 64 is a top view of the mold 540 of FIG. 61 ; and FIG. 65 is a top view of the mold 550 of FIG. 62 . FIG. 66 is a perspective view of a wound structure 600 created using one or more of the molds of FIGS. 60-65 . However, in some instances the realism of the wound is enhanced by providing surface treatments to the wound structure 600 . To that end, FIGS. 67-71 illustrate a series of surface treatment steps to enhance the realism of the wound based on the wound structure 600 according to an embodiment of the present disclosure. Additional aspects of these exemplary features are described below. Further, FIG. 72 illustrates the attachment of tubing 602 to the wound structure 600 according to an embodiment of the present disclosure. In some instances, the tubing 602 is fluidly coupled to the pump and valve system described above in order to selectively provide simulated blood to the wound structure 600 to further enhance the realism of the wound. FIG. 73 is a perspective view of an arm tourniquet housing 610 according to an embodiment of the present disclosure. To that end, in some implementations tubing (such as tubing 602 ) extending through the arm and/or leg of the patient simulator is positioned within tourniquet housing 610 such that upon proper application of a tourniquet around the arm/leg the flow of fluid through the tubing will be stopped. In particular, the compression of the tourniquet compresses the tubing, which prevents the flow of fluid through the tubing. FIG. 74 provides a perspective, exploded view and a perspective, assembled view of a mold system 620 for forming the tourniquet housing 610 according to an embodiment of the present disclosure. As shown, the mold system 620 includes a component 622 that is configured to receive an insert 624 to collectively define a space corresponding to the shape of the tourniquet housing 610 . Referring now to FIGS. 75-104 , shown therein are aspects of the upper leg assembly 350 and corresponding manufacturing components and techniques according to embodiments of the present disclosure. In that regard, FIG. 75 is a perspective, side view of the upper leg assembly 350 according to an embodiment of the present disclosure, while FIG. 76 is a perspective, bottom view of the upper leg assembly. As shown, the leg assembly 350 includes a recess 630 for receiving a wound and a recess 632 for receiving the tourniquet housing 610 described above. FIGS. 77-79 illustrate aspects of a mold system 650 for forming the upper leg assembly 350 according to an embodiment of the present disclosure. As shown, the mold system 650 includes an upper component 652 and a lower component 654 that mate with one another and/or a central plate. FIG. 80 is a perspective side view of the upper leg assembly 350 manufactured using the mold system 650 shown with a wound 660 received within the recess 630 . FIGS. 81-86 illustrate aspects of mold systems for forming various leg wounds and/or leg blanks according to embodiments of the present disclosure. More specifically, FIG. 81 is a perspective, transparent view of a mold 670 for forming a portion of the wound of the upper leg assembly 350 according to an embodiment of the present disclosure. As shown, the mold 670 includes a recess 672 configured to receive a material that is to form at least a portion of the wound and a plurality of members 674 . The plurality of members 674 are configured to define passages through the resulting wound structure that can be utilized to pass fluid in a manner that simulates bleeding. FIG. 82 is a perspective, transparent view of a mold 680 for forming another wound and/or portion of the wound of the upper leg assembly according to an embodiment of the present disclosure. Similarly, FIG. 83 is a perspective, transparent view of a mold 690 for forming yet another wound and/or portion of the wound of the upper leg assembly according to an embodiment of the present disclosure. FIG. 84 is a top view of the mold 670 of FIG. 81 ; FIG. 85 is a top view of the mold 680 of FIG. 82 ; FIG. 86 is a top view of the mold 690 of FIG. 83 . FIG. 87 is a perspective view of a wound structure 700 created using the molds of FIGS. 81-86 . FIGS. 88-97 illustrate a series of steps to assemble a wound structure according to an embodiment of the present disclosure, while FIGS. 98-103 illustrate a series of steps to enhance the realism of the wound structure according to an embodiment of the present disclosure. These steps are discussed in greater detail below with respect to the exemplary manufacturing techniques described herein. FIG. 104 illustrates the attachment of tubing to the wound structure according to an embodiment of the present disclosure. The combat wounds and tourniquet site composition and assembly for the arm and the leg described herein will allow a pioneering, dynamic and interactive scenario simulating fatal hemorrhaging battle wounds that require immediate attention and adequate care. Combat wounds that go untreated or incompetently overseen can ultimately result in terminal consequences. Providing the proper care is a vital point in the healing process as well as the patient recovery, immediate cautious procedure such as packing the wound can cease the bleeding and allow the medical practitioner to focus in stabilizing the patient's vital signs. The user will be immersed in a realistic scenario produced from a combat patient experiencing deadly hemorrhaging where applying the proper packing pressure as well as, alternatively, implementing an adequate tourniquet at the suitable site can stop the wounds from further blood loss. The combat wounds and tourniquet site composition and assembly's goal is to offer a realistic interpretation of a human experiencing lesions or laceration from similar nature caused by battle, combat, explosion or trauma with or without blood supply for added realism. Delivering combat wounds and tourniquet site relevant in anatomical size, organic shape, natural feel and adequate pigmentation medical recognition and familiarity can be obtained in order to successfully perform the procedures being it proper tourniquet or adequate wound packing as well as attain the skills of tactile and recognize the adequate amount of applied pressure and packing technique in a stress free environment apt for troubleshooting and trial and error learning approaches. The products outlined in this disclosure include the combat arm wound (A), combat leg wound (B), arm tourniquet site (C) and leg tourniquet site (D) for medical procedures resulting in hemorrhaging from but not limited to combat and/or accidental occurrences. The combat wounds and the tourniquet site composition and its assembly properly adapts to the wound location as well as the tourniquet location for the patient simulator and simultaneously connects to its hi fidelity system in order to provide an accurate anatomical medical platform that works in harmony as an overall training mechanism. The combat wounds and tourniquet sites consistency portrays a relatively soft feel representative of the common human tissue in the hardness range of 30 in the 00 scale and 10 in the A scale under the Rockwell hardness standard using platinum cured silicon as primary material as well as the appropriate life-like flesh pigmentation and geometry composition of a natural wound. For platinum cured silicone it is preferred but not strictly assigned to a 1:1 ratio of Ecoflex® 0030 and Dragon Skin® 10 Medium, Smooth-On, Inc., Easton, Pa. as the most successful for the use and construction of the uterine material due to its effective endurance to pressure, tear, needle puncture, cutting, and suture retention while maintaining relevant to a high degree of realism. Alternatively, the inside wound composition is consistent and depict a softer feel characteristic of that found in the typical human flesh in the hardness range of 10 in the 00 scale and 10 in the A scale under the Rockwell hardness standard using platinum cured silicone as its material composition as well as the proper red pigmentation. The selected platinum cured silicone material but not limited to represent the inner flesh wound is Ecoflex® 0030, Smooth-On, Inc., Easton, Pa. as the most effective for the added softness in comparison to the wound and its consistency to the human tissue. For the blood makeup, the opted but not required platinum cured silicone material used in its composition is Dragon Skin® 30, Smooth-On, Inc., Easton, Pa. as the most efficient in order to compensate the fibroid hollow construction and the needed hardness to resemble those found in the human body. Additionally, selected featured hardness can be achieved with a mixture of different silicone hardness under the Rockwell hardness standards. In essence the wounds are constructed from designed layers, starting with the outer wound housing the assembly, followed by open cell foam to allow blood-like fluid to enter, diffuse and disperse evenly throughout the cross-sectional area to ultimately enter the inner wounds pores and discharge out of the wound. Therefore, one wound will be conformed of three independent components and utilize 2 separate molds in its manufacturing. Inner wounds are conformed of open pores that cover most of the top surface of the piece and go through to its bottom side allowing simulation of the hemorrhaging effect of an inflicted laceration. The pores are effectively achieved by the arrangement of permanent pins of approximately 1/16 inches within the mold assembly. The benefit of producing or forming the pores of the inner wounds directly from the mold versus that of punching or extruding its cut include adequate pore placement and higher tear strength resistance therefore sustaining a larger load before tearing. The following solid models further expose the mold and its pin organization for the inner wound of both, the arm and the leg. Manufacturing Procedures Cleaning and Prepping the Molds a. Lightly we cloth with isopropanol and wipe inside of mold cavity as well as exterior regions and mold core (for tourniquet molds only) in order to remove any dust particles and/or silicone residues from previous use. b. Use air hose gun to remove silicone residues from Inner Wound Molds blowing in between pins. c. Lightly coat mold cavity and core with mold release agent. Materials and Utensils Setup a. Organize and collect all materials required for the manufacturing of Combat Hal's wounds, blanks and tourniquet site. i. Tubing No. 2 (Dimensions: ID ⅛″, OD ¼″, wall thickness 1/16″; Excelon™ RNT Tubing) ii. Super Glue iii. Silicone Primer (Loctite 770) iv. Open Cell Foam cutouts of 0.50 and 0.25 inches wide v. Ecoflex® 30 Silicone Part A and B vi. Dragon Skin® 10 Silicone Part A and B vii. Slo-Jo® (Smooth-On) viii. Sil-Poxy® (Smooth-On) ix. Slic-Pig® (Smooth-On) “Old Blood” x. Slic-Pig® (Smooth-On) “Red” xi. Slic-Pig® (Smooth-On) “Blue” xii. Slic-Pig® (Smooth-On) “Black” xiii. Slic-Pig® (Smooth-On) “Off White” xiv. Slic-Pig® (Smooth-On) “Flesh” b. Organize and collect all utensils required for the manufacturing of Combat Hal's wounds, blanks and tourniquet site. i. Q-tips ii. Paintbrush iii. Rags for cleaning iv. Rubber bands v. Exacto vi. Tongue depressors vii. Mixing buckets Outer Wounds, Blanks and Tourniquet Sites of the Arm and Leg i. Dragon Skin 10 and Ecoflex 30 Mixing Ratio 1:1 (600 grams: 600 grams) Place clean mixing bucket on scale and pour: 1. Ecoflex ® 30 Part B 300 grams 2. DragonSkin ® 10 Part B 300 grams 3. Slo-Jo ®  12 grams 4. Slic-Pig ® “Flesh”  3.6 grams ii. Hand mix thoroughly for approximately 2 minutes and skin flesh tone is homogeneous throughout the material. iii. Place bucket at scale and pour: 1. Ecoflex ® 30 Part A 300 grams 2. DragonSkin ® 10 Part A 300 grams iv. Hand mix once more thoroughly for approximately 2 minutes and skin flesh tone is homogeneous throughout the material. v. Place bucket inside vacuum until pressure inside reaches approximately 27 psi and turn off vacuum, close valve and allow material to sit for approximately 3 minutes before valve is opened and air enters chamber. vi. Remove bucket from vacuum and pour into: 1. Outer Leg Wound 2. Outer Arm Wound 3. Leg Blank 4. Arm Blank 5. Leg Tourniquet Site 6. Arm Tourniquet Site vii. Pouring is to be made up to mold surface level avoiding any inner mold wall to be exposed. viii. Place poured molds in 66° C. oven to accelerate curing time for 45 minutes. ix. Retrieve molds from oven and allow cooling down for 30 minutes before de-molding. x. Once piece is de-molded, carefully use scissors to clip additional side flashing. Inner Wounds i. Place clean mixing bucket on scale and pour: 1. Ecoflex 30 Part B 100 grams 2. Slic-Pig “Old Blood”  0.6 grams ii. Hand mix thoroughly for approximately 1 minutes and old blood tone is homogeneous throughout the material. iii. Place bucket at scale and pour: 1. Ecoflex 30 Part A 100 grams iv. Hand mix once more thoroughly for approximately 1 minutes and old blood tone is homogeneous throughout the material. v. Place bucket inside vacuum until pressure inside reaches approximately 27 psi and turn off vacuum, close valve and allow material to sit for approximately 1 minute before valve is opened and air enters chamber. vi. Remove bucket from vacuum and pour into: 1. Inner Leg Wound. 2. Inner Arm Wound. vii. Pouring is to be made up to mold surface level avoiding any inner mold wall to be exposed. viii. Place poured molds in 66° C. oven to accelerate curing time for 20 minutes. ix. Retrieve molds from oven and allow cooling down for 15 minutes before de-molding. x. Once piece is de-molded use blow hose gun to blow from top of pores to allow flashing to be exposed and clip with finger tips. xi. Carefully use scissors to clip additional side flashing. Assembling the Leg and Arm Wounds i. Dremel shinny film from open-cell foam cut-outs off from both sides in order to open the flowing channel through foam. (See step 710 in FIG. 88 ) ii. Prior to all use clean Sil-Poxy dispensing tip from dried or old silicone adhesive residues. iii. Use Q-tip to spread Sil-Poxy on the inside bottom of the Leg/Arm Outer Wound piece. Avoid Sil-Poxy adhesive to enter the molds designed flowing channels and localized reservoirs. (See step 720 in FIG. 89 ) iv. Place Leg/Arm corresponding open-cell foam cut-out inside Leg/Arm Outer wound piece and press firmly to enhance the surface adhesion. (See step 730 in FIG. 90 ) v. Use Q-tip to spread Sil-Poxy in between foam wall and Mold inside wall to firmly fix foam in place and seal side gaps that will affect the function of the final product. (See step 740 in FIG. 91 ) vi. Secure rubber band on the perimeter of the Leg/Arm Outer Wound at foam level, Use Q-tip to push in foam into edges to avoid any gaps that will create a reservoir and cause the fluid to create a damming pressure prior to entering the foam. (See step 750 in FIG. 92 ) vii. Clean excess silicone adhesive with Q-tip. viii. Place 200 gram weight on center of partially assembled wound and transfer system to 100° C. oven for 3-5 minutes. ix. Remove system from oven and allow 1-2 minutes for cooling before rubber band is removed. x. Use Q-tip to spread Sil-Poxy on the bottom and around the Leg/Arm Inner Wound piece pores. Avoid Sil-Poxy adhesive to enter any of the designed pore openings as this will block the fluid flow and disrupt the wound's function. (See step 760 in FIG. 93 ) xi. Place Leg/Arm Inner Wound piece on top of foam and inside wound partial assembly and press firmly. (See step 770 in FIG. 94 ) xii. Use Q-tip to spread Sil-Poxy in between Leg/Arm Inner Wound wall and Mold inside wall to firmly fix silicone parts together and seal side gaps. (See step 780 in FIG. 95 ) xiii. Secure rubber band on the perimeter of the Leg/Arm Outer Wound at Leg/Arm Inner Wound level, Use Q-tip to push in Silicone inner wound into edges to avoid any gaps. (See step 790 in FIG. 96 ) xiv. Clean excess silicone adhesive with Q-tip. xv. Place 200 gram weight on center of partially assembled wound and transfer system to 100° C. oven for 3-5 minutes. xvi. Remove system from oven and allow 1-2 minutes for cooling before rubber band is removed. xvii. Semi-finished good is now available for final aesthetic manufacturing procedure. (See step 800 in FIG. 97 ) Application of Pigmentation to the Leg Wound for Realism For the application of pigmented silicone prefabricated mixture of Ecoflex 30 part B must be available. Using the materials specified three shades of red are created, one off white and one bluish black. Alternatively, Ecoflex 30 part A must be available. Note that in order to allow pigmented silicone to properly cure, equal amounts of Part A and B must be mixed together to allow the catalyzation process to take place. Ultimately, the bare model must look real as in the injury caused by an explosion where tissue is exposed and torn ligaments, dried blood as well as fresh bleeding blood is observed. Accordingly, in some instances, the following steps are utilized to enhance the realism of the leg wound(s). i. Filling in the borders with “fresh blood” (See step 810 in FIG. 98 ) 1. Mix in a plate a small amount consisting of: 2. 1 part Old Blood pigmented Ecoflex 30 Part B 3. 2 parts Red pigmented Ecoflex 30 Part B 4. 3 parts Ecoflex 30 Part A ii. Creating Injury depth (See step 820 in FIG. 99 ) 1. Mix in the plate a small amount consisting of: 2. 1 part Black pigmented Ecoflex 30 Part B 3. 1 part Blue pigmented Ecoflex 30 Part B 4. 2 parts Ecoflex 30 Part A iii. Produce ligament simulation (See step 830 in FIG. 100 ) 1. Mix in the plate a small amount consisting of: 2. 1 part Off White Pigmented Ecoflex 30 Part B 3. 1 part of Ecoflex 30 Part A iv. Create blood layering and dulling (See step 840 in FIG. 101 ) 1. Mix in the plate a small amount consisting of: 2. 1 part old blood pigmented Ecoflex 30 Part B 3. 1 part of unpigmented Ecoflex 30 Part B 4. 2 parts of Ecoflex 30 Part A v. Create illusion of fresh blood (See step 850 in FIG. 102 ) 1. Mix in the plate a small amount consisting of: 2. 1 part of red pigmented Ecoflex 30 Part B 3. 1 part of Ecoflex 30 Part A vi. Old Blood overtone (See step 860 in FIG. 103 ) 1. Mix in the plate a small amount consisting of: 2. 1 part old blood pigmented Ecoflex 30 Part B 3. 1 part of unpigmented Ecoflex 30 Part B 4. 2 parts of Ecoflex 30 Part A vii. Assembling fluid tubing port (See step 870 in FIG. 104 ) 1. Using an exacto, carefully make an “x” incision on the foam through the bottom opening. 2. Brush primer generously on wound opening as well as the no. 2 tubing. 3. Insert No. 2 tubing through hole and inside the foam at the “x” incision. 4. Squeeze in “super glue” at sides in between the wound opening and the tube wall. 5. Hold assembly in place to allow glue to set in and dry. Application of Pigmentation to the Arm Wound for Realism For the application of pigmented silicone prefabricated mixture of Ecoflex 30 part B must be available. Using the materials specified three shades of red are created, one off white and one bluish black. Alternatively, Ecoflex 30 part A must be available. Note that in order to allow pigmented silicone to properly cure, equal amounts of Part A and B must be mixed together to allow the catalyzation process to take place. Ultimately, the bare model must look real as in the injury caused by an explosion where tissue is exposed and torn ligaments, dried blood as well as fresh bleeding blood is observed. Accordingly, in some instances, the following steps are utilized to enhance the realism of the arm wound(s). i. Filling in the borders with “fresh blood” (See FIG. 67 ) Mix in a plate a small amount consisting of: 1. 1 part Old Blood pigmented Ecoflex 30 Part B 2. 2 parts Red pigmented Ecoflex 30 Part B 3. 3 parts Ecoflex 30 Part A ii. Produce ligament simulation (See FIG. 68 ) Mix in the plate a small amount consisting of: 1. 1 part Off White Pigmented Ecoflex 30 Part B 2. 1 part of Ecoflex 30 Part A iii. Create illusion of fresh blood (See FIG. 69 ) Mix in the plate a small amount consisting of: 1. 1 part of red pigmented Ecoflex 30 Part B 2. 1 part of Ecoflex 30 Part A iv. Creating Injury depth (See FIG. 70 ) Mix in the plate a small amount consisting of: 1. 1 part Black pigmented Ecoflex 30 Part B 2. 1 part Blue pigmented Ecoflex 30 Part B 3. 2 parts Ecoflex 30 Part A v. Create blood layering and dulling (See FIG. 71 ) Mix in the plate a small amount consisting of: 1. 1 part old blood pigmented Ecoflex 30 Part B 2. 1 part of unpigmented Ecoflex 30 Part B 3. 2 parts of Ecoflex 30 Part A vi. Assembling fluid tubing port (See FIG. 67 ) 1. Using an exacto, carefully make an “x” incision on the foam through the bottom opening. 2. Brush primer generously on wound opening as well as the no. 2 tubing. 3. Insert No. 2 tubing through hole and inside the foam at the “x” incision. 4. Squeeze in “super glue” at sides in between the wound opening and the tube wall. 5. Hold assembly in place to allow glue to set in and dry. One or more of the features of the present disclosure can be combined into a patient simulator to help train combat medics who must quickly perform a few, very critical steps before the soldier is transported. In some embodiments, the patient simulator is sized and shaped to simulate an adult male. Further, in some embodiments, the patient simulator is operable without physical connection to an external device. In that regard, in some instances the patient simulator includes one or more devices configured to facilitate wireless communication with one or more other components. In some instances, the patient simulator is configured to communicate wireless over a distance of 300 meters or more. Wireless communication can include audio, video, sensor data, control signals, and/or any other information associated with the patient simulator. For example, in some implementations the patient simulator wireless communicates with a controller and/or control system configured to control one or more aspects of the patient simulator. To facilitate tetherless operation, the patient simulator includes an onboard power supply, such as a single battery or a plurality of batteries, that is configured to provide at least 6 hours of simulator operation on a single charge. Further, the patient simulator must be designed, assembled, and constructed in a manner to withstand the rigors associated with combat medic scenarios without adversely affecting performance of the patient simulator. In some instances, the patient simulator includes one or more wounds. In some instances, the patient simulator includes wounds that require proper tourniquet application to stop the wound from bleeding. Further, in some instances the patient simulator includes a trachea device that allows training on proper tracheostomy procedures, including insertion of a trachea tube such as a Shiley tracheostomy tube, size 8. In that regard, the trachea device includes a surgical cricoid insert with anatomic landmarks. The surgical cricoid insert is formed of sufficiently durable materials to be repeatedly subjected to a tracheostomy hook. In that regard, in typical use the combat medic will make two incisions (one medial, one lateral) through the trachea skin cover over the surgical cricoid. Then the medic will insert the tracheostomy hook into the cricoid cartilage at the intersection of the incisions and lift upward. The tracheostomy hook is utilized to hold the trachea steady during the tracheostomy procedure. Once the opening has been created, the combat medic inserts a tracheostomy tube thru the cricoid cartilage such that oxygen can be provided to the wounded soldier. Further, the neck of the patient simulator provides the carotid pulse in some instances. In some instances, the patient simulator includes device positioned where the sternum would be located that is configured to accept fluids, can be used multiple times without needing to replace the device, and provides for the infusion of medication. In some instances, the device is configured to be used with the FAST-1 intraosseous device. Further, the patient simulator breathes in accordance with a respiratory pattern. In that regard, the patient simulator has chest rise and fall corresponding to the respiratory pattern. To simulate some scenarios, one or both of the left and right lungs can be disabled to simulate pneumothorax. To that end, the patient simulator includes pneumothorax simulation components in some instances that allows training of pneumothorax procedures. In particular, in some instances the patient simulator facilitates training of needle chest decompressions using a 3¼ inch long and 14 gauge needle, or other suitable needles, at the 2nd intercostal space bilaterally. The skin of the patient is durable with respect to needle punctures such that these procedures can be performed multiple times without needing to change the skin of the patient simulator. Sensors detect the needle insertion and communicate the action to the controller or control system that controls the respiratory pattern of the patient simulator. Accordingly, the controller or control system adjusts the respiratory pattern based on the treatment administered to the patient simulator in some instances. In some instances, an arm of the patient simulator includes a venous network to allow the start an IV drip. Further, a drain in the arm allows large volumes of fluid to be infused. Further, in some instances an arm simulates a severe wound, such as a partial limb loss. In one specific embodiment, half of the left forearm has been lost. The resulting wound looks realistic and bleeds as a function of blood pressure and heart rate. In that regard, use of a standard tourniquet, if applied correctly, will trigger a sensor that causes the bleeding to stop. Further, still, in some instances the shoulder connections of the arms are configured to provide natural motion/flexibility, yet provide strength and durability sufficient to allow the simulator to be dragged. In some embodiments, the shoulder connections include openings extending therethrough to allow passage of communication cables and/or tubing for introduction of fluids (e.g., simulated blood). Further, still, in some instances the should connections limits arm range of motion to a natural range (e.g., approximately 270 degrees), but prevents full rotation of the arm to prevent unwanted kinking and/or damage to the communication cables and/or tubing going through the shoulder connection and into the arm. In some embodiments, an arm of the patient simulator includes a large bleeding wound near axilla, inside of arm beneath bicep. The wound is configured to accept packing material and applying pressure to the wound stops the bleeding of the wound. In that regard, a sensor detects the application of pressure, which in turn causes the control system to stop sending blood to the wound. One or both of the arms of the patient simulator may include radial and brachial pulses that are controlled by the controller or control system. In some instances, the patient simulator includes a groin wound and a sensor located at femoral location where pressure (usually Medic's knee) is applied to decrease bleeding at groin wound. Again, the sensor detects the application of pressure, which in turn causes the control system to stop sending blood to the wound. Similar to the arms, one or both of the legs may includes bleeding wounds that accept packing material and where application of pressure stops the bleeding of the wound. In that regard, the fluid reservoir housing the blood that is utilized to simulate the bleeding of the wounds is contained in one or both of the legs in some instances. In some instances, the reservoir contains 1.5 liters or more of simulated blood that is utilized to cause simulated bleeding of axilla wound, groin wound, amputation arm, and/amputation leg. In that regard, in some instances the patient simulator bleeds at a rate of approximately 0.25 liters per minute. Accordingly, in some instances a sensor is included to monitor the amount of blood within the reservoir so that a user or instructor can be aware when the simulator is running low on blood and replenish the reservoir as needed. Also, similar to the arms, an embedded sensor in the leg detects when a standard tourniquet is properly applied and can stop the flow of blood accordingly. In some instances, one of the legs contains a compressor that is utilized to control various pneumatic aspects of the patient simulator including, for example, portions of the respiratory and circulatory systems of the patient simulator. The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for other devices that simulate medical scenarios and situations, including those involving human tissue. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations to the embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Also, it will be fully appreciated that the above-disclosed features and functions, and variations thereof, may be combined into other methods, systems, apparatus, or applications.
Devices, systems, and methods appropriate for use in combat medical training are provided. In some instances, the combat medical simulators facilitate training of common field medical techniques including tracheostomy, wound care, tourniquet use, pneumothorax, cardiopulmonary resuscitation, and/or other medical treatments. Further, the combat medical simulators have joints that provide realistic ranges of motions to enhance the realism of the training experience.
6
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of U.S. Provisional Application No. 61/475,791, filed Apr. 15, 2011, which is incorporated herein by reference in its entirety for all purposes. BACKGROUND OF THE INVENTION [0002] The present invention relates to recurring payment cancellation services and, more particularly, to a system and method for upgrading cancellation services relating to the identifying of cancelled recurring payments. [0003] Recurring payments are common in the marketplace. A cardholder preauthorizes a merchant to automatically bill a credit or debit card at a preset interval (e.g., monthly, quarterly or annually). This is typically done for a matter of convenience for both the cardholder and the merchant. These payment transactions typically occur without incident. [0004] However, changes in the merchant/cardholder relationship can introduce challenges into the process. For example, the cardholder may revoke preauthorization to bill his account due to either a change in payment type or discontinuation of a merchant relationship. Although most merchants quickly honor the change in the recurring payment billing arrangement, there are times when the merchant does not make the requested change in a timely fashion. In this case, the cardholder continues to incur the periodic charge. He then contacts the card issuer, and requests a refund. This request for a refund results in the issuing bank seeking a chargeback from the merchant bank. [0005] Although a payment network such as the MasterCard Worldwide Network includes a procedure for chargebacks, this process nevertheless results in cost to the participants, as well as a potential loss of goodwill between the issuing back and the cardholder. Continued billing to a cardholder's account results in complaints to the issuer's customer service department, and may even result in the cardholder asking to have his or her account closed. [0006] To reduce the frequency of chargebacks resulting from cancelled recurring payments, as well as to maintain the relationship between the issuing bank and its cardholder, a cancellation service can be provided whereby a database is maintained of unauthorized recurring payments associated with particular cards. An issuing bank can participate in such a cancellation service by inputting information associated with a particular card into the database to prevent future unauthorized billing from a selected merchant. In this way, the recurring charge is blocked before it can appear on the cardholder's bill, thus eliminating complaints from the cardholder, as well as the need for a chargeback by the issuing bank. [0007] Although databases of cancelled recurring payments are effective in blocking unauthorized recurring payments, the existing systems require the issuing bank (or some other authorized entity) to provide the database with the necessary financial data, e.g., account number, merchant identity, merchant bank identity and transaction amount. Typically, this data is manually entered into the database by an employee of the issuing bank. As a result, the entry of data into the cancellation database can be delayed and/or never completed due to the time and effort involved with inputting such data. [0008] In addition, some charges are not properly identified as recurring payments by the submitting merchant. This failure to identify the payment as a recurring payment can result in the bypassing of the cancellation database during the authorization/clearance process. [0009] There is therefore a need in the art for a system and method for providing an updated database of cancelled recurring payments for comparison during the authorization and/or clearance process. There is a further need in the art for a system and method of identifying cancelled recurring payments even when the submitted charge is not properly identified as a recurring payment. SUMMARY OF THE INVENTION [0010] The present invention involves a method of reducing chargebacks due to a cancelled recurring payment, wherein the payment occurs within a card-based financial network, and wherein the network includes a database of unauthorized recurring charges and a defined chargeback procedure. The method generally includes the step of creating an entry within the database during the chargeback procedure when the chargeback procedure is related to a cancelled recurring payment, whereupon the cancelled recurring payment is subsequently identified in the database as an unauthorized recurring charge. [0011] In a preferred embodiment, the method further includes the step of extracting predefined data associated with the cancelled recurring payment, wherein the creating step includes the further step of populating a field associated with the database with the predefined data. Also, the creating step preferably includes the further steps of comparing the predefined data associated with the cancelled recurring payment to file data contained within the database and inputting at least one item from the predefined data into the database in accordance with predefined parameters. [0012] The present invention also involves a method of reducing chargebacks due to a cancelled recurring payment, wherein the payment occurs within a card-based financial network, and wherein the network includes a database of unauthorized recurring charges and a defined automatic billing updating procedure for assigning a new account number to a cardholder. The method generally includes the step of updating the database during the automatic billing updating procedure when the network identifies an unauthorized recurring charge in said database associated with said cardholder. [0013] In a preferred embodiment, the method includes the further step of extracting predefined data associated with the automatic billing updating procedure, and the updating step includes the further step of populating a field associated with the database with the predefined data. When the unauthorized recurring charge is associated with an old account number, the updating step preferably includes the further step of associating the new account number with the old account number in the database, wherein a file is created containing both the old account number and the new account number for subsequent comparison. [0014] The present invention further involves a method for reducing chargebacks due to a cancelled recurring payment, wherein the payment occurs within a card-based financial network, and wherein the network includes a cancellation service, which includes a database of unauthorized recurring charges. The method generally includes the steps of receiving a financial processing request identifying a card-based payment without a recurring payment code, determining whether the issuing bank associated with the request is a participant within the cancellation service, comparing data associated with the request to the unauthorized recurring charges contained within the database and determining a response to the processing request in accordance with predefined parameters. [0015] In a preferred embodiment, the comparing step provides a plurality of authorization comparisons and includes the further step of assigning values to each of the authorization comparisons. The authorization comparisons are preferably related to selected secondary criteria, which includes information relating to at least one of a merchant identity, a merchant size, a length of time a merchant has been doing business, a number of cancelled recurring payments associated with a merchant, a number of chargebacks associated with a merchant or a billing date. The determining step preferably includes the further step of combining the values, and rejecting the processing request when the combination of values exceeds a predefined threshold, wherein the predefined threshold is determined by an issuing bank. [0016] In another method for reducing chargebacks due to a cancelled recurring payment, the method generally includes the steps of receiving a financial processing request identifying a card-not-present (CNP) transaction, determining whether the issuing bank associated with the request is a participant within the cancellation service, comparing data associated with the request to the unauthorized recurring charges contained within the database and determining a response to the processing request in accordance with predefined parameters. [0017] In a preferred embodiment of this method, the comparing step again provides a plurality of authorization comparisons, and includes the further step of assigning values to each of the authorization comparisons, wherein the authorization comparisons are related to selected secondary criteria. The determining step again preferably includes the further step of combining the values, and rejecting the processing request when the combination of values exceeds a predefined threshold, wherein the predefined threshold is determined by an issuing bank. This method is also carried out when the financial processing request is received without a recurring payment code. [0018] A preferred form of the method according to the present invention, as well as other embodiments, objects, features and advantages of this invention, will be apparent from the following detailed description of illustrative embodiments thereof, which is to be read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0019] FIG. 1 is a schematical diagram of a card-based payment system; [0020] FIG. 2 is a flow diagram of a file maintenance process for a cancellation listing system; [0021] FIG. 3 is a flow diagram of an authorization and clearance process for a card-based transaction; [0022] FIG. 4 is a flow diagram depicting the updating of a recurring payment cancellation service (RPCS) file during a chargeback process; [0023] FIG. 5 is a flow diagram depicting the updating of a RPCS file during an automatic billing updating process; [0024] FIG. 6 is a flow diagram of an alternative authorization and clearance process for a card-based transaction; and [0025] FIG. 7 is a flow diagram of still another alternative authorization and clearance process for a card-based transaction. DETAILED DESCRIPTION OF THE INVENTION [0026] Referring first to FIG. 1 , in a typical card-based payment system transaction, a cardholder 10 presents his credit/debit card to a merchant 12 for the purchase of goods and/or services. This transaction is indicated by arrow 14 . It will be understood that prior to the occurrence of transaction 14 , cardholder 10 was issued a card by issuing bank 16 . Moreover, it will be understood that merchant 12 established a relationship with a merchant bank 18 , thereby allowing merchant 12 to receive credit/debit cards as payment for goods and/or services. The merchant banks and issuing banks may participate in various payment networks, including payment network 20 . One such payment network is referred to as the MasterCard Worldwide Network. [0027] After presentation of a card to merchant 12 by cardholder 10 , merchant 12 sends an authorization request (indicated by arrow 22 ) to bank 18 . In turn, bank 18 communicates with network 20 (indicated by arrow 24 ), and network 20 communicates with the issuing bank 16 (indicated by arrow 26 ) to determine whether the cardholder is authorized to make the transaction in question. An approval or disapproval of the authorization request is thereafter transmitted back to merchant 12 (indicated by arrows 28 , 30 and 32 ). Merchant 12 thereafter either completes or cancels the transaction based upon the response to the authorization request. [0028] If transaction 14 is approved, the transaction amount will be sent from issuing bank 16 through network 20 to bank 18 . This transaction amount, minus certain fees charged by both network 20 and bank 18 , will thereafter be deposited within a bank account belonging to merchant 12 . Issuing bank 16 thereafter bills cardholder 10 (indicated by arrow 34 ) for the amount of such transaction, and cardholder 10 follows by a submission of payment(s) (as indicated by arrow 36 ) to issuing bank 16 . This submission of payment(s) (as indicated by arrow 36 ) by cardholder 10 may be automated (e.g., in the case of debit transactions), may be initiated by the cardholder for the exact amount matching costs of purchases during the statement period (e.g., charge cards or credit balances paid in full), and/or may be submitted (in part or in whole) over a period of time that thereby reflects the costs of the purchases plus financing charges agreed upon beforehand between the cardholder and the cardholder's issuing bank (e.g., revolving credit balances.) [0029] When cardholder 10 receives an unauthorized recurring charge, (whether a one-time, or a recurring charge), on his statement, the cardholder contacts issuing bank 16 (indicated by arrow 38 ) and requests a refund. Issuing bank 16 then initiates a chargeback (indicated by arrows 40 , 42 ), requesting a refund of the payment from merchant bank 18 . This refund is provided back to the cardholder (as indicated by arrows 44 , 46 , 48 ). [0030] Network 20 preferably includes at least one server 49 and at least one database 50 . Server 49 may include various computing devices such as a mainframe, personal computer (PC), laptop, workstation or the like. The server can include a processing device and be configured to implement an authorization and clearance process, which can be stored in computer storage associated with the server. The authorization and clearance process can be implemented by the server to prevent and/or reduce unauthorized recurring payments. Database 50 may include computer readable medium storage technologies such as a floppy drive, hard drive, tape drive, flash drive, optical drive, read-only memory (ROM), random access memory (RAM), and/or the like. [0031] Referring now to FIG. 2 , a cancellation listing system 51 of the present invention is shown. System 51 is preferably implemented by network 20 , and is preferably maintained by the network provider, e.g., MasterCard, or by an independent authorized third party. System 51 preferably includes an account management system (AMS) file 52 , a recurring payment cancellation service (RPCS) file 54 and a billing service file 56 . AMS file 52 , RPCS file 54 and billing service 56 are preferably stored in database 50 of network 20 , and processed by server 49 . Although FIG. 2 depicts AMS file 52 , RPCS file 54 and billing service file 56 as separate discrete files, these separate files could be contained within one larger file. In one preferred application, the mentioned files are stored within a single storage device as separate files. In another preferred application, RPCS file 54 is a sub-file of AMS file 52 . [0032] AMS file 52 is preferably a database of cards which have been flagged for non-authorization, e.g., lost or stolen cards, cards in collection and cards participating in the recurring payment cancellation service. In other words, the AMS file is essentially a negative database. AMS file 52 preferably communicates with both RPCS file 54 and billing service file 56 . File 56 is associated with the billing of an issuing bank for each card entered into RPCS file 54 . [0033] Entering data into AMS file 52 , and ultimately into RPCS file 54 , may be accomplished in at least two ways. In the first way, a written request 58 is forwarded to the operator of system 51 . The written request 58 includes the necessary data (e.g., account number, merchant identity, merchant bank identity, transaction amount) to be entered into RPCS file 54 . The data is thereafter entered into RPCS file 54 by authorization support 60 . The second method of inputting data into the RPCS file 54 involves the direct input of data by issuing bank 16 (or an authorized entity). More particularly, issuing bank 16 communicates with a system input 62 , which then forwards the data through an issuer file 64 . The input of the data into AMS 52 is depicted by arrows 66 , 68 , and the confirmation of the input of such data is depicted by arrows 70 , 72 . It is contemplated herein that system input 62 can be accomplished by various computing devices such as a mainframe, personal computer (PC), laptop, workstation, handheld device, or the like. [0034] As will be recognized by those skilled in the art, the transaction processing of card-based payments include both an authorization side and a clearance side. The authorization side involves the process of confirming that the cardholder has a sufficient line of credit to cover the proposed payment. The clearance side of the transaction involves the process of moving funds from the issuing bank to the merchant bank. FIG. 3 depicts a transaction processing flow chart showing both the authorization side and the clearance side of the card-based payment. [0035] Referring to FIG. 3 , and to the authorization side of the transaction, an authorization request 74 is submitted by a merchant bank to network 20 . Network 20 first considers whether the charge included in authorization request 74 is a recurring payment ( 76 ). In this regard, merchants and/or merchant banks preferably indicate a recurring payment as such by utilizing defined criteria, e.g., an identifying code. If the proposed charge is not a recurring payment transaction, then the processing of the authorization request continues at step 78 in ordinary fashion. However, if the proposed charge is indicated to be a recurring payment, then network 20 determines whether the issuing bank is an issuer participant ( 80 ). If the issuing bank is not an issuer participant, then the processing of the transaction continues at step 78 in ordinary fashion. If the issuing bank is an issuer participant, then network 20 determines whether the data associated with the proposed charge defined in the authorization request matches a recurring account charge (RAC) blocking criteria ( 82 ). This step is indicated at 84 , and is accomplished by accessing RPCS file 54 . If RAC blocking criteria are not found, then the processing of the authorization request continues in step 86 in ordinary fashion. If RAC blocking criteria are found, then the authorization request is rejected, as indicated by steps 88 and 90 . [0036] Turning now to the clearance side of the transaction, a clearing presentment 92 is submitted to network 20 . Network 20 determines whether clearing presentment 92 involves a recurring payment ( 94 ), and if not, directs network 20 to continue processing the clearing presentment at step 96 in ordinary fashion. If clearing presentment 92 involves a recurring payment, then network 20 determines whether the issuing bank is an issuer participant ( 98 ). If the issuing bank is not an issuer participant, then network 20 continues processing the clearing presentment at step 96 in ordinary fashion. If the issuing bank is an issuer participant, then network 20 determines whether the data associated with the charge defined in the clearing presentment matches the RAC blocking criteria ( 100 ). This step is indicated at 102 in FIG. 3 , and is accomplished by accessing RPCS file 54 . If RAC blocking criteria are not found, then the processing of the clearing presentment continues at step 104 in ordinary fashion. If RAC blocking criteria are found, then the clearing presentment is rejected at step 106 . [0037] At present, the RPCS file maintenance described in FIG. 2 is isolated from the typical chargeback process described with respect to FIG. 1 . In other words, unless the issuing bank ensures that the appropriate data is entered into RPCS file 54 (by either input 62 or written request 58 ), then the process described in FIG. 3 will be ineffective in identifying unauthorized recurring charges, and will be unable to reject such charges. [0038] Accordingly, one aspect of the present invention is to associate the chargeback process with the RPCS file such that the process of performing a chargeback results in the creation of an entry within RPCS file 54 which will be available for future comparison during steps 82 and 100 of the transaction process. This entry in RPCS file 54 can be created because the chargeback process requires the input of the same or similar data required to flag an unauthorized recurring payment, e.g., the account number, merchant identity, merchant bank identity and transaction amount. [0039] When issuing bank 16 initiates a chargeback within network 20 , the chargeback is preferably associated with RPCS file 54 whereby the server(s) (e.g., server 49 ) and database(s) (e.g., database 50 ) involved in the chargeback process communicate with RPCS file 54 , either directly or through AMS file 52 , to add and/or update the data contained in RPCS file 54 . The association between the chargeback process and RPCS file 54 is shown in greater detail in FIG. 4 . More particularly, in addition to the normal steps incurred during a typical chargeback 108 , the present invention adds the additional step ( 110 ) of contacting RPCS file 54 and determining whether a match is found in the stored data for the payment associated with the chargeback. Step 110 is preferably initiated when the chargeback 108 includes a predefined code indicating that such chargeback is due to a “cancelled recurring” charge. If a match is found in RPCS file 54 for the payment associated with the chargeback, then the updating process of RPCS file 54 is discontinued at step 112 . If no match is found in RPCS file 54 for the payment associated with the chargeback, then RPCS file 54 is updated at step 114 to add the data associated with the chargeback to RPCS file 54 , e.g., account number, merchant identity, merchant bank identity and transaction amount. [0040] It is contemplated herein that network 20 may also include an automatic billing updater (ABU) platform 200 . ABU platform may be stored in database 50 , and processed by server 49 . ABU platform 200 is used to automatically maintain the accuracy of account data for account-on-file payments, including recurring payments, between participating issuers, acquirers and merchants. Another aspect of the present invention is to associate ABU platform 200 with the RPCS file 54 such that the process of performing an ABU account number change results in the updating of RPCS file 54 . More particularly, the RPCS file 54 can be updated to also include the new account number provided through the ABU account number change. In other words, RPCS file 54 will now include both the old and new account numbers, such that if a merchant attempts to process an unauthorized recurring payment using the new card number, the transaction will be flagged and subsequently rejected. [0041] Thus, as shown in FIG. 5 , ABU platform 200 creates a file 202 containing both the old and new account numbers associated with a cardholder. The system then communicates with RPCS 54 to determine whether a listing exists for the old account number ( 204 ). If a listing 206 exists, then the system can either create a new RPCS listing with the duplicate information ( 208 ), or update the existing RPCS listing with the new account number ( 210 ). If no existing RPCS listing is found in step 204 , then the process is terminated at step 212 . [0042] Although merchants and merchant banks are supposed to indicate recurring charges by coding such charges in a particular manner, this coding is not always associated with a recurring payment. The failure to properly code a payment can result from oversight, error or even intentional omission. Existing cancellation listing services require the payment to be identified as a “recurring payment” to trigger the RPCS file inquiry. Accordingly, a merchant may intentionally omit the recurring payment designation to avoid having the transaction denied. The present invention further contemplates at least two authorization and clearance processes (as shown in FIGS. 6 and 7 ) which consider the possibility that payments have been improperly labeled, i.e., that a recurring payment has not been labeled as such. [0043] Turning to the first embodiment shown in FIG. 6 , an authorization request 116 is submitted to network 20 , which then considers whether the payment associated with the request is a recurring payment ( 118 ). If the submitted payment is identified as a recurring payment, then the process continues at step 120 as discussed hereinabove with respect to step 76 in FIG. 3 . However, if the payment associated with authorization request 116 is not identified as a recurring payment, then network 20 considers whether the issuing bank is an issuer participant ( 122 ). If the issuing bank is not an issuer participant, then the transaction is continued at step 124 in ordinary fashion. If the issuing bank is an issuer participant, then network 20 determines whether the data associated with the proposed charge defined in the authorization request matches the RAC blocking criteria ( 126 ). This step is indicated at 128 , and is accomplished by accessing RPCS file 54 . If RAC blocking criteria are not found, then the processing of the transactions continues at step 130 in ordinary fashion. If RAC blocking criteria are found, then the process considers certain secondary criteria ( 131 ). [0044] In this first embodiment, network 20 considers selected secondary criteria in step 131 before approving or denying the authorization request. More particularly, the process can be configured to deny the authorization request at 132 when a predefined number of secondary criteria are matched, or when a particular weighting of all criteria has been reached. These secondary criteria can include the identity of the merchant, the size of the merchant, the length of time such merchant has been doing business, the number of cancelled recurring payments associated with such merchant, the number of chargebacks associated with such merchant, the billing date, etc. It is contemplated that different secondary criteria can be assigned different values. It is also contemplated that the number of matches necessary to cause an authorization request to be denied can be targeted and specific to a particular issuing bank. This can provide the issuing bank with an additional degree of control over the cards and accounts issued to its customers. Considering these additional criteria before denying an authorization request can reduce the likelihood that a legitimate charge is denied. [0045] Inasmuch as a card based payment also involves a clearance process, this provides the issuing bank with a second opportunity to identify an unauthorized charge. As shown in FIG. 6 , clearing presentment 134 is submitted to network 20 . If the payment associated with clearing presentment 134 is a recurring payment, then the process continues at step 136 as discussed hereinabove with respect to FIG. 3 . However, if the payment associated with clearing presentment 134 is not identified as a recurring payment then the network considers whether the issuing bank is an issuing participant ( 138 ). If the issuing bank is not an issuer participant, then the process continues at step 140 in ordinary fashion. If the issuing bank is an issuer participant, then network 20 determines whether the data associated with the charge defined in the clearing presentment matches the RAC blocking criteria ( 142 ). This step is indicated at 144 , and is accomplished by accessing RPCS file 54 . If RAC blocking criteria are not found, then the process continues at step 146 in ordinary fashion. If RAC blocking criteria are found, then the clearing process considers certain secondary criteria ( 147 ). [0046] In this first embodiment, network 20 considers selected secondary criteria before approving or denying the presentment request. More particularly, the process can be configured to deny the presentment at 148 when a predefined number of secondary criteria are matched, or when a particular weighting of all criteria has been reached. These secondary criteria can include the identity of the merchant, the size of the merchant, the length of time such merchant has been doing business, the number of cancelled recurring payments associated with such merchant, the number of chargebacks associated with such merchant, the billing date, etc. It is contemplated that different secondary criteria can be assigned different values. It is also contemplated that the number of matches necessary to cause a presentment to be denied can be target and specific to a particular issuing bank. This can provide the issuing bank with an additional degree of control over the cards and accounts issued to its customers. Considering these additional criteria before denying a payment request can reduce the likelihood that a legitimate charge is denied. [0047] Turning to the second embodiment shown in FIG. 7 , an authorization request 150 is submitted to network 20 , which then considers whether the payment associated with the request is a card-not-present (CNP) transaction ( 152 ). CNP transactions include, among others, the recurring payments discussed herein. If the submitted payment is not identified as a CNP transaction, then the process continues at step 154 in ordinary fashion. However, if the payment associated with authorization request 150 is identified as a CNP transaction, then network 20 considers whether the issuing bank is an issuer participant ( 156 ). If the issuing bank is not an issuer participant, then the transaction is continued at step 154 in ordinary fashion. If the issuing bank is an issuer participant, then network 20 determines whether the data associated with the proposed charge defined in the authorization request matches the RAC blocking criteria ( 158 ). This step is indicated at 160 , and is accomplished by accessing RPCS file 54 . If RAC blocking criteria are not found, then the processing of the transactions continues at step 162 in ordinary fashion. If RAC blocking criteria are found, then the authorization request is rejected at step 164 . [0048] Inasmuch as a card based payment also involves a clearance process, this provides the issuing bank with a second opportunity to identify an unauthorized charge. As shown in FIG. 7 , clearing presentment 166 is submitted to network 20 , which then considers whether the payment associated with the presentment is a CNP transaction ( 168 ). If the payment associated with clearing presentment 166 is not identified as a CNP transaction, then the process continues at step 170 in ordinary fashion. However, if the payment associated with clearing presentment 134 is identified as a CNP transaction, then the network considers whether the issuing bank is an issuer participant ( 172 ). If the issuing bank is not an issuer participant, then the process continues at step 170 in ordinary fashion. If the issuing bank is an issuer participant, then network 20 determines whether the data associated with the charge defined in the clearing presentment matches the RAC blocking criteria ( 174 ). This step is indicated at 176 , and is accomplished by accessing RPCS file 54 . If RAC blocking criteria are not found, then the process continues at step 178 in ordinary fashion. If RAC blocking criteria are found, then the clearing presentment is rejected at step 180 . [0049] Thus, in this second embodiment, network 20 identifies all CNP transactions, and automatically checks for matching blocking criteria for participating issuers—irrespective of how the transaction is coded. In this way, an issuer is more likely to “catch” unauthorized recurring charges which have not been properly coded as such, whether done innocently or intentionally. In other words, if the data associated with the proposed transaction matches the RAC blocking criteria in the RPCS file, and the transaction is a CNP transaction, then the authorization request or presentment will be denied. [0050] It will be appreciated that the present invention has been described herein with reference to certain preferred or exemplary embodiments. The preferred or exemplary embodiments described herein may be modified, changed, added to or deviated from without departing from the intent, spirit and scope of the present invention, and it is intended that all such additions, modifications, amendments and/or deviations be included in the scope of the present invention.
A method of reducing chargebacks due to a cancelled recurring payment, wherein the payment occurs within a card-based financial network, and wherein the network includes a database of unauthorized recurring charges and a defined chargeback procedure. The method generally includes the step of upgrading a recurring payment cancellation services file based on predefined occurrences relating to the identifying of cancelled recurring payments.
6
PRIORITY AND CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 14/584,981, filed on Dec. 29, 2014, which is a continuation of U.S. patent application Ser. No. 13/854,795, filed on Apr. 1, 2013, now U.S. Pat. No. 8,959,863, which claims the benefit of U.S. Provisional Patent Application 61/650,179, filed on May 22, 2012, the disclosures of each incorporated herein by reference in their entirety. TECHNICAL FIELD OF THE INVENTION [0002] The present invention relates in general to a method and apparatus for filling and fire-proofing holes in concrete floors, and more specifically, to a method for utilizing an apparatus or precast plug to repair and restore holes. COPYRIGHT & TRADEMARK NOTICE [0003] A portion of the disclosure of this patent application may contain material that is subject to copyright protection. The owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever. [0004] Certain marks referenced herein may be common law or registered trademarks of third parties affiliated or unaffiliated with the applicant or the assignee. Use of these marks is by way of example and should not be construed as descriptive or to limit the scope of this invention to material associated only with such marks. BACKGROUND OF THE INVENTION [0005] Typically, a condition in a lease contract between a commercial building owner and a tenant is that at the end of the lease the tenant must return the leased premises in the same condition that it was in at the time the tenant took possession, save for normal wear and tear. During the course of a tenancy, a lessee will typically cause numerous holes to be drilled into the concrete floor and/or ceiling of his suite to accommodate the routing of electrical wires, plumbing pipes, voice cables, and other such items that run through the floors. In the great majority of mid and high rise office buildings, these floors are constructed of a lightweight aggregate poured on a metal underlayment or pan. This flooring assembly provides a fire break between floors. When the tenant vacates the premises, the drilled holes during the tenancy are left wide open as a result of the removal of the wiring, plumbing, etc. that had been previously installed. This is potentially a breach of the fire control properties of the flooring assembly. These holes are typically three to four inches in diameter, but can range up to twelve inches or larger. Until recently, most property owners did not recognize this as a problem, and as a result did not require the vacating tenant to repair and restore these holes. More recently, it has been recognized, however, as an issue that must be remedied before a new tenant can take possession of the property. [0006] There are several products on the market that can be used to restore the fire break properties of the flooring assembly. Most utilize a mechanical closure of the hole by installing an expandable metal plug or cap, and require that they be installed through the bottom of the hole. This solution often requires that access to the underside of the floor be granted by another tenant or the owner. Such access may be disruptive, cause security and liability issues, necessitate that the repair work be performed after normal working hours, and cause possible damage to another tenant's property. The parts and labor associated with these products tend to be rather expensive as well. [0007] Another problem with other products is that the final repair results in a protruding floor surface. This is a design flaw that complicates future use of the floor where the protrusion is located. [0008] Yet another problem related to repairing holes after a lease has expired is shoddy repair work. To honor the lease, a tenant may merely stuff a rag or other such material in the hole and then fill it with a plaster, such as FIX-IT-ALL™. Such a repair is insufficient, as there is nothing to keep the rag and plaster from falling through the floor into the suite below. Moreover, such a repair may be prone to water leaks and likely does not conform to the fire code, and testing these properties would be overly burdensome, defeating the purpose of the repair in the first place. [0009] Therefore, there are several problems with the current state of the art, which have not been adequately addressed. The problems persist because a need to provide a method and apparatus for filling & fire-proofing holes in concrete floors has not been adequately met. It is to these ends that the present invention has been developed. BRIEF SUMMARY OF THE INVENTION [0010] To minimize the limitations in the prior art, and to minimize other limitations that will be apparent upon reading and understanding the present specification, the present invention describes a method and apparatus (or precast plug) for sealing a hole in a floor comprising a concrete housing and at least one rod whereby the distal end of said at least one rod makes at least one protrusion from at least one edge of said concrete housing. [0011] An apparatus, in accordance with an exemplary embodiment of the present invention, comprises: a concrete housing configured to substantially seal a hole in the floor of a building; a rod situated within the concrete housing, the rod including a first and second portions protruding from the concrete housing, wherein the first and second portions are configured to register with one or more grooves on the surface of the floor and adjacent to the hole; and a support component coupled to the rod, the support component embedded within the concrete housing. [0012] A method, in accordance with an exemplary embodiment of the present invention, comprises: dry-fitting a precast plug into a hole of a floor assembly; drawing an outline of one or more rods that extend from the concrete housing of the precast plug; creating grooves adjacent to the hole, the grooves configured to receive portions of the rod external to the concrete housing; applying a sealant to the interior surface of the hole; applying sealant to the concrete housing of the precast plug; and inserting the precast plug into the hole in a manner so that: the external portions of the rod register with the grooves adjacent to the hole, and the external portions of the rod are substantially flush with the surface of the floor. [0013] Another method, in accordance with an exemplary embodiment of the present invention, comprises: preparing a wet cement mixture; pouring said wet cement mixture into a form mold housing; installing into said form mold housing a first rod whereby the distal end of said first rod makes a first protrusion from a first edge of said form mold housing and the proximal end of said first rod makes a second protrusion from a second edge of said form mold housing; allowing said mixture to cure with said first rod in place, thereby creating said pre-cast plug; grinding a first and second groove into said floor to house said distal and proximal ends of said first rod; coating said precast plug's edges with said sealant; placing said precast plug into said hole such that the distal and proximal ends of said first rod rest in said first and second grooves; and allowing said sealant to cure. [0014] It is an objective of the present invention to seal a hole in a floor such as to make it fire resistant, water resistant, and structurally sound. [0015] It is another objective of the present invention to allow for ease of installation, making a repair job quick and efficient. [0016] It is yet another objective of the present invention to repair a hole in a floor, such that the apparatus is flush with the floor's surface. [0017] These and other advantages and features of the present invention are described herein with specificity so as to make the present invention understandable to one of ordinary skill in the art. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS [0018] Elements in the figures have not necessarily been drawn to scale in order to enhance their clarity and improve understanding of these various elements and embodiments of the invention. Furthermore, elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the apparatus and method. [0019] FIG. 1 is a three dimensional exploded cross-section view depicting an apparatus, in accordance with an exemplary embodiment of the present invention, above a cutout section of a floor assembly with a hole, before it is place in said hole. [0020] FIG. 2 is a three dimensional cross-section view of an apparatus that has been placed in a hole in a cutout section of a floor assembly. [0021] FIG. 3 depicts a top view of an apparatus used to fill a hole, in accordance with an exemplary embodiment of the present invention, fully installed into a hole. [0022] FIG. 4 depicts a cross-sectional side view of the apparatus as shown in FIG. 3 . [0023] FIG. 5 depicts a top view of an apparatus used to fill a hole, in accordance with another exemplary embodiment of the present invention. [0024] FIG. 6 depicts a cross-sectional side view of the apparatus as shown in FIG. 5 . [0025] FIG. 7 depicts a top view of an apparatus used to fill a hole, in accordance with another exemplary embodiment of the present invention. [0026] FIG. 8 depicts a cross-sectional side view of the apparatus as shown in FIG. 7 . [0027] FIG. 9 depicts a top view of an apparatus used to fill a hole, in accordance with another exemplary embodiment of the present invention. [0028] FIG. 10 depicts a cross-sectional side view of the apparatus as shown in FIG. 9 . [0029] FIG. 11 is a three dimensional exploded cross-section view depicting an apparatus, in accordance with another exemplary embodiment of the present invention, above a cutout section of a floor assembly with a hole, before it is place in said hole. [0030] FIG. 12 is a perspective view of the apparatus depicted in FIG. 11 , showing a rod situated within a housing, and a support component coupled to the rod. [0031] FIG. 13 is a cross-sectional side view of the embodiment of the apparatus depicted in FIG. 12 . [0032] FIG. 14 is a perspective view of the apparatus depicted in FIG. 11 , which includes another embodiment of a supporting component coupled to the rod. [0033] FIG. 15 is a side-view of the supporting component depicted in FIG. 14 . [0034] FIG. 16 is a cross-sectional side view of the embodiment of the apparatus depicted in FIG. 14 and FIG. 15 . [0035] FIG. 17 is a top view of the apparatus depicted in FIG. 11 or FIG. 14 , used to fill a hole. [0036] FIG. 18 is a perspective view of another exemplary embodiment, wherein an additional support rod is used. [0037] FIG. 19 is a top view of the apparatus depicted in FIG. 18 , used to fill a hole. [0038] FIG. 20 is a flow-chart describing one exemplary method for filling a hole in accordance with practice of the present invention. [0039] FIG. 21 is a flow-chart describing one exemplary method for creating an apparatus in accordance with the present invention. DETAILED DESCRIPTION OF THE INVENTION [0040] In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying drawings that form a part thereof, where depictions are made, by way of illustration, of specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the invention. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims. [0041] FIG. 1 is a three dimensional exploded cross-section view depicting an apparatus, in accordance with an exemplary embodiment of the present invention, above a cutout section of a floor assembly with a hole, before it is place in said hole. More specifically, FIG. 1 depicts precast plug 101 before it is placed in hole 102 . This embodiment is a basic depiction of how precast plug 101 may function, namely to seal hole 102 . It also depicts the various components of precast plug 101 including rod 104 . [0042] Precast plug 101 may be constructed off site, i.e., from where the hole it intends to repair is located. However, this is not to limit the scope of precast plug 101 . If a particular location required precast plug 101 to be made on site, such as a remote location and time was of the essence, this could be accomplished by making precast plug 101 at the site of hole 102 . [0043] In either case, precast plug 101 may be constructed of the same material as floor 103 , which in the typical scenario will be a lightweight aggregate or other cement, which has fire and water resistant properties in addition to structural integrity, similar to floor 103 . For example, Rapid Set® Cement All™ may be used to construct precast plug 101 , but this is not to limit the scope of the apparatus and method. In another embodiment, precast plug 101 may be constructed of plastic, steel, or any other material suitable for filling a hole or cavity. Where a cement-like material is used to prepare precast plug 101 , it may be mixed with the requisite amount of water (and coloring if desired) to form a wet mixture. This mixture may then be poured into a form mold. [0044] The shape and size of form mold, and therefore precast plug 101 , may vary depending upon the type of repair job—for example, this may depend on the thickness of the floor assembly needing repair. The embodiment depicted in FIG. 1 shows precast plug 101 as having a cylindrical shaped housing with a top planar surface, an outer wall, and a bottom planar surface that are integral to and unitarily form the concrete housing. The outer walls may have a slight inward taper from the top of precast plug 101 where logo 105 is located to the bottom of precast plug 101 . However, a straight cylindrical form mold may also be employed to create precast plug 101 with no taper. Other embodiments of precast plug 101 may be cast in square, rectangular, triangular, and other variable sized and shaped form molds to create variable sized and shaped precast plugs 101 . Precast plug's 101 diameter (or general width) is also variable depending upon the actual size of hole 102 to be repaired. A larger hole may necessitate a larger diameter form mold while a smaller hole may necessitate a smaller diameter form mold. Finally, the height of hole 102 is relevant to the size of the form mold to be used, which in the typical repair job may be three and one half inches. As mentioned above, this may vary depending upon the type of repair job—for example, this may depend on the thickness of the floor assembly needing repair. Typically, the thickness of the floor will vary with 3.5″ being the minimum thickness. Nevertheless, exemplary embodiments may be designed to provide a certain fire rating (e.g. a 2.0-hour fire rating) when installed according to directions, regardless of actual thickness of floor assembly. The embodiment shown in FIG. 1 depicts precast plug 101 to be of substantially the same height as the height of hole 102 , meaning from the top of floor 103 to the bottom of floor 103 , however the actual height of precast plug 101 may vary. In exemplary embodiments, the height of the concrete housing is the minimum height of the hole. [0045] Before the cement mixture cures in the properly sized form mold, an appropriately sized rod 104 may be inserted into the wet cement housing of precast plug 101 . Rod 104 may be comprised of any number of materials, including steel, plastic, multiples of rods, etc., as will be further discussed below. As depicted in FIG. 1 , rod 104 may be constructed of steel and may also be bent or molded such that it forms a “C” like shape in the center of rod 104 . This allows for the “C” portion of rod 104 to be fully embedded within the form mold cement mixture, and the ends of rod 104 to extend from either side of what is soon to become precast plug 101 after curing. The ends, or “wings” of rod 104 , may give precast plug 101 support when resting in hole 102 and prevent precast plug 101 from falling through the floor. [0046] Precast plug 101 may also be embossed as depicted in FIG. 1 with logo 105 before cement mixture cures. However, this is not to limit the scope of the invention. Logo 105 may also be a stamp, painting, etching, or any other mark to indicate who made precast plug 101 . In FIG. 1 , logo 105 consists of a capital “C” and a capital “P” indicating for example, a trademark. However, logo 105 may also consist of other combinations of letters, numbers, symbols, and/or pictures. [0047] Precast plug 101 may also be stamped, as depicted in FIG. 1 , with size indicator 106 . Again, size indicator 106 may also be embossed, painted, etched, or generally engraved in such a way that it clearly communicates information about precast plug's 101 and/or hole's 102 dimensions. In FIG. 1 , it may be noted that size indicator 106 is represented by a “#30”. This may be a shorthand method of indicating that hole 102 is three inches for example. It could also be used to communicate that the width of precast plug 101 is three inches, if that would be a preferable method of measuring. However, other methods of communicating the size of precast plug 101 or the size of hole 102 may be employed such as a size indicator 106 depiction of “(3″)” or “3 In.”. [0048] Logo 105 and size indicator 106 may also be used to communicate other desirable information, such as implied information. Implied information may be apprised from both logo 105 and size indicator 106 to indicate to appropriate authorities, such as a fire marshal, that the plug that is going to be installed or already has been installed into floor 103 is of such a quality and design that it meets appropriate fire codes and/or other safety regulations. Accordingly, information that may be stamped, embossed, or otherwise applied to the housing of precast plug 101 may include a batch control number, a date of manufacture, or any other pertinent information that may be useful to an installer, inspector, or user of the apparatus. [0049] Further depicted in FIG. 1 are grooves 107 on either side of hole 102 . Grooves 107 may not be preexisting. If not, grooves 107 may be ground out, for example, with an angle grinder, chiseled with a chisel, or carved out using some other device, tool or mechanism to accommodate the portions of rod 104 that are situated external to the concrete housing—or “wings” of rod 104 . Once the appropriate number of grooves 107 are carved out (and in the proper places), precast plug 101 may be inserted into hole 102 such that each “wing” of rod 104 may rest snugly within its own groove 107 and the top of precast plug 101 may rest flush with floor 103 . This may be desirable for several reasons, including so that the finished repair does not protrude above the floor surface—this facilitates installation of finish floor surface material. [0050] In another embodiment, rather than utilizing the technique of grooves 107 , holes may be drilled in either side of the wall of hole 102 , beneath the surface of floor 103 . Similar tools may be employed as may be used to carve out grooves 107 , including a right angle drill. Utilizing this technique, it would be possible not only to repair a hole in a floor below one's feet, but also a floor above one's head, i.e. a ceiling. In such a case, various embodiments of precast plug 101 may include logo 105 and size indicator 106 embossed or otherwise marked on the bottom side of precast plug 101 , or rather on both ends of precast plug 101 to make it visible to one viewing precast plug 101 from above or below. The “wings” of rod 104 may also extend from a more central portion of precast plug 101 rather than being substantially flush with the top of precast plug 101 . To accommodate the “wings” of rod 104 it may be necessary to drill deeper holes on either side of hole 102 . After drilling the holes, one “wing” of rod 104 may be fully inserted into said drilled hole such that the side of precast plug 101 and interior of hole 102 are flush and the other “wing” of rod 104 is fully within hole 102 and extended in the direction of the drilled hole that it is to occupy. The entirety of precast plug 101 may then be laterally moved in that direction such that it is centered in hole 102 and both “wings” of rod 104 come to rest in either drilled hole. [0051] FIG. 2 is a three dimensional cross-section view of precast plug 101 , which has been placed in hole 102 of floor 103 . This embodiment is a basic depiction of how precast plug 101 functions, i.e. to seal hole 102 such that hole 102 is fire resistant, water resistant, and structurally sound. FIG. 2 also depicts how the top portion of precast plug 101 may not protrude from floor 103 , but is relatively flush with floor 103 . FIG. 2 further depicts how the bottom of precast plug 101 may be flush with the bottom side of floor 103 . [0052] Before appropriately sized precast plug 101 is fitted into hole 102 , however, sealant 201 may be beaded around the exterior wall of precast plug 101 and the interior wall of hole 102 , after which precast plug 101 may be fitted into hole 102 . Once the wings of rod 104 are snugly within grooves 107 , sealant 201 may be inserted into any voids such that hole 102 is completely full and/or excess sealant 201 may be wiped away from the area of hole 102 . Sealant 201 may also be applied over the top of the wings of rod 104 to further secure rod 104 in place. After sealant 201 cures, what is left is a fire resistant, water resistant, and structurally sound repair job, which may be impliedly indicated by logo 105 as discussed above. As an example, 3M™ Fire Barrier Sealant IC 15WB+ or CP 25WB+ may be used as sealant 201 , however, this is not to limit the scope of the invention. Other products with similar properties may be employed in lieu of said brand. Typically, the sealant used should comply with fire stop properties in accordance with jurisdictional codes or well-known standards (for example as set forth in ASTM E 814-13a). [0053] FIG. 3 depicts a top view of precast plug 101 fully installed into hole 102 in a cutout section of floor 103 . FIG. 3 also introduces another aspect of the present invention, namely, various dimensions of an apparatus in accordance with the present invention. Before installation of precast plug 101 , it may be necessary to measure the size of hole 102 that is to be repaired. For example, size indicator 106 depicts a “#30”, which may mean that before installation, it was measured that the size of hole 102 to be repaired was three inches. In such a case, whatever the width of hole 102 may be, D 2 represents this dimension. D 1 represents the width of precast plug 101 . Finally, both d's represent the portion of how far rod 104 extends into floor 103 . Depending upon the nature of the repair to be made, any and all of these dimensions may be lengthened or shortened to accommodate the repair. FIG. 3 also depicts sealant 201 surrounding precast plug 101 . Sealant 201 , however, may also be applied over the top rod 104 to give further stability. [0054] FIG. 4 depicts a cross-sectional side view precast plug 101 fully installed into hole 102 in a cutout section of floor 103 . The location of the cross section is indicated in FIG. 3 by the 4 - 4 cross-section line. As can be seen in this embodiment, rod 104 has a “C” shaped bend allowing for rod 104 to penetrate into the center of precast plug 101 . This bend into the center of precast plug 101 allows for rod 104 to lend structural support to precast plug 101 . Also seen from this view, the wings of rod 104 extend into floor 103 on either side of precast plug 101 , where grooves 107 may have been chiseled or carved to allow for proper installation of precast plug 101 . This embodiment also depicts the slight inward taper of precast plug 101 at an unspecified degree. However, as mentioned above, this taper is not necessary, and in another embodiment, precast plug 101 may have an outward taper, which may make it easier to apply sealant 201 . Another dimension depicted in FIG. 4 is the height h of floor 103 . As mentioned above, precast plug 101 may be adapted to accommodate the varying heights of concrete floors in different buildings. [0055] FIG. 4 also depicts sealant 201 as extending from the bottom edge of floor 103 to the top edge of floor 103 and fully encompassing the space between floor 103 and precast plug 101 . In another embodiment, less sealant 201 may be applied such that enough is applied to fulfill its purpose, which is to seal hole 102 . [0056] FIG. 5 is a top view depicting an alternative embodiment of precast plug 101 comprising multiple (i.e. two in this embodiment) rods 104 housed within precast plug 101 rather than one as in previous figures. Multiple rods 104 may be suitable to lend further support for a larger precast plug 101 to repair a wider diameter hole 102 or a floor 103 of an increased height. In one embodiment (as shown), multiple rods 104 are substantially parallel to each other and configured to register with grooves (i.e. multiple grooves 107 ) adjacent to the hole. FIG. 5 depicts a different sized precast plug 101 as indicated by size indicator 106 . As discussed above, size indicator may refer to the size of precast plug 101 or the size of hole 102 . For example, the “#65” in FIG. 5 may indicate that hole 102 has a diameter of six point five inches. [0057] FIG. 6 depicts a cross-sectional side view of the embodiment shown in FIG. 5 . The location of the cross-section is indicated in FIG. 5 by the 6 - 6 cross-section line. This embodiment generally depicts, however, how multiple rods 104 may be lengthened and positioned in order to accommodate a larger precast plug 101 that may be situated in a deeper hole 102 as may be the case with floor 103 of a greater height, such that multiple rods 104 may still penetrate the center of precast plug 104 and lend full support. [0058] FIG. 7 is a top view of yet another embodiment of the present invention, which also utilizes multiple rods. However, as shown and as clarified further by the 8 - 8 cross section line in FIG. 8 , the two rods 104 act as their own wings so that a pair of rod wings in this embodiment are not part of a single rod. These separate rods 104 may be inserted into precast plug 101 in a similar fashion as described above, i.e., before the wet cement mixture fully cures within the form mold and such that the wings are substantially flush with the top of precast plug 101 . In another embodiment, rods 104 may be positioned such that the wings of said rod extend from a central or lower position on either side of precast plug 101 , rather than being flush with the top of precast plug 101 . Utilizing one of these embodiments, precast plug 101 may be inserted into a ceiling as described above. [0059] FIG. 7 further depicts another potential embodiment as represented by size indicator 106 , which shows a “#45”. This may represent that either hole 102 or precast plug 101 has a width of four and one-half inches. However, the embodiments depicted in FIGS. 7 and 8 are not to be construed as limiting the scope of the present invention. For example, rods 104 in FIG. 7 need not be within substantially the same plane as one another, but may be cured into precast plug 101 in a staggered fashion such that they are rather substantially parallel to one another. In another embodiment, four separate rods 104 similar to those used in FIGS. 7 and 8 may be cured into a single precast plug 101 and arranged in a fashion such that there are two pairs of rods 104 (see FIG. 7 for an example of an arrangement of one pair of rods) with each pair on substantially the same plane when viewed from above and the first pair being substantially parallel with the second pair. [0060] In yet another embodiment, four separate rods 104 similar to the rods 104 depicted in FIGS. 7 and 8 may be cured into precast plug 101 such that each wing when viewed from above would point in a different direction, such as twelve o'clock, six o'clock, three o'clock and nine o'clock substantially bisecting precast plug 101 both vertically and horizontally. With such an embodiment, the method of installation may be modified to account for the requisite number of grooves 107 to house such wings. [0061] FIG. 9 depicts a top view of an apparatus used to fill a hole, in accordance with yet another exemplary embodiment of the present invention. Rather than a tubular shape as discussed above, rod 104 may take on a substantially rectangular shape. In this embodiment, rod 104 may be comprised of a plastic “T” bar with a break away joint at the “T” intersection, as can be seen in the 10 - 10 cross section line in FIG. 10 . The breakaway joint and base of the “T” of rod 104 may be a cylindrical arrow-like shape. Such an embodiment allows for this breakaway joint and base to grip the housing of precast plug 101 , providing additional support so that precast plug 101 does not fall through hole 102 . Rod 104 in plastic form, is not to limit the scope of the present apparatus and method. Other embodiments may include iron, wood, silicone, or other durable composite materials. Also, as mentioned above sealant 201 may be applied between precast plug 101 and floor 103 , and over the top of rod 104 in the embodiment depicted in FIG. 9 . [0062] Size indicator 106 depicts a “#112”. As explained above, this may indicate that either hole 102 or precast plug 101 may be eleven point two inches wide for example. FIG. 10 also depicts precast plug 101 with no tapered edge, an alternative embodiment to the present invention. An even column of sealant 201 fills the space between floor 103 and precast plug 101 . In another embodiment, however, more or less sealant may be applied, e.g., if precast plug 101 were to taper outward or inward, or hole 102 were to taper inward or outward. In yet another embodiment sealant 201 may be applied such that it covers the bottom edge of precast plug 101 and/or the top edge of precast plug 101 , such as to give further protection to precast plug 101 and floor 103 . [0063] Turning to the next figure, FIG. 11 depicts a three dimensional exploded cross-section view of another exemplary embodiment of precast plug 101 , before it is place in hole 102 . In this embodiment, precast plug 101 may be adapted for a much narrower construction. That is, there may be certain circumstances in which a narrower housing such as housing 101 a is preferred. Such embodiments may employ rod 150 rather than rod 104 as shown with reference to FIG. 1 . Rod 150 may have a smaller C shape bend, or dip, in a middle portion of the rod to accommodate the narrower construction of housing 101 a . That is, in instances where housing 101 a is so narrow that a support rod of appropriate diameter or width may not be easily implemented, precast plug 101 may implement rod 150 , which is configured to couple with an anchor or support component 151 . [0064] Support component 151 may be a rod with a smaller diameter than rod 150 , and which is shaped in a manner so that support component 151 may couple with rod 150 —for example at the bend or dip of rod 150 . Furthermore, rod 151 may be shaped in a variety of forms in order to provide a keyway that will lock the support component into the concrete housing, thereby providing support for precast plug 101 . [0065] FIG. 12 is a perspective view of the apparatus depicted in FIG. 11 , showing rod 150 and support component 151 situated within housing 101 a . In this embodiment, support component 151 is helical or having the shape or form of a helix or spiral so that a body of support component 151 may wound or twist uniformly and around in a cylindrical or conical manner. In exemplary embodiments, support component 151 comprises an elongated body such as a rod with a lesser diameter than rod 150 , and which is shaped in a manner so that it can be embedded securely within the concrete housing of a precast plug, such as concrete housing 101 a . Although the shown embodiment includes a shape that twists or is helical in shape, other shapes that allow support component 151 to be embedded securely within concrete housing 101 a may be implemented. [0066] A top portion of support component 151 may be configured to wrap around or hook onto a portion of rod 150 that is within concrete housing 101 a of precast plug 101 . In exemplary embodiments, a top portion of support component 151 may be hooked or wrapped around, or otherwise coupled to a middle bent portion of rod 150 . Of course, other means of coupling the two components may be implemented, including gluing, soldering, or any other manner of securely coupling the support component to the rod. Further, support component 151 may be typically coupled in a manner so that it is substantially perpendicular to rod 150 . Of course, other variations may include configurations in which rod 150 and support component 151 are not substantially perpendicular but at other angles in relation to each other. Whatever the configuration, it may be desirable that support component 151 is embedded within an internal portion of the concrete housing of precast plug 101 the will provide the most support—to these ends, in exemplary embodiment, support component 151 may be embedded within a middle portion of the concrete housing. [0067] FIG. 13 is a cross-sectional side view of the embodiment of the apparatus depicted in FIG. 12 , which shows how support component locks into place within concrete housing 101 a of precast plug 101 . The location of the cross section is indicated in FIG. 17 by the 10 - 10 cross-section line. This embodiment of support component 151 is embedded within the concrete housing so that a cross-section of the concrete housing with the embedded support component includes a first plurality of vertically oriented cross-sections 153 of support component 151 running parallel to a second plurality of vertically oriented cross-sections 154 of support component 151 , situated below a cross-section of rod 150 . Further, a cross-section 155 of support component 151 is shown in FIG. 13 , corresponding to a top portion of support component 151 , which wraps around or hooks onto rod 150 at a middle bent portion of the rod. [0068] FIG. 14 is a perspective view of the apparatus depicted in FIG. 11 , which includes another embodiment of a support component 151 coupled to rod 150 . In this embodiment, support component 151 may be a rod with a smaller diameter and shaped in a manner so that the support component 151 forms a plurality of curves situated and aligned along a single plane (i.e. flat) as depicted in FIG. 14 and FIG. 15 . A top portion of support component 151 may be configured to wrap around or hook onto rod 150 . FIG. 15 is a side-view of the support component depicted in FIG. 14 . Although this embodiment of support component 151 is shown as flat (wherein all curving elements of support component 151 are situated in a single plane), in other embodiments, each curving portion may be situated in alternating planes or different planes, without deviating from the scope of the present invention. [0069] FIG. 16 is a cross-sectional side view of the embodiment of the apparatus depicted in FIG. 14 and FIG. 15 . The location of the cross section is indicated in FIG. 17 by the 10 - 10 cross-section line. This embodiment of support component 151 is embedded within the concrete housing so that a cross-section of the concrete housing with the embedded support component includes a plurality of cross-sections 156 that form a single vertical line substantially directly below cross-section 157 of support component 151 , corresponding to a top portion of support component 151 . [0070] FIG. 17 is a top view of the apparatus depicted in FIG. 11 or FIG. 14 , used to fill a hole. As may be appreciated, the embodiments discussed with reference to FIG. 11 - FIG. 16 differ internally due to support component 151 , and externally merely due to the size of housing 101 a. [0071] FIG. 18 is a perspective view of another exemplary embodiment, wherein an additional support rod is used. This configuration may be desirable for additional support in situation in which, for example, an odd-shaped hole must be filled and fire-proofed. In this embodiment, a second rod 152 may be utilized, wherein the second rod is crossed over the first rod 150 in a manner so that it sits atop a portion of rod 150 (e.g. over the bend or dip on rod 150 ). In some embodiments, rods 150 and 152 may be positioned so that they each lay substantially horizontally or longitudinally along the top planar surface of the concrete housing of precast plug 101 , and are perpendicular to each other so that an angle β along lines A and B (parallel to rods 152 and 150 , respectively) forms a ninety-degree angle. In other embodiments, rods 150 and 152 may be positioned so that they cross at an angle β other than a ninety-degree angle. FIG. 19 is a top view of the apparatus depicted in FIG. 18 , used to fill a hole—this embodiment showing rods 152 and 150 perpendicular to each other. [0072] Turning now to the last set of figures, FIG. 20 is a flow-chart describing one exemplary method for filling a hole in accordance with practice of the present invention, more specifically, the flow-chart depicts method 2000 for filling a hole using a precast plug for which installation may be achieved from above a floor assembly; method 2000 may comprise of several steps as follows: [0073] In step 2001 , an apparatus in accordance with the present invention such as a precast plug may be dry fit into a hole of a floor assembly from above. For example, a precast plug comprising of a concrete housing and a rod partially situated within the concrete housing, may be simply placed inside the hole to make sure that the correct size housing is being utilized. [0074] In step 2002 , outlines of the rods that extend beyond the concrete housing may be drawn so as to determine the location of the grooves to be carved adjacent to the hole. Once marked, the precast plug may be removed and set aside. In this step, an installer may desire to install temporary material within the hole in order to prevent grinding dust or debris from falling through the empty hole. Notably, step 2001 may not be necessary for several reasons—for example, a template or other guidelines for outlining where the grooves may be placed on the floor surface adjacent to the hole may be used so that a dry fit is unnecessary. [0075] In step 2003 , a grinder or other tools may be used to grind or carve the grooves or slots for receiving the outer portions (or wings) of the rod (or rods) external to the concrete housing. In some embodiments, this step may include grinding slots in the floor that are approximately 5/16 of an inch deep and of sufficient length to allow the precast plug to rest slightly below the surface of the floor or in a manner so that installation of the precast plug results in a top surface of the apparatus being flush with the surface of the floor. Removal of the temporary material used to plug the hole may be required if this precaution was taken in step 2002 . [0076] Moreover, this step may further include dry fitting the precast plug again to be sure the entire apparatus rests below surface of floor or is otherwise flush with the surface of the floor adjacent to the hole. Afterwards, the precast plug may be removed and the interior walls of the floor's hole may be wiped cleaned with a damp sponge, rag or paper towel to remove debris. [0077] In step 2004 , sealant may be applied. In exemplary practice, a bead of sealant (of approximately on-half inch thickness) may be applied below the top of the hole. In some embodiments, a spreader may be used to spread the sealant around the entire internal circumference of the hole. Furthermore, a similar thickness of sealant may be applied to the circumference of the concrete housing of the precast plug, particularly to the bottom circumference of the concrete housing then spreading throughout the entire circumference or outer walls of the concrete housing. [0078] In step 2005 , the precast plug may be inserted into the hole using a twisting motion into the concrete housing so that the protruding portions of the rod (or rods) rest in the previously carved out grooves or slots, allowing the entire precast plug to rest slightly below the surface of the floor. A spreader may be used in this step to level and remove any sealant that protrudes above the surface of the floor. In order to facilitate installation inspection, an installer may desire to keep the top surface of the precast plug clean (especially when the top portion may include a logo and other information relevant for inspection). [0079] Now turning to the last figure, FIG. 21 is a flow-chart describing one exemplary method for creating an apparatus in accordance with the present invention, the flow-chart depicts method 2100 for creating or constructing a precast plug; method 2100 may comprise of several steps as follows: [0080] In step 2001 , a wet cement mixture may be prepared. In step 2002 , the wet cement mixture may be poured into a form mold housing for creating the concrete housing of the precast plug. [0081] In step 2003 , one or more rods may be installed into the form mold housing whereby a distal end of one of the one or more rods makes a first protrusion from a first edge of said form mold housing and the proximal end of the rod makes a second protrusion from a second edge of the form mold housing. This step may be repeated depending on whether a single or multiple rods will be implemented with the precast plug being created. In alternative embodiments, the one or more rods may be positioned on the form mold housing prior to pouring the wet cement mixture. [0082] In step 2004 , the mixture may be allowed to cure with said the one or more rods in place, thereby creating said precast plug. This step may also include embossing the precast plug with a logo and or a size indicator, or stamping the precast plug with a logo and a size indicator, or otherwise including any pertinent inspection-relevant information onto the concrete housing as the cement mixture cures. [0083] Naturally, the steps above should not be limiting, and these steps and additional steps may be performed in the same sequence or alternative sequence without deviating from the scope of the present invention. As may be appreciated by a person of ordinary skill in the art, one of the advantages of the present invention is that an apparatus to fill and fire-proof a hole in a concrete floor may be achieved with installation from above. Typically, in order to meet the requirements under well-known standards access from below a floor assembly is required. As described above, an apparatus in accordance with the present invention may be simply placed inside the hole, sealed using certain sealants, and adjusted so that it is flushed with the surface of the floor adjacent to the hole. [0084] A method and apparatus for filling and fire-proofing holes in concrete floors has been described. The foregoing description of the various exemplary embodiments of the invention has been presented for the purposes of illustration and disclosure. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit of the invention.
The present apparatus and method relates in general to sealing a hole in a floor with a precast plug. A precast plug is created by pouring a wet aggregate mix into a form mold and thereafter inserting a pre formed rod into the uncured mixture, positioning it such that the center of the rod rests in the center of the form mold and the ends of the rod extend outward near the top of the form mold. The mix is then cured. The precast plug may then be transported to the hole that it is destined to fix. Grooves may be carved on either side of the hole to accommodate the rod's ends. The interior of the hole and the exterior of the plug may then be covered with a sealant, after which the plug may be inserted into the hole. Once the sealant cures, the hole is fully repaired.
4
BACKGROUND OF THE INVENTION This invention relates to precision stops, and more particularly to adjustable precision stops which are free of backlash and which are easily adjustable within a range of positions to locate one or more exterior stop surfaces, and which positions are repeatable. Industrial operations and industrial equipment often require the interposition of stop members, the position or thickness of which may be accurately controlled. As an example, the patent of Phelps U.S. Pat. No. 4,495,886 issued Jan. 29, 1985 shows the employment of stops in the form of replaceable micrometer blocks for the purpose of accurately defining and maintaining a gap between a metering roll and a coating transfer roll in a precision roll coater. In that case, a tolerance of positioning was required within 75 microinches. Another requirement for precision stops is that of maintaining a nip gap in the calendaring of paper. Commonly, tapered wedges or other mechanical arrangements have been used for the purpose of forming an adjustable stop but they suffer from the fact that their positioning is not accurately repeatable, and the fact that they are not always free of backlash and can be difficult to move under high loading conditions. SUMMARY OF THE INVENTION This invention is directed to an improved precision stop member in which a closed or sealed cavity in a rigid body is filled with a relatively incompressible fluid. At least one wall of the cavity is formed by a semi-flexible or deflectable plate that defines, on an outer surface, a precision force locating pad or stop surface. A fluid displacement member in the form of a piston or plunger is axially moveable in order to displace fluid from this piston/cylinder area to the deflectable wall or plate. A constant volume of the fluid is maintained within the cavity. During initial assembly of this fluid, the cavity and seals provide a predetermined minimum loading pressure thereby applying a predetermined stress to this wall. The position of the plunger is adjustable to adjust the static position of the locating surface on the wall, with respect to the body or with respect to a second located surface on the body. In a preferred embodiment of the invention, the cavity-defining body is relatively inflexible or rigid, and supports a pair of opposed semi-flexible disc-shaped walls in sealing relation to the internal cavity. The cavity is filled with an incompressible high bulk modulus fluid, such as glycerin (glycerol), although water may also be used. The assembly must be purged of any compressible gas (such as air) during initial assembly. A plunger has a portion moveable into the cavity to displace a variable quantity of fluid thereby stressing the opposed walls outwardly from each other by a predetermined amount, for accurate positioning or spacing between the respective location surfaces thereon. Varying the fluid displacement within the cavity provides a linear adjustment while resisting large magnitude external force with very small backlash. It is preferred that the semi-flexible wall or walls be formed of a geometrically uniform pattern, such as a circle, with a generally uniform wall thickness throughout. It is preferred that a stop or force transmitting or locating surface be formed on the exterior surface which is geometrically central to the semi-flexible wall geometry. The wall thus may be mounted on an annular substantially rigid body defining a cylindrical cavity with opposed wall-receiving surfaces by which a pair of such disc-like walls may be mounted in opposed relation to each other thereby encapsulating the cavity. The walls may be attached to the body by means of a plurality of bolts arranged in a closely spaced circular pattern. Seals are interposed between the respective walls and the body. Such an arrangement provides for a limited range of deflection or movement of the semi-rigid walls, which movement is a linear relation to fluid volumn in the cavity caused by the displacement of the threadably mounted plunger. The plunger is displaced by rotation of a plunger support on the threads in a bonnet, to displace a volume of fluid within the cavity accompanied by substantially uniform, equal, and repeatable deflections of the semi-flexible walls and the associated locating pads for surfaces formed on the outer surface of these walls. Due to the fact that a minimum constant and positive pressure is maintained in the interior cavity, all components and seals are stressed in the same direction, and a precise position is maintained without stress reversals. Therefore, backlash is eliminated. A gauge or force transducer may be associated with the cavity for the purpose of assisting in the attainment of an adjusted stop position and to provide a visual or electrical indication of the maintenance of a predetermined pre-load pressure within the cavity, thereby indicating the proper operation of the adjustable stop device. In another embodiment of the invention, a cavity is formed in a generally cup-shaped rigid body and is closed by a single semi-flexible wall. Such a stop device may be preferred due to its lower cost and due to the fact that all of the fluid displacement results in deflection substantially of one wall only. Such a single-sided stop may be preferred in those instances where the stop defines a travel limit with respect to other movements and where it is desired to mount the stop body rigidly to other components. A particular advantage of the hydraulic stop device is the fact that, within its range, there is a substantially linear relationship between the extent of movement of the plunger and the position of the stop surface or surfaces. Preferably, the plunger is mounted on threads extending through a valve-type bonnet and is adjustable by simple rotation. The pre-load pressure of the liquid on the plunger assures the take up of backlash at the threads and at the seals. Two or more of the devices may be positioned in tandem to each other to permit stacking. The adjustable hydraulic stops according to this invention are particularly adapted for automatic control such as by automatic control of the position of the fluid displacement member in accordance with a feedback or a control signal. Since the position or positions of the adjustable stop are substantially linearally related to the extent of movement of the plunger, under appropriate circumstances, control may be by open loop, such as by process parameters, provided that appropriate precautions are taken to assure that such parameter controls do not exceed an acceptable stress range for the particular hydraulic adjustable stop. It is therefore an important object of the invention to provide an accurate repeatable no backlash adjustable hydraulically-operated mechanical stop. A further object of the invention is the provision of a precision stop in the form of a pressure vessel having at least one non-permanent elastically deformable moveable wall, in which an interior volume comprises a generally incompressible liquid and is maintained under positive pressure, and in which the pressure is adjustable by the movement within the pressure vessel of a moveable stop member or plunger or by loads applied to the deformable walls. The invention has, as its objective and feature, high resolution for linear adjustment permitting, in the preferred embodiment, control to within 0.0001 inches of adjustment. The apparatus is characterized by high load capacity with relatively low internal hydraulic pressures which can easily be handled by conventional o-ring-type seals. The apparatus is further characterized by a simplicity of components, making the same easy to manufacture and to assemble. These and other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a precision hydraulic adjustable stop made in accordance with this invention. FIG. 2 is an end view of the stop of FIG. 1; FIG. 3 is a sectional view looking generally along the line 3--3 of FIG. 2; and FIG. 4 is a sectional view through a modified form of the invention. DESCRIPTION OF PREFERRED EMBODIMENTS Referring to the figures of the drawings, which represent preferred embodiments of the invention, a precision hydraulic adjustable stop in accordance with this invention is illustrated generally at 10 in FIGS. 1 and 2. In this embodiment of the invention, the stop 10 comprises a rigid body 12 in the general form of an annulus, also referred herein as annular body 12. The body 12 defines an internal cavity 15 which has a pair of opposed open faces, namely an open face 16 on one lateral side and a diametrically opposed open face 17 on the opposite lateral side. Each of the open faces 16 and 17 is closed by an elastically deformable, semi-flexible liquid impervious disc-shaped wall or plate 20 and 21. The plate 20 closes the cavity 15 at the face 16, while the plate 21 closes the cavity 15 at the face 17, so that the plates 20 and 21 are mounted in opposed relation to each other on the body 12. For the purpose of this description, it is assumed that the plates 20 and 21 are identical in construction, are interchangeable, and therefore, the description herein of plate 20 may also be applied to plate 21. The body 12 may be a pressure casting, like a high pressure valve body housing, or may be machined to form the open cavity 15. Annular locating surfaces 25 are formed in surrounding relation to the open faces 16 and 17 onto which the walls 20,21 are respectively located. The surfaces 25 are provided with annular outwardly facing grooves into which static o-ring seals 27 are placed. The O-ring seals 27 are engaged by the radially flat face of an annular ring-like portion 28 of each of the plates, designed to mate directly against the body surfaces 25. The major portions of each of the disc-like walls or plates are formed radially flat with parallel inside and outside surfaces defining a substantially uniform thickness throughout the major extent of each of the such plates. These walls are substantially thinner and more flexible than any portion of the body 12 so that any measurable deflection of the body 12 under internal pressures is negligible compared to the pressure-induced deflection of either of the plates 20 or 21. Each of the plates 20 and 21 has formed, on an outer surface thereof, a geometrically centrally located force or pressure pad 30. Since the plates are formed as a circular disc, in outline, as shown in FIG. 2, the pressure pads 30 are located at the geometric center. They have outer radially flat surfaces which are slightly elevated or raised in relation to the remaining portion of the respective wall to form a precision contact or pressure surface. The body 12 is further provided with a plunger opening 32, positioned on a generally radial axis with respect to the body. The plunger opening 32 opens into the cavity 15. A displacement plunger 35 is mounted for axial movement within the opening 32, and is supported in a bonnet 40. The bonnet 40 is threadably received and seated within an enlarged threaded opening 42, concentric with the plunger aperture 32 and is sealed with respect to a flat annular locating surface 45 between the bore 32 and opening 42, by a static o-ring 50. The plunger 35, on the other hand, is sealed to the bonnet 40 by an o-ring 52 received within the bonnet and in sealing engagement with an outer cylindrical surface of the plunger 35. An operator stem 60 is threadably received within an outer extension 62 of the bonnet 40 and has an inner end 64 in engagement with the plunger 35. Rotation of the stem 60 in the bonnet 40, such as by the manual knob 70, or by suitable automated means is translated as an axial movement of the plunger 35 in the bore 32. The invention further includes means for monitoring the pressure within the cavity 15 and, for the purpose of this invention, is shown in the form of a dial-type gauge 75 having its inlet stem 76 threaded into and sealed at an opening 77 leading into the interior of the body 12 at the cavity 15. Other forms of pressure transducers may be used. Each of the semi-flexible disc-shaped walls or plates 20 and 21 is mounted to the body 15 by means of cap bolts 80 formed in a bolt circle and extending into suitable threaded openings within the body 12, as illustrated by the end view in FIG. 2 and by the sectional view of FIG. 3. The cavity 15, including all closed off openings leading thereto, is completely and totally filled, without any entrapped air, by a substantially incompressible liquid. The preferred liquid is a high bulk modulus fluid such as glycerin although, in many application, water alone or a water/antifreeze mixture is sufficient. The walls 20 and 21 are preferably made of high strength alloy, such as AISI #4140 heat treated to a medium hardness, such as about 300 Brinell. Good results have been obtained in which the bore diameter of the cavity 15 is four inches, and in which the wall thickness "A" of the end plates 20 and 21 is 0.156 inches, and the pressure pad 30 is 0.5 inch in diameter. In operation of the embodiment of FIG. 1-3, the cavity and all interior openings are completely filled with a liquid such as glycerol, preferably by assembling the unit while submerged in the liquid, with the plunger 35 retracted radially outwardly of the bore 32. The cap bolts 80 are threaded into the body and the bonnet 40 is likewise threaded into the body, with the resulting compression of the o-ring seals, thereby building up an initial static pressure within the cavity 15. Such an initial static pressure is desirable in that it assures that all of the seals and threads are preloaded. A pre-load pressure of 150 psig has been found to be satisfactory. The pressure may be increased by rotating the handle 70 and stem 60, thereby depressing the plunger 35 into a fluid displacing relationship with respect to the interior cavity 15, accompanied by a slight outward flexure of the walls 20 and 21 and their respective force loading pads 30. Thus, in a position of initial loading, the loading pads may be moved relative to each other by increasing the displacement of fluid by the rotation of the stem 60. This displacement of the stop or locating surfaces may, in the example given, be as much as 0.025 of an inch with pressures increased therein up to about 550 psi. Best results are obtained where the plates 20 and 21 are pre-loaded externally by loads which do not exceed the design load of the unit. Such initial loading provides physical support to the plates 20 and 21. Plots of internal pressure versus pad positions demonstrate a substantially straight line function within displaceable limits between pressure increases or decreases, (as measured by turns of the stem 60 on its threads by actual pressure changes within the chamber 50) These straight line functions have no significant hysteresis loop between increasing pressure and decreasing pressure traces. In the example given, static loading as high as 900 lbs. as been applied at the pads 30 and no significant difference in slope or displacement of the plot or tracing has been seen over static loading of 650 lbs. Two or more of the adjustable stops of this invention may be stacked, one against the other, for the purpose of extending the effective range of adjustment, which is permissible. When pressure is loaded, all of the seals and all of the threads are biased in one direction only. Therefore, the plunger 35 may be extended or retracted with respect to the cavity 15 with no backlash effects. The o-ring seal between the outer circumference of the plunger 35 and the inner circumference of the bonnet 40 is subject to little wear since it is contemplated that the unit will be set at a single adjusted position over long periods of time. Perfect sealing at the internal pressures contemplated are well within the limits of conventional o-ring design. A second preferred embodiment of the invention is illustrated in the partial sectional view of FIG. 4, in which like parts are represented by like reference numerals. This embodiment is particularly adapted to provide a single elastically deformable and semi-flexible moving wall having a locating surface, in relation to a relatively rigid body. Therefore, body 12A has a generally cup-shaped internal cavity 15A which is totally closed, on one side, by an integral section 12B of the body 12A. The body 12A is formed within flat mounting surface 90. The opposite open side is closed by a single plate or wall 20A which, for the purposes of this description, may be considered to be identical to the construction of the wall 20 previously described in connection with the embodiments of FIGS. 1-3. Further, the remaining components of the invention as previously described, remain unchanged and are labeled in FIG. 4 with the same reference numerals which have been applied to the corresponding components in FIGS. 1-3. The wall 20A and the locating surface 30, will be deflected twice the extent of the deflections of the walls 20 and 21, assuming no change has been made in the pitch of the threads supporting the operator stem 60 or in the size or displacement of the plunger 35. As previously mentioned, the apparatus of this invention is particularly adapted for use in an automatic control system, in which the position or positions of the surface or surfaces 30 is controlled by an automated control of the position of the plunger 35. This automated control may take the place of the handle 20, with a direct driving connection to the stem 60 such as by a suitable controllable actuator connected to the stem. Such an actuator may, in a closed loop control system, be responsive to a strain feedback signal or, in appropriate cases, may be made responsive to process parameters. Position feedback from the servo itself, or from an LVDT, could be used in appropriate circumstances, in accordance with well known process control technology. The lack of backlash in the adjustable stop provides a mechanism which is repeatable, in an automatic control system, with high accuracy. While the forms of apparatus herein described constitutes preferred embodiments of this invention, it is to be understood that the invention is not limited to these precise forms of apparatus, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.
Repeatable no-backlash adjustable hydraulic stops are disclosed which have a rigid body which defines a cavity. One or more elastically deformable end plates are mounted in closing relation to the body cavity for enclosing and encapsulating an amount of liquid therein. A plunger in the body is movable in fluid displacing relation to the cavity for providing an accurate elastic displacement of the enclosing end plates which elastic displacement or movement is accurately repeatable by rotating an actuator rod which engages the plunger for varying the fluid displacing relationship to the interior of the cavity. An initial static pressure is formed within the cavity for pre-stressing the components and providing for no-backlash adjustment. Locating pads are formed exteriorly of the flexible walls defining an accurate stop position.
5